October 2021 Effectively Use Cyclones for Particulate Air ...

Bulk Solids Innovation Center Journal

October 2021

Is the Homogeneity of Your Dry Mix Acceptable?

Case Study: Verifying the Performance of a System Upgrade is in Everyone’s Best Interest

Effectively Use Cyclones for Particulate Air Pollution Control

S O L I D S I N S I G H T S F O R I N D U S T R Y

Bulk Solids Innovation Center JournalEditor in Chief

Mark [email protected]

Executive Editor

Todd [email protected]

Associate Editors

Raju [email protected]

Kevin [email protected]

Contributing Editor

Tom [email protected]

Art Director

Jennifer [email protected]

Production Manager

Daniel [email protected]

Publisher

Brian [email protected]

Bulk Solids Innovation Center

Journal is published jointly by

the Kansas State University

Bulk Solids Innovation Center,

607 N. Front Street, Salina,

KS 67401, and Putman Media,

1501 E. Woodfield Road, Suite

400N, Schaumburg, IL 60173.

Copyright 2020, Kansas State

University Bulk Solids Innovation

Center and Putman Media. All

rights reserved. The contents

of this publication may not be

reproduced in whole or in part

without the consent of the

copyright owners.

CONTENTS

Effectively Use Cyclones for Particulate Air Pollution Control 3Learn how to size and design them for optimal efficiency

Is The Homogeneity Of Your Dry Mix Acceptable? 9Understand how to correctly validate the results of mixing

Case Study: Verifying the Performance of a System 14Upgrade Is in Everyone’s Best InterestIt is a cheap insurance policy for large-scale project performance

Vibratory Feeding Technology Gets Sophisticated 18Patent-pending technology allows a line of vibratory feeders to achieve high accuracy

Improve Batch Weight Calculations 22Combine the right slide gate and pneumatic actuator to reap cost savings

Mission and Capabilities of the Kansas State University 26Bulk Solids Innovation Center Are ManyHere’s what the BSIC does to help industry

KSUPBSA Offers Professional Education Courses and Training 28Keeping skills up to date matters now more than ever

AD INDEX

Vortex • www.vortexglobal.com 8

Rembe • www.rembe.us 13

Coperion K-Tron • www.coperion.com 17

Inpro-Seal • www.inpro-seal.com 21

BSIC • https://bulk-solids.k-state.edu 25

October 2021 / Bulk Sol ids Innovat ion Center Journal-2-

mailto:[email protected]







Cyclones are one of the simplest and most reliable devices for separating particles from a gas stream. They are not appropriate

for very small particles, especially below 20 microns, but they can be effective air pollution control devices for larger particles in a variety of applications.

Cyclones rely on centrifugal force to separate parti-cles from the gas stream. As dust-laden air enters the cyclone, centrifugal force pushes heavier particles to the sidewall, as shown in Figure 1. As the gas stream spins in a vortex inside the cyclone, the particles’ iner-tia causes them to continue in the original path and be separated from the airstream.

The interactions in the cyclone are complex. At first, everything spirals downwards, but the friction of particles against the sidewall slows the particles and helps them separate from the gas stream. When it approaches the bottom of the cyclone, the clean

Effectively Use Cyclones for Particulate Air Pollution Control

Learn how to size and design them for optimal efficiency

By Todd Smith, KSU-Bulk Solids Innovation Center

CYCLONE SEPARATION

Figure 1. Centrifugal force separate particles from the gas stream, pushing heavier particles to the sidewall.

Clean gas out

Gas-solids in

Inner vortex takes gas out

Outer vortex takes particles

to wall

Material out


gas continues to spin, but the vortex reverses direction and becomes an inner vortex going upward.

The inner vortex spi-rals upward toward the gas outlet at the top, often carrying some of the finest particles with it. Most or all of the particles will separate from the gas stream and thus be discharged out the bottom of the cyclone.

CYCLONE LIMITATIONS

Cyclones have good separation efficiency if particles are large, espe-cially above 20 microns in size. Separation effi-ciency drops off rapidly as particles get much smaller. If better separa-tion efficiency is required for small particles, then a unit with fabric filter bags or pleated filter cartridges will be more appropri-ate. Cyclones also work best with steady processes; efficiency will suffer if the system cycles on and off or if the gas flow rate goes up and down. Another limitation of cyclones is the head-height requirement — they are tall!

CYCLONE ADVANTAGES

Cyclones are simple in concept and low in price. They have no moving parts and therefore require little maintenance. Other than possible wear to the side-wall over time, there is nothing to wear out. Cyclones don’t need services such as compressed air or electricity. They work well with

nasty environments such as high temperatures or acidic gases.

They work okay with moist or slightly sticky par-ticles and therefore often are used to collect pet food and snacks as they come off an extruder. In this case, cyclones are better because the undried product would stick to and gum up typical filter bags in a baghouse or dust collector.

CYCLONE SIZING

Numerous studies have helped optimize cyclone geometry to achieve the best separation efficiency. In general, cyclone diame-ter, height and cone height are chosen based on the inlet velocity needed to achieve desired vortex speed and number of turns within the cyclone.

Cyclones used in fan systems generally are designed with inlet velocities of approximately 3,000 ft/min (15 m/sec) ±25%. In practice, the air volume is determined first, and then the inlet size is chosen to achieve the desired inlet velocity. Then the recommended cyclone geometry (Figure 2) is employed to determine the other dimensions.

RECOMMENDED CYCLONE GEOMETRY

Figure 2. Recommended cyclone geometry is used to determine other dimensions after air volume and inlet size are known.

0.5D

0.25DDiameter

0.75D

2D

2D

0.25D (not critial)

Gas outlet

Particle ladengas in

0.5D

Particles out


The high range of approxima-tion (±25%) is appropriate because everything about the airflow is an estimate, and precision is not nec-essary or practical. Furthermore, it allows the system designer to use standard sizes of pipe and ducting as off-the-shelf items are most economical and practical. In other words, one would not choose an odd size of tubing, say 9 in. or 13 in., but would instead pick the closest size of available standard products.

Because pneumatic convey-ing systems use blowers rather than fans as the air mover, pneumatic conveying has much higher system pressures than fan systems. Therefore, pneumatic conveying systems can tolerate

higher pressure drops than would be practical in a fan system.

Accordingly, cyclones used in pneumatic conveying systems generally will have a higher inlet velocity, say 3,500 ft/min (18 m/sec.) ±25%. The higher velocity allows the unit to be smaller, and the resulting higher pressure drop actually results in a better separa-tion efficiency because more energy goes into separating the particles from the gas stream.

A disadvantage of cyclones is that the recommended dimensions result in a very tall unit. That typi-cally is not a problem if the device is placed outdoors as long as the support stand is designed to handle the wind load’s forces trying to overturn the support. But if the

cyclone is located indoors, then head height can be an issue.

Designers sometimes will cheat and make the unit shorter. The first choice is to reduce the height of the cylinder sidewall from 2D to per-haps 1.5D if necessary. Any other shortening will significantly harm the cyclone’s ability to separate fine particles from the gas stream.

WHY PROPER CYCLONE

DESIGN IS IMPORTANT

Proper design of the cyclone’s inlet, gas outlet and particle outlet is critical. Smooth transitions that avoid turbulence are required to establish an uninterrupted vortex. Good separation efficiency is pos-sible only if both the downward outer vortex and the upward inner vortex are smooth and continuous. Any turbulence can cause particles to become re-entrained and carried away by the airstream instead of remaining separated from it.

INLET DESIGN

To avoid turbulence, the incom-ing gas and particles must spiral downward quickly, away from the inlet. As soon as they make one

CYCLONE WITH HELICAL INLET

Figure 3. With the efficient helical inlet, a cyclone’s top deck spirals down, forcing the incoming gas stream below the inlet by the end of the first revolution.


revolution, friction with the side-wall will cause gas and particles to be slower than the incoming stream. Therefore they should not be allowed to mix with the incom-ing stream because the resulting turbulence will cause remixing and poor separation of the par-ticles and gas. A helical inlet, as shown in Figure 3, achieves the best efficiency because the cyclone’s top deck spirals down, forcing the incoming gas stream below the inlet by the end of the first revolution.

But helical inlets are difficult to build, especially in larger units. Therefore, involute inlets are more common. As shown in Figure 4, an involute design’s inlet is moved outward, farther away from the center. In this manner, the incom-ing gas is moved away from the spiral, reducing the chance of tur-bulence and mixing.

A tangential inlet, as shown in Figures 2 and 4, is the simplest and least expensive option. But it is more likely to experience tur-bulence and mixing because the

incoming air can touch the parti-cles and gas stream that already are moving downward. Accordingly, a tangential inlet design is less likely to achieve high separation efficiency than a helical or involute inlet cyclone.

GAS OUTLET DESIGN

The gas outlet also must be designed to eliminate any turbu-lence. Again, the key is to allow the gas to exhaust while maintaining a smooth inner vortex. Any turbu-lence, erratic airflow or disruption in the vortex will cause particles to mix with the airstream. If parti-cles become remixed with the gas stream, the gas velocity is higher than the terminal settling veloc-ity of the particles; therefore, the high-velocity gas stream will carry particles away instead of allowing the solids to drop to the bottom of the cyclone.

The simplest gas outlet design is a straight, smooth tube, as shown in Figures 1 and 2. But many times, that isn’t practical. For example, if the unit is out-doors, a weather hood is required to keep precipitation from enter-ing the top. A weather hood typically will have a top cone over the opening, with a large gap for air to exhaust between the top of the tube and the cone.

HELICAL, INVOLUTE AND TANGENTIAL INLETS

Figure 4. With the involute design, the inlet is moved away from the center, allowing incoming gas to be moved away from the spiral. This reduces turbulence and mixing, whereas the tangential inlet’s design allows for more turbulence and mixing, resulting in less separation efficiency than found with a helical or involute inlet cyclone.

HELICAL INLET INVOLUTE INLET TANGENTIAL INLET


On the other hand, if the outlet needs to be ducted elsewhere, or if it needs to be connected to a suction fan or blower, then a

special tangential outlet needs to be used, as shown in Figure 5. A tangential outlet will work well, and the horizontal tube can be rotated in any direction as long as the tangent is placed on the correct side of the outlet tube. In other words, it needs to allow the vortices to spin in the same direction. If the inlet ori-entation causes the vortex to spin clockwise, then the outlet tube connection also needs to encour-age similar clockwise movement of the inner vortex.

SEPARATION CHAMBER

One last design feature, called a separation chamber, can be added at the bottom of the cyclone to help particles separate from the gas stream. If a separation chamber is not used, then a takeaway device such as an airlock rotary valve can be bolted directly to the cyclone’s bottom discharge flange. This will work fine if dust loading is light; for example, many dust collection systems have dust loading less than .007 lb/cu ft (110 g/cu m) of air.

But in systems with heavier material loading, such as

pneumatic conveying, some of the particles will hit the bottom valve and then be swept up into the inner vortex and carried away by the gas stream before they can exit the bottom. In these cases, it is best to add a small chamber between the cyclone’s discharge flange and the airlock rotary valve, as shown in Figure 5. This chamber allows the particulate material to fall out of the cyclone while the outer and inner vorti-ces stay within the cyclone. The chamber won’t have appreciable airflow; therefore, it can be any shape, round or square, as long as it allows particulate material to flow out of it by gravity.

SUMMARY

Cyclones have been around for decades. But they are still an important option, appropriate for many industrial processes. Proper design will help ensure optimal separation efficiency.

TODD SMITH is Business and Strategy

Manager at KSU-Bulk Solids Inno-

vation Center. He can be reached at

[email protected].

TANGENTIAL GAS OUTLET AND EXPANSION CHAMBER PARTICLE OUTLET

Figure 5. This configuration works well if an outlet needs to be ducted elsewhere or connected to a suction fan or blower. A separation chamber also can be added to allow particulate material to fall out of the cyclone while the outer and inner vortices stay within the cyclone.

Tangentialgas outlet

Expansionchamber



http://www.vortexglobal.com

Is The Homogeneity Of Your Dry Mix Acceptable?

Understand how to correctly validate the results of mixing

By Thomas Lamotte, Nestlé Research & Development Singapore

Dry mixing plays an important role in many processes. The operation

can take place at different stages of a process, for example at the beginning to mix raw materials or at the end to disperse addi-tives into a product. Regardless, the purpose of the mixer remains the same: creating a mixture homogeneous enough for the intended application.

This article aims to help pro-cess designers and plant operators understand what homogeneity in solids processing is, how to charac-terize it, and how to validate a dry

mixing operation by measuring the degree of mixing.

HOMOGENEITY

A perfect degree of homogeneity, or mixture quality, means ingredi-ents appear in the same proportions in any sample taken at any point of a mixture. Of course, this ideal result doesn’t occur in the real world. Instead, differences between components, mainly in terms of particle sizes, always will constitute a natural limit to homogeniza-tion. (We won’t consider coating effects in this article.) Addition-ally, the sample size matters when

checking homogeneity — assessing the same mix using two different sample sizes may lead to differ-ent conclusions.

As a consequence, discussing the homogeneity of a mix of solids demands care. The nature of the solids being mixed and the sample size significantly affect the con-fidence you should place in any measurement of homogeneity. Sample size is a critical parameter (Figure 1). So, always reflect upon what represents a meaningful sample size for an application; selecting too small a size will make it difficult to determine if the mix


is homogeneous, while too large a size almost certainly will make the mix appear homogeneous. For example, if a mixture is intended to be consumed (such as a pharma-ceutical or food), the appropriate sample size is the serving size.

The mixing quality is defined in regards to a specific property the processor wants to be equal at any point in the mixture. This sometimes is a physical property like particle size distribution but more often is ingredient compo-sition. Here, we will focus only on composition.

For practical use in processing, the notion of homogeneity must be translated mathematically using statistics. This usually is done by calculating a sample vari-ance (S2) of the concentration of one component from an analysis of samples taken from the mixer.

The analysis is performed on a tracer, a component of the mix-ture whose distribution is taken as representative of the state of the mixture. Getting meaningful results, i.e., rather narrow confi-dence intervals, generally requires a minimum of 30 samples from the mix, with a sampling methodol-ogy that doesn’t leave part of the mix unsampled.

The lower the sample variance is, the higher the degree of mixing or homogeneity and the better the quality of the mix.

CRITICAL FACTORS

Achieving valid insights from sam-ples requires careful attention to three key preliminaries: the desired target value, the choice of tracer and the sampling procedure.

Setting the target value. Measuring mixture quality only makes sense if a processor has set sample variance targets to enable comparing the measurement to an objective. Such targets depend upon the application. Consider two examples:

1. The mixture is used internally for another unit operation on site; the company itself defines the specifications, which may allow quite a large variation to ensure a smooth operation.

2. The mixture is sold directly, e.g., as a pharmaceutical tablet; the specifications must meet legal regulations, which may be very narrow.

This highlights a general point. If the mixture is used in an inter-mediate process step, the quality of the mix may not be critical and rel-atively high composition variations may be acceptable. However, if the mixture is an end product subject to strict regulation (such as a phar-maceutical or food), much more stringent control of the mix quality is required and the validation of the mixer must ensure the mix always will be within specifications.

Let’s now look at how to validate the mixture quality and compare the actual state of the mix to a target.

Choosing a tracer. Determining the composition of complex sam-ples (beyond a binary mixture) sometimes is difficult, if not impos-sible. That’s why analysis often is done only on a single component, the tracer.

INFLUENCE OF SAMPLE SIZE

Figure 1. Reducing sample size from the recommended size (25 g) increases the variance of concentration between samples and results in a higher CV.

Trac

er c

once

ntra

tion

in s

ampl

es, m

g/1

00 g

120

100

80

60

40

20

00 5 10 15 20 25 30 35

Samples taken from mixer

Sample size = 25 gCV = 5.9%

Sample size = 2.5 gCV = 22.2%

CV(

%) o

n tr

acer

con

cent

ratio

n in

sam

ples

Mixing time

Variance on samplinghigh versus actual

composition variance. CV(%) appears higher

than it should be.

Sampling 1: Incorrect sampling procedure (sampling tool creating bias)

Sampling 2: Recommended sampling procedure (negligible sampling variance)


Selection of the tracer demands care. It shouldn’t be a major ingredient, except if the mixture contains only major components. It usually is chosen from small/minor ingredients that often are of interest in the mix (nutrient, active substance, etc.). Because of its low concentration, that component will take longer to homogenize, and thus represents a worst case among all the ingredients.

The tracer should lend itself to easy analysis. It’s better if the tracer is part of the mix formula (vitamin, active substance, reactive chemical, etc.). However, sometimes adding another component as the tracer can make sense to ease the mixer validation exercise, for example, adding salt.

Proper sampling procedure. After mixing according to the specified parameters — typically mixing time and speed, batch size and the

sequence to fill the mixer — you must take samples to measure the quality of the mix.

The way you take samples is crit-ical for a correct assessment of the degree of homogeneity (Figure 2).

For example, consider a batch mixer containing powder at the end of a mixing cycle. Taking every sample only on the left of the mixer, only in the middle or only on the right makes no sense because the samples must represent the whole mix, not only one part.

For this, different methods are possible:

The best approach is to discharge the contents of the mixer and take samples at regular intervals on the free flowing powder, from the very beginning to the very end of the flow. This ensures that no powder area in the mix was left untouched. Sam-pling must occur in a specific way by quickly “cutting” the flux of powder.

If that approach isn’t possible, you must resort to sampling in the mixer. For this, you must use a sampling tool and define a sam-pling plan that ensures every area of the mixer gets sampled. This method is more difficult because easily reaching every point of the mixer may prove impossible, and the sampling tool may induce a sampling bias on the results.

ANALYZING THE SAMPLES

After getting the samples, you must analyze each one. In the best case, you can use the whole sample for analysis (e.g., diluted if necessary). However, if the sample is too large, you must divide it. Don’t take what’s needed for the analysis directly from the sample; this would lead to further sampling bias. Instead, use a sample divider to minimize the risk of mistakes due to re-sampling.

If you’re not that familiar or com-fortable with the analysis method, it’s best to analyze each sample a second time to account for the variability of the analysis. Record the results obtained for each sample.

Calculating the degree of mixing. The mean concentration of the tracer and the variance of the tracer concentration are used to calculate the relative standard deviation (RSD) of the mix, a value reflective of homogeneity:

RSD = (S2)½/µ (1)

IMPACT OF SAMPLING METHOD

Figure 2. Results using the same mixer illustrate that incorrect sampling method can lead to wrong conclusions about mixing quality.

Trac

er c

once

ntra

tion

in s

ampl

es, m

g/1

00 g

120

100

80

60

40

20

00 5 10 15 20 25 30 35

Samples taken from mixer

Sample size = 25 gCV = 5.9%

Sample size = 2.5 gCV = 22.2%

CV(

%) o

n tr

acer

con

cent

ratio

n in

sam

ples

Mixing time

Variance on samplinghigh versus actual

composition variance. CV(%) appears higher

than it should be.

Sampling 1: Incorrect sampling procedure (sampling tool creating bias)

Sampling 2: Recommended sampling procedure (negligible sampling variance)


where S2 is the samples’ variance (this isn’t the actual variance because sam-ples only can provide an estimation) and µ is the arithmetical average of the samples’ concentration calculated from the samples.

Rather than relying on vari-ance or RSD, industry often uses the coefficient of variation (CV), expressed in percentage, to describe the degree of mixing (homogeneity):

CV(%) = [(S2)½/µ] × 100 (2)Warning: the CV obtained

actually has several components; some of these must be calculated to estimate the actual homogene-ity variance.

The sample variance is calcu-lated via:

S2 = S2mix + S2

analytical + S2sampling (3)

The variability due to sampling is very difficult to determine. Thus, in practice, it gets included in the mixture variance. However, for this assumption to give meaningful results, it’s critical to sample the mix following the methods explained above — preferably on the free flow-ing powder — so that the variance due to sampling is negligible com-pared to the actual mixture variance.

The variability due to analysis might be known if experiments have been done before or can be determined for the particular homogeneity validation by dou-bling the measurement on the same sample.

You then can calculate S2mix and

followed by CVmix(%).Confidence interval. Once

you’ve calculated CVmix

(%), you can’t just compare it to the spec-ification. Indeed, the variance calculated is not a true variance but an estimate based on the sam-pling. If sampling is repeated on the same mix, the value obtained certainly will differ.

You must take this variation into account by calculating a confidence interval, generally at 95%, which corresponds to 2 sigma on each side of the mean, i.e., CVmix is within CVlower_limit and CVupper_limit.

The confidence interval depends on the number of samples; the higher the number of samples, the narrower it is. Good practice usually is to take a minimum of 30 samples per mix.

COMPARISON TO

SPECIFICATION

The specification often is given as a maximum acceptable CV on the composition CVspec. It then can be compared to the confi-dence interval:

CVupper_limit < CVspec — the mixing is successful because the mix exceeds the specification;

CVlower_limit < CVspec < CVupper_limit — the mixing may be successful but it’s also possible that the actual variability is higher than the speci-fication; and

CVlower_limit > CVspec — the mixing homogeneity attained isn’t good enough for the application.

For the first case, the proces-sor has achieved the right mixing quality but may wish to test other parameters to optimize the mixing process (e.g., shorten mixing time to increase capacity).

For the two last cases, the plant team must engage in a case-by-case discussion:

• Accept the mix if the applica-tion isn’t sensitive and CVspec is close to CVupper_limit; or

• Reject the mix and look for root causes (mixer speed, filling rate of mixer, etc.).

ACHIEVE SOLID SUCCESS

Validating mixing performance is crucial for controlling pro-cesses that involve dry mixes. You must pay careful attention to key preliminaries, especially defining the sample size, the tracer, the sampling methodology and the analysis technique. Any mistake in sampling or analysis can lead to errors in interpreting mixing quality and, ultimately, to a non-compliant product or a non-optimized process.

THOMAS LAMOTTE is a

senior process engineer at the

Nestlé Research & Development

Center in Singapore.Email him at

[email protected].


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Recently, an engineering contract company had been hired to revamp a

pneumatic conveying system. It successfully designed a new system to replace an existing one at its customer’s site, allowing for theo-retical improvements in efficiency and performance.

However, as is true with many large capital investment projects, theory, equations and common sense are not always enough to fully convince all interested par-ties that a project is valid and will be successful. This is especially true when a new system is to replace an existing system, which will require production downtime for the necessary renovations.

While in this somewhat pre-carious position, the contracting company contacted the Bulk Solids Innovation Center (BSIC) for assistance to help put scientific data behind its full system design to ease any concerns. Further dis-cussions defined the project to the extent that the end user customer was most concerned with attrition of the material conveyed through the system, especially with refer-ence to the number of elbows in the system and material:air ratios. The additional effort and resources needed to design and build systems mimicking the existing and pro-posed systems were considered to be an inexpensive insurance policy to assure the final full-scale system

will meet the expectations of all parties involved.

MEASUREMENT VARIATIONS

Even in a state-of-the-art full-scale test laboratory such as the BSIC, limitations quickly became obvious in the mimic system designs. The first was distance; real-life design was going to be more than 1,000 ft, which extends beyond the limitations of the BSIC. However, the designs were able to match the differences in lengths for the two systems.

Additionally, the real-life cur-rent system pipe diameter was to be reduced in the proposed system. The BSIC had existing equipment at 4- and 6-inch pipe

Case Study: Verifying the Performance of a System Upgrade

Is in Everyone’s Best InterestIt is a cheap insurance policy for large-scale project performance

By Kevin Solofra, KSU-Bulk Solids Innovation Center

Date 2021 / Bulk Sol ids Innovat ion Center Journal-14-

diameters to allow for the impact of the change in pipe diameter to be taken into account, but both still were smaller than the existing and proposed systems. The mimic designs were able to match the exact number of elbow differences,

which was considered by all par-ties as the common sense point where the majority of the existing attrition was occurring.

Obviously, the shorter overall lengths and differing pipe sizes did not allow for an exact match in the pressure drops throughout the system. Nevertheless, with a focus on the attrition, the real-life and proposed systems were designed to handle the same target maximum throughput. The current system had a known air flow, and the proposed system had a designed airflow. These were both used to verify an air velocity of the material at the material pickup point.

Having a target velocity for the two systems that was about the

same, as expected, the maximum throughput was used to calculate the material:air ratios for the cur-rent and proposed systems. The mimic systems’ flow and through-put then were scaled accordingly to match the velocity at the pickup

point and the system material:air ratio, while the pressure was recorded and monitored but not used for design purposes.

MIMIC SYSTEMS ASSEMBLY

Using all of this information, the mimic systems were assembled in the BSIC full-scale lab. Feed rates and air flows were verified with direct measurements. Test-ing was performed on a large scale with 2,000 lb of material per test to allow for full system stability running for anywhere from 15 to 30 minutes.

Additionally, because the mimic systems did not impact production timelines, testing allowed for vari-ables to be changed to monitor the system, including but not limited to

higher air flow/velocities, increased system pressure drops and through-put quantities. This allowed for additional information to be pro-vided on the existing and proposed systems to be able to predict how the proposed system would react to different parameters as compared to the existing system, including identifying low-end air flows that would cause plugging.

The high-end tests of the air flow during the trials were of particular interest, as well, in the event of future conditions when the oper-ator of the proposed system might increase the air flow in an effort to “fix” a reduced throughput or the like.

During the actual test runs, samples were taken from each supersack using a sample thief to quantify the starting conditions of material size. At the end of each run, a thief was used to sample material from the system’s receiv-ing hopper. With testing available on-site, the particle size distribu-tion testing was performed after each run for an immediate results review. This allowed for guidance to the next scheduled test, which led directly to performing extra tests that otherwise would not have been considered. In the end, material attrition remained the

Equations and common sense are not always convincing enough

about potential success.


main target of the testing. The end customer had a minimum particle size target for material at the end of the pneumatic convey-ing process step. The lab testing at the BSIC was able to confirm as good or better particle size results coming out of the proposed system as compared to the existing system. This, in and of itself, was a positive result from all of the testing, but so much other infor-mation was revealed.

ADDITIONAL TESTING RESULTS

The additional flow and particle size distribution changes from various pneumatic flow parame-ters could help with future issues, which otherwise would have to have been achieved by trial and error during a process upset, emergency or planned process downtime of standard production. The impact is a potential savings of production time and product in the future for the new proposed system.

Beyond the condition of the material in the various runs, this testing allowed for the realization of another issue that may have been missed without full-scale testing prior to field installation. As the material was put into a hopper and run through the

pneumatic mimic system, the throughput was monitored and found to drop out sporadically. This was observed in every trial, so it could not be discounted as an anomaly and ignored.

The material was found to be bridging under its own weight

in the hopper. After approxi-mately half of the material was transported from the hopper, no further dropouts were noted in any of the tests. To get away from the bridging, different flow aids were employed. With the number of trials performed, a final recom-mendation was made for fluidizer pads in the hopper’s lowest section as they were the most effective flow aid tested.

The goals laid out from per-forming appropriate testing prior to design approval and field installation were achieved. The end customer and the contractor now have numerical data to use comparing the performance of the

existing and proposed systems. The resultant data also was in line with expectations that the pro-posed system would be as good or better than the existing system as it related to attrition.

While this information was all that originally was needed, the

testing also supplied information about low-flow and high-flow conditions that would have created equipment issues in the field with a completed system. In addition, the end customer receiveda recommen-dation for flow aids in storage to prevent issues.

Overall, the testing program proved to be a great insurance policy to help prevent operations resulting in material not meeting specifications and to identify limits to avoid undesirable process condi-tions from occurring.

KEVIN SOLOFRA is laboratory manag-

er for the Bulk Solids Innovation Center.

Reach him at [email protected].

The high-end tests of the air flow during the trials were

of particular interest.


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When it comes to designing a chemical process system to ensure reliability, optimal energy sav-ings and process efficiency, look no further than the feeders and conveying components within it. www.coperion.com/components

CP-BSICJ_Oct21_Chemicals_feeding-conveying-K2-KCMIII_200x266-7mm_en.indd 1CP-BSICJ_Oct21_Chemicals_feeding-conveying-K2-KCMIII_200x266-7mm_en.indd 1 14.07.2021 14:07:5614.07.2021 14:07:56

http://www.coperion.com/components

Free-flowing bulk-solids handling can be tricky. You need to ensure a uniform

discharge while maintaining the integrity of fragile, friable, abrasive or fibrous materials. Coperion K-Tron has thoughtfully engineered a line of vibratory feeders that achieve high accuracy via patent-pend-ing technology.

Chemical Processing spoke with Urs Helfenstein, R&D mechan-ical engineer, Coperion K-Tron, regarding what makes the K3 vibratory feeders different from other feeding technologies.

Q. What factors affect the selection?

A. With vibratory devices, there are very different technologies available. For example, there are electric drives, which create a lot

of noise. There are pneumatic devices, but pressurized air is an expensive power source. There are rotating masses to create vibration or oscillation. In this case you have moving parts, which means maintenance issues. We went down a new road and examined how masses are balanced.

Shock absorbers are essen-tial when it comes to vibratory technology because you need to separate the vibration of the device from the environment or the structure where it is fixed. Without it, everything would vibrate and make a lot of noise and would be very inefficient. Most vibratory drives use shock-absorb-ing elements that are springs or rubber. We found that if it is on springs or on the rubber element, the vibratory drive can move in

all directions. This has disadvan-tages. The oscillation can be very unpredictable. For example, if you have one material you have a certain center of gravity. But with another material that has a differ-ent density, the center of gravity may change and it causes trouble because it starts to oscillate dif-ferently. This is why some people think vibratory technology is not as reliable or predictable.

Q. How does K3 technology

address that?

A. We use pendulums. They move only in one direction. And that’s the direction where we want to absorb these vibrations. But all other degrees of freedom are restricted. We achieve shock absorption but we restrict all the other effects.

Vibratory Feeding Technology Gets Sophisticated

Patent-pending technology allows a line of vibratory feeders to achieve high accuracy

By Urs Helfenstein, R&D mechanical engineer, Coperion K-Tron


Q. What are other advantages?

A. A big advantage is improved accuracy because we have the same motion for every section of the vibratory tray and the same speed of material, which with the other tech-nologies, you have different speeds on the tray and material height changes over the tray. With our tech-nology, the material moves straight so you have a constant height. This means the material flow is much more controllable and responds to change much faster. We did tests with different materials and with different feed rates and achieved 35% better accuracy on average.

Another important advantage is weighing. If we have less vibra-tion on the scale, we have less errors through this vibration. And together with this adaptive digital filter technology we have in the scale, we don’t see any effect of vibration on the accuracy results. In general, it’s a pretty simple device when it is designed right. And it has very low maintenance require-ments and is much easier to clean than a screw feeder.

Q. Are there any underappreci-

ated aspects?

A. One thing that is not very obvi-ous is the balance. We have a top part where the tray is mounted and there is a counter motion. So, if one

moves up the other moves down and vice versa. And the centers of gravity of these two masses are oscillating in counter directions. If they are in line with the motion, you can reduce the vibration to the environment and scale a lot.

Q. What mistakes are made when

selecting vibratory feeders?

A. It’s not an all-purpose device. It is only for free-flowing material. We do not have an enforced material motion like in a screw feeder. But sometimes facilities want to compromise on this because of the advantages.

Q. Are there special design

considerations?

A. One point to be considered is we don’t have agitators inside, so

it is more sensitive to blocking. To remedy this, we have a technology called ActiFlow™, which uses vibra-tion to break bridges in the hopper. It’s a smart device. If the vibration is not strong enough, it will not break the bridges. And if it is too strong, it will compact the material and then it bridges even more than before. The device measures how much material is on the tray and calculates from there. Many people prefer this over a mechanical agitator since you don’t have to clean something inside because it’s already outside of the hopper.

Q. How does the K3 differ from

other alternatives?

A. We’ve talked about the pendu-lum shock-absorber technology. There is nothing like this on the

K3 VIBRATORY FEEDER

The Coperion K-Tron K3 line of vibratory feeders features improved high accuracy thanks to innovative patent-pending drive technology. They are available in a standard design or a hygienic easy-to-clean design.


market. What we haven’t talked about is the hygienic design. We have a device that needs to vibrate. Usually to allow these vibrations, you have gaps. But for hygienic environments you try to avoid gaps. We designed a silicone boot, which covers the whole drive. There are no gaps. It is completely enclosed.

Another is the controller itself. It is a closed-loop control. We measure the motion 1,500 times per second. And by measuring the motion, we can adapt the excitation signal of the coil in real time. Others do not measure any vibra-tion, they only increase the signal or lower it. We measure the motion and compare it to the excitation and then we see if we are in reso-nance, and we drive our vibratory in resonance frequency. Most of the devices on the market avoid resonance frequency.

For example, if you are on a swing and you are moving in the right frequency, with a little motion you get a big oscillation. This means you’re in resonance. But if you move in a much faster frequency, you get almost no oscillation. This is what most devices on the market do. We

measure the current 25,000 times per second and make adjustments to ensure a clean sine curve and very smooth motion. This reduces noise and vibration.

Compared to other devices, which are pretty simple, it’s very complicated, but it gives us a lot of controllability as well as efficiency.

To give you an example, we mea-sured power consumption at a feed rate of 12,566 pounds (5,700 kilo-grams) an hour. We used only 20 watts of power to feed that amount. That’s a third of a light bulb. Because we drive it in resonance, we only need a little bit of energy to keep it moving.

Q. Anything you’d like to add?

A. We should talk about the weigh-ing technology, which is a core competence of our company. We build our own scales and controls. If you apply more force to the scale, the vibrating wire is more loaded and the resonance frequency increases. By measuring this res-onance frequency, we know how much weight is on the scale. We measure over 100 times a second.

We achieve higher accuracy because the scale is adapted to the environment. We have a demo video (https://bit.ly/k3-feeder) that shows one scale with the filter and one without, both subjected to vibrations. On one you see a noisy signal and on the other one, you see a straight signal. On the one with filter you can actually see the change in weight signal due to drops falling out and on the other you see noth-ing because the signal is very noisy. So that’s very impressive.

Something else we haven’t dis-cussed is pressure in the system. Pressure fluctuations can seriously impact the weighing accuracy of a feeding system. This leads to incorrect weight signals, causing erroneous mass flow and poor feeding accuracy. We’ve devel-oped EPC -- electronic pressure compensation. We measure the pressure on the outlet and in the hopper. And if the pressure changes, we compensate this error on the scale electronically.

Coperion K-Tron has over 100 patents for mechanical components and control technologies to our feeding and weighing solutions. This experience allows us to tailor our products and services to the needs of various industries.

URS HELFENSTEIN is R&D mechani-

cal engineer at Coperion K-Tron. Contact

him at [email protected] or visit

www.coperion.com

“Some people think vibratory technology is not as reliable or predictable...

we went down a new road.”



http://www.coperion.com

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In most bulk powder handling applications, slide gates are used predominantly to either

completely shut off or completely open the flow of material. In some instances, it may become necessary to limit the amount of material that is allowed to pass through the gate. When controlling the flow of dry bulk solid materials, varying controls can be used to meter the volume and flow rate.

Flow controls are components that can be added to a pneumatic actuator to assist in controlling material flow. Pneumatic actuators are more cost-effective than electric actuators and can reposition the blade quickly. Comprising an air cylinder, piston/diaphragm, rod and valve stem, pneumatic actua-tors also can be modified to include a material flow control device to assist in providing accurate mate-rial metering.

These accessories are espe-cially beneficial in applications that include:

• loss-in-weight feeders• material metering

• truck and railcar loadout• dribble flow• scaling operations• batching ingredients• maintaining flow ratesImplementation of material

flow controls and accessories can lead to improved accuracy with precise batch weight calculations whether filling small bags or con-tainers or topping off trucks on scales. Other benefits include the reduction of fill times between workstations and control flow

when handling floodable materi-als that can fill rapidly.

ADJUSTABLE VARIABLE

POSITIONER

The most commonly used and customizable material flow control assembly is the adjustable variable positioner (AVP) (Figure 1). It the most universal option for material flow control. Unlike other options, the AVP can control flow on both the opening and closing strokes. It is a cost-effective option and offers

Improve Batch Weight Calculations

Combine the right slide gate and pneumatic actuator to reap cost savings

By Austin Anderson, Vortex Global USA

ADJUSTABLE VARIABLE POSITIONER

Figure 1. This commonly used positioner controls flow on both the opening and closing strokes and accommodates many intermediate positions.


highly accurate positioning up to 3/16 of an inch.

The AVP can accommodate numerous intermediate positions. The number of intermediate posi-tions is determined by the number of magnetic reed switches mounted to the (pneumatic) actuator. The number of AVP intermediate posi-tions is limited only by magnetic reed switch size, available space along the pneumatic actuator’s tie rods and verification the sens-ing ranges of the magnetic reed switches do not overlap. An AVP requires a programmable logic controller (PLC).

INFINITE VARIABLE POSITIONER

Contrary to other material flow control options, the infinite variable positioner (IVP) (Figure 2) allows for the total control of variable posi-tioning on both opening and closing strokes. The IVP relays blade posi-tion feedback along the entire stroke of the blade by using a linear output transducer. A key benefit of the IVP’s immediate feedback capability is the option for a gate to be moved into any position at any time.

A control box or PLC is used to operate the gate, which can be operated manually at the valve or synchronized with a PLC to auto-mate operations. The IVP’s variable positions are adjusted using tech-nology unlike other material flow control assemblies.

Common applications for IVP are those in which accuracy of material flow needs to be the most precise. In these cases hitting the exact weight of a bag or container is crucial as being off by a small frac-tion can be costly to the company.

VARIABLE POSITION OPEN

In the variable position open (VPO) configuration, a gate can begin in the closed position, actu-ate into a variable position on the opening stroke and then return to the full closed position or continue to the full open position. The VPO is not backward-compatible. If the blade is in the full open position, it cannot be actuated into a variable position on the closing stroke.

First it must be actuated back

to the full closed position before it then can reopen into a variable position. If needed, the VPO also allows traditional full open-to-full closed actuation and vice versa. The VPO is useful during applications that involve dribble flow metering.

CONTROL VARIABLE

POSITION OPEN

The control variable position open (CVPO) modification is ideal for use in applications in which there is a need to limit the full open position to avoid flooding processes downstream. A threaded rod is included at the cylinder housing’s end on the air cylinder itself with the CVPO modification. Manual adjustments can be made to the threaded rod to limit the opening

INFINITE VARIABLE POSITIONER

Figure 2. This positioner offers total control of variable positioning on both opening and closing strokes and allows a gate to be moved into any position at any time.


stroke of the blade. When using the CVPO option, the blade’s full open position becomes the set point established by the threaded rod.

CVPO is used only in appli-cations in which a client needs to limit the opening stroke. Due to the manual nature of this material flow control, changes are infrequent.

VARIABLE POSITION CLOSED

In the variable position closed (VPC) configuration, a gate can begin in the open position, actuate into a variable position on the clos-ing stroke and then return to the full open position or continued to the full closed position.

Like the VPO configuration, the VPC is not backward-compatible.

If the blade is in the full closed position, it cannot be actuated into a variable position on the opening stroke. First it must be actuated back to the full open position before it can be reclosed into a vari-able position. The VPC also allows traditional full open-to-full closed actuation and vice versa. This is another flow control device that is useful in dribble flow metering.

VARIABLE POSITION OPEN

— VARIABLE POSITION

CLOSED ASSEMBLY

The variable position open — variable position closed assembly (VPO-VPC) configuration is used in applications that require control of the blade’s open and close positions to achieve a dribble feed of material.

This assembly combines the aspects of the VPO and VPC controls to allow for the manual adjustment of the intermediate blade position by implementing air control solenoids and a pneumatic trip switch.

TWO-STAGE AIR CYLINDER

The two-stage air cylinder is designed with a magnetic piston to accommodate magnetic switches for position indication. Most suit-able for applications in which the blade needs to stop at the same intermediate position each time, the combined cylinder provides blade positioning at three positions: blade open, blade partially open and blade closed. Two-stage air cylinders commonly are used with three-way diverters in which the stroke needs to be exact to accom-modate the middle position.

EVALUATE YOUR OPTIONS

Manufactures of slide gates can assist in evaluating which material flow control options is best-suited for your specific application. Many details need to be evaluated to determine the best option, includ-ing characteristics of the materials being handled and the gate con-trol’s location within the system.

AUSTIN ANDERSON is content

marketing manager at Vortex Global

USA. Reach him at austinanderson@

vortexglobal.com.

VARIABLE POSITION OPEN — VARIABLE POSITION CLOSED ASSEMBLY

Figure 3. The intermediate blade position can be adjusted manually with this assembly, which combines aspects of the VPO and VPC controls.




Mission and Capabilities of the Kansas State University Bulk Solids

Innovation Center Are ManyHere’s what the BSIC does to help industry

By Kevin Solofra, KSU-Bulk Solids Innovation Center

The mission of the Kansas State University Bulk Solids Innovation Center

(BSIC) is to support industry by improving technology and knowl-edge related to powder and bulk solids handling. BSIC services include material properties test-ing, education classes, product and equipment testing, research and consulting services related to powder and bulk solids materials.

This seems both straightfor-ward and a bit vague at the same time. The straightforward aspect is a support of powder and bulk solids in just about any possible fashion. From the vague point of

view, powder and bulk solids is a large topic to cover and seems to have endless possibilities in today’s world.

OUR CREDENTIALS

Behind all of this, the BSIC staff has decades of experience and dedi-cation to the craft. With experience ranging from academia to indus-trial and manufacturing roles, the experiences blend nicely to support the specific needs and the more ambiguous concepts presented under the umbrella of powder and bulk solids industry.

All of our above-mentioned ser-vices require specific expertise or

equipment to best serve industry. The ability to bring all of this under one roof at the BSIC helps us to fulfill our mission successfully.

STEPS TO SUCCESS

Properties testing. Properties test-ing and material characterization are the first steps in solving issues and achieving optimal equipment designs. The BSIC can provide the most basic of properties needed, including, but not limited to, particle size distribution, surface characterization, angle of repose and various categories of density.

The capability also exists for more in-depth properties such


as wall friction, flow functions through shear cell testing, material aeration, particle velocities and moisture isotherms. Regardless of how far along a project is, many future roadblocks can be avoided by understanding a little more about the material you are testing.

Product and equipment testing. Once the necessary properties are understood, the BSIC can fur-ther support product and process improvement. Every company wants to find the next competitive advantage or bring a cost savings project to fruition to gain a market advantage. In addition, equip-ment manufacturers need a place where they can test equipment performance, new products and prototype options.

The BSIC’s full-scale lab and data acquisition systems often are used to test parameters such as pressure drop, mixing, cross-con-tamination, life cycle and wear. Difficulties can be common when attempting to scale up from lab or pilot plant or test new processes or formulations without imped-ing upon standard production by shutting lines down or losing pro-duction. Alternatively, a material produced with a new formula-tion or process can be difficult to characterize due to insufficient or incorrect equipment in house.

With the properties testing mentioned and a full-scale test lab where new equipment designs and concepts can be worked into stan-dard production systems, the BSIC is a one-stop shop for all of these needs. This combination of product and equipment helps companies understand proper flow chutes and hoppers, air filtration and dust collection, particle size reduction, conveying system requirements, processing and troubleshooting.

Education. The BSIC provides industry-focused short courses to further industry and employee education. Topics covered include powder and bulk solids handling, storage, flow, conveying, dust hazards and material properties, among others. In-person courses are hosted at the BSIC, as the world situation allows, and com-bine a robust discussion of theory along with practical hands-on experimentation in the our lab facilities.

Online courses use the same mix of theory and practical demon-strations and are offered in a fully virtual environment to main-tain consistent training support throughout the year. The BSIC also is available to work with your com-pany to develop customized, on-site or online training solutions tailored to your company’s specific needs.

Research. The BSIC is used to study and develop the under-standing of bulk solids materials handling, in turn enhancing the businesses that use these mate-rials or manufacture the systems that convey, store and dispense them. This is supported through a university-level research center program, which is the only one of its kind in North America. The university- and industry-spon-sored research is performed in six laboratories within the BSIC and includes topics from material properties understanding through full-scale equipment impacts on processes and materials.

Consulting. Our final capabil-ity is consulting, which combines all of the other capabilities discussed. The BSIC has the facility, equipment and staff to evaluate a company’s bulk solids issues. It can offer suggestions for appropriate testing and follow through by working together toward a final solution. The great-est successes within the BSIC is helping companies improve their businesses and increas-ing the state-of-the-art bulk solids processes.

KEVIN SOLOFRA is laboratory manag-

er for the Bulk Solids Innovation Center.

Reach him at [email protected].


There is an increasing focus on improving bulk solids education

and training to ensure higher quality, greater access and better preparation of the workforce to meet industry needs. Even though 80% of bulk solids are used by the public, today’s powder and bulk solids industry lacks a skilled, educated and adaptable workforce. Bulk solids industry leaders rec-ognize this and know that formal education in this area is not widely addressed by academia in under-graduate engineering courses.

Recognizing the need for edu-cation and training to address this skills and knowledge gap propelled the Kansas State University Bulk Solids Innovation Center (BSIC)

to foster a creative and collaborative partnership with Salina Economic Development and industry to provide value-added education, training, solutions and services to enhance efficiency and productivity in a variety of industries — food, chemicals, minerals, pharmaceuti-cals and plastics.

This article summarizes the creation of the Powder and Bulk Solids Academy (PBSA), the courses and training the BSIC offers, as well as the unique experi-ential learning aspects and benefits. Visit the following link to learn more about education and training information at Educational Powder Flow Training and Class for Conveying and Handling of Bulk Solids (k-state.edu).

ADDRESSING THE NEED

FOR PROFESSIONAL

EDUCATION AND TRAINING

Several training programs have been developed to teach and train bulk solids professionals. Com-panies often provide their own in-house training and development programs to improve their employ-ees’ skills and abilities. With the obvious need to address the skills gap in the industry, it is essential to train the existing bulk solids workforce, including sales repre-sentatives, practicing engineers, operators, engineering managers, equipment and system suppliers, consultants, designers and those who need a better understanding of the practical and technical issues involved with the reliable and safe

KSUPBSA Offers Professional Education Courses and Training

Keeping skills up to date matters now more than ever

By Raju Dandu, KSU-Bulk Solids Innovation Center


https://bulk-solids.k-state.edu/particle-training-classes/




handling, storage and conveying of powders and bulk materials.

Working with key stakeholders in the industry, we conducted a comprehensive due diligence exercise to identify existing train-ing offerings in the marketplace. This provided an opportunity to develop a credible, independent and university-affiliated powder and bulk solids education and training program, which led to the creation of the PBSA and its pro-fessional development courses. The courses include KSU university staff, instructional designers and industry subject matter experts.

The purpose is to provide a focused and systematic approach to support industry and train the

new, existing and experienced workforce with relevant, neces-sary and value-added knowledge in bulk solids. Our approach is to provide a sustainable framework, logical flow and a foundation for professional education and training that emphasizes not only theory but also hands-on

practice-oriented skills based on industry needs.

PROFESSIONAL EDUCATION

AND TRAINING PROGRAM

OBJECTIVES

The PBSA has several objectives in mind:

• to address the recognized powder and bulk solids science, engineering and practice-ori-ented knowledge and skills through in-person, online, custom courses and training

• to provide industry and its workforce with flexible learn-ing options through standalone modular courses or options at BSIC, online or at cus-tomer sites

• to create opportunities for effective networking and knowledge exchange among academia, peers and industry

• to ensure that the PBSA courses benefit employees and employers with an unparalleled level of education and train-ing benefits

TYPE OF EDUCATIONAL

COURSE AND TRAINING

OFFERINGS

Based on best practices, a val-ue-added workforce training and development program must mix knowledge and hands-on experience that will be relevant and useful for the employees and industry. Our course offerings are a set of skill-building modules designed to assist individuals in obtaining new or enhancing exist-ing knowledge so they gain a better understanding of technical and practical skills.

PBSA offerings seek to accom-plish specific objectives and improve workplace performance that is targeted to a specific audi-ence, centered on the learner and relevant to the workplace. There are many types of professional devel-opment course offerings, but PBSA has focused on in-person or online and at customer locations. Remem-ber that the specific professional education and training opportu-nities that are right for you will depend on your personal goals and employee and employer needs.

The primary in-person courses varied from two to three days at the BSIC facility. The attend-ees received a classroom lecture on a specific topic and relevant practical, hands-on lab-scale and

Academia does not widely address bulk solids in under-

graduate engineering education.


full-scale testing experience. To continue enabling and delivering the short courses, BSIC adapted to deliver them live online without compromising the importance of practical skills. To help migrate an in-person course to fully online, we were purposeful and inten-tional to rethink the learner’s experience. The online courses were designed for shorter inter-actions for four days, each day for four hours and two days a week. This allowed a meaningful learn-ing experience for all participants.

Recognizing that there are limits to delivering online courses, we evaluated different technolo-gies and methods during and after the delivery to maximize learner experience and in-person feel. In addition to in-person and online, to address customer needs, BSIC started offering focused and cus-tomized training to the industry in the United States. The BSIC team works with the bulk solids handling industry to understand specific employer and employee professional training needs to create a customized training plan. This plan can be used for in-per-son, hybrid, online or live-online courses and additional consulting as needed. These custom offerings are delivered at the customer’s site, at the BSIC facility or online.

AVAILABLE COURSES

PBSA offers the following courses:• Basics of Pneumatic Convey-

ing. This is the first course in the PBSA. This introductory course describes all types of pneumatic conveying, along with pluses and minuses of each. All major components are taken apart and discussed. Basic sizing, applications and troubleshooting are covered.

• Material Properties Testing and

Results Application. This course covers major material properties tests and describes how the test results are used for designing and improving equipment and systems for storage, flow, con-veying and air filtration of dry bulk solid materials.

• Storage and Flow of Bulk

Solids. This course provides an overview of powder and bulk solids handling. Flow of material through silos, bins, chutes, feeders, screws and process equipment are emphasized, with a practical understanding of how solid material properties are used to design reliable equipment and processes.

• Advanced Pneumatic Con-

veying. This course provides a deep dive into specify-ing, designing and sizing a

pneumatic conveying system. It involves a combination of theory, calculations and practi-cal hands-on application.

• Industry Safety of Bulk Solids

Handling: Dust Hazards. This course covers the basics of combustible dust and empha-sizes practical aspects of dust hazard analysis, design of dust control systems and good dust housekeeping as well as best National Fire Protection Association (NFPA) practices concerning dust explosion, prevention, suppression and isolation. Numerous examples illustrate key concepts along with detailed analysis of dust explosion case studies.

BENEFITS OF PBSA

PROFESSIONAL EDUCATION

COURSES AND TRAINING

Over the past six years, BSIC has gradually expanded its short course offerings and training, bringing in industry and academic experts. These experts not only help deliver lectures but also infuse relevant case studies providing interactive and hands-on practice-oriented experiences. The unique and major advantage of PBSA professional education courses is the hands-on learning and earning certificate of continuing education units (CEU).


Most short courses are lec-ture-based, and PBSA wanted to enhance the learner experience by helping them to not only under-stand but also have the opportunity to practice the concepts taught in the course. Further, in-person course participants have the oppor-tunity to tour local bulk solids equipment manufacturing facilities.

Employees get a lot of benefits from the employee training and development program:

• Employee professional edu-cation and training programs significantly help to improve performance by strengthening employees’ job-specific and general professional skills.

• The benefits of ongoing edu-cation and training include improved morale and reten-tion, increased employee independence and more effi-cient workflows.

• Continued employee education programs are important for any industry to stay solvent and competitive in the market. Though it is expensive for the industry to spend money on its employees, this investment is positive for the industry to hold its place in the market.

IMPACT OF PBSA

The bulk solids industry has benefited from the PBSA

course offerings; participants came from varying background levels — from sales to project engineers and managers — and from various industries — food,

chemicals, minerals, pharma-ceuticals and plastics (Figure 1). They also came from local, national and international loca-tions (Figure 2).

ATTENDANCE BY INDUSTRY

Figure 1. This chart shows the variety of industries PBSA course attendees represent.

ATTENDANCE BY LOCATION

Figure 2: This map shows the number of attendees from various locations who partici-pated in PBSA courses.

2

2

1

1

4 4 4

55

14

2

2

2 2 2

7

8

2

1010

16

16

78

39

1214

15

15

2024

3

3

3

3

3

5

5

6

6

6 9

9

6

14

International

Chemical20%

Plastics13%

Other17%

Food16%

Pharmaceutical3%

Engineering/Construction3%

Equipment manufacturer/distributer

28%


TESTIMONIALS

Here are some professional educa-tion course and training participant testimonials:

“Very useful for industry pro-fessionals, very good training, very useful in seeing the demon-stration of dilute and dense phase conveying.”

“Analyze material properties in the lab, design conveying system for it, and actually run it in system, and assess dust risks for it.”

“Hands on experience was extremely valuable. Keep doing it and incorporating it in the course.”

“Case study was helpful to being able to apply what we’ve learned. Seeing actual systems in pictures and discussing what each component is. More real-world examples.”

“I thought this was a great course for people searching broad knowl-edge about bulk solids conveying, and hope to attend an advanced course in the future.”

“Well put together, logically pre-sented, nice facilities, environment, and people.”

“Liked 2 day option instead of

much longer. Liked industry tours. Excellent facility and personnel. Great hands on demo.”

CONCLUSION

The Kansas State University Bulk Solids Innovation Center listened and understood the need for rel-evant and hands-on professional education and training for employ-ees and employers. The Powder and Bulk Solids Academy and its courses and training are a pathway

to address the lack of formal edu-cation in bulk solids in academia. We reached out to address a knowledge and skills gap within a range of the workforce, from early engineers to project managers who need a better understanding of the practical and technical issues involved with the reliable and safe handling, storage and con-veying of powders and bulk solids materials.

Participant feedback and tes-timonials demonstrated course quality and relevance to address the skills and knowledge gap in bulk solids. KSU-BSIC’s modular and flexible professional edu-cation courses and training are provided to ensure the current workforce talent pipeline has con-tinuous and lifelong professional development. These courses are led by industry and academic experts focused on learner-cen-tered and work-relevant programs for the bulk solids industry.

RAJU DANDU is the director of the

KSU-Bulk Solids Innovation Center. He

can be reached at [email protected].

Modular and flexible courses and training address the skills and knowledge gap in bulk solids.



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