Digital Re-print January | February 2014

Design of an efcient intake pit dedusting system the state-of-the-art in technology

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16 | January - February 2014

GRAIN

&FEED MILLING TECHNOLOGY

Design of an efficient intake pit dedusting system the state-of-the-art in technology

by Andreas Rembeck and Rico Hindemith, Bhler GmbH he unloading of bulk materials such as cereals into intake pits is generally associated with considerable dust emissions. The reasons for the need for an efficient receiving pit dust control system can be diverse. They range from reducing dust emmissions in neighboring residential areas to improving health and safety at work for those working on site and the imperative requirement of preventing serious damage to plant and danger of fatal injury from dust explosions. Bhler Grain Logistics offers a choice between two systems, depending on application requirements: namely central or distributed receiving pit dust control. These can be further subdivided on the basis of whether extraction is above or below the grid iron. Both systems are of modular design and can therefore be customized to the specific conditions of each situation. To ensure that the required aspiration capacity of the intake pit dedusting is kept

to the minimum, every component needs to be optimized. It is therefore an advantage if there are gates at the entrance area which are kept closed at all times during unloading so that undesired air draughts and dust escaping to the surrounds can be prevented at the outset. For an optimum air flow inside the reception area, the upper section of the side wall is fitted with louvers. This prevents dust getting whirled up and ensures that the dust which collects is directed towards the extractors (Figure 1). Another technical step towards minimising dust emissions can be taken by installing a dust barrier. The barrier has dust retention panels (Figure 2) and prevents dust whirling up in the hopper. Practical experience from day-to-day operations has shown that up to 75 percent of the dust which is generated is produced when the bulk material hits the floor of the hopper. The dust barrier reduces air requirements, allows smaller filters and fans and cuts the power requirements of the fans by approximately 60 percent.

Filters for intake pits (decentralized)

For operations such as grain collection facilities or farms where the amount of dust generated is insignificant or plays only a minor role at most, decentralized dedusting is the more appropriate solution (Figure 3). In this case two adjustable inlet openings allow the air which requires cleaning to flow into the filter panels, from which it is directed to the fan through a manifold pipe line. The filter modules are connected using elements to form a single unit and the cleaned dust falls back into the reception pit via a diagonal plate.

Centralized intake pit dedusting

Centralized dedusting is designed more for food processors such as grain mills and producers of pasta, where removing dust from the raw product is essential. As in decentralized dedusting, the air to be cleaned is also caught by an aspiration panel. The individual aspiration modules are screwed together, which means that a variety of intake hopper sizes can be created ranging from 4 m to a maximum of 24 m in length. The aspiration panel is connected to a dust manifold pipe line which leads to a Bhler round filter. The round filter is a central filter with a jet-pulse cleaning system. This is where the flow of raw gas which is picked up and the dust which is retained are separated. The dust is conveyed through dust discharge chutes to separate dust containers or big bags. As a result, the undesired dust no longer comes into contact with the product, thereby ensuring improved hygiene and greater safety. This system could be described as a form of initial pre-cleaning.

Filter
TA-Luft directive requirements under the German Federal Immissions Control Act stipulate emission limits of 20 milligrams of residual dust per normal cubic meter of air. The use of antistatic filter bags is one way of ensuring compliance with these reference values. They are more effective at cleaning than filter cells and also permit higher airto cloth ratios.

Figure 1: Schematic diagram of an intake pit

17 | January - February 2014

GRAIN

&FEED MILLING TECHNOLOGY

Figure 3. Filters for intake pits (decentralized)

Figure 4: Type RB round filter

Cleaning is on a time-controlled and/or differential pressure controlled basis, which ensures optimum filter performance and saves energy.

Comparison
The two types of intake pit dedusting systems can be designed for both side and rear unloading. With their adjustable double gap they can be customized to local conditions and are capable of aspiring even if the intake pit is overfilled. Depending on requirements the walls can be supplied with filter modules only or with partition walls as well, enabling sizes ranging from 2x3 to 4x24 square meters.

The differences between the two filter systems are as follows: whereas the decentral dedusting system has a larger surface and therefore a lower filter load than the central dust removal system, the maximum dischargeable air rate of 55 m per minute and meter of pit length with a filter load of 5 m per minute and m of filter surface (grain) is less than the dischargeable air rate of the central solution, which is a maximum of 65 m per minute and meter of pit length for the same filter load. Separate dust separation means that the central version requires more space for Bhler round filters (Figure 4) and

dust containers. On the other hand the decentralized dedusting system involves additional costs in terms of compressed air for cleaning the filter bags. The purchase costs of the central receiving pit dedusting system are generally higher than for a decentralized system because the former has more components. In terms of operating costs, however, the central solution normally works out better. Both systems have their advantages. The decision as to whether preference should be given to the central or decentral option depends on the specific application. www.buhlergroup.com

About Bhler
Bhler is a global technology leader which specializes in the supply of equipment, systems and services for the conversion of renewable resources derived from food and synthetic substances into top quality functional products and materials. Bhler operates in over 140 countries and has some 10,000 employees worldwide. In fiscal 2012, the Group generated sales revenue of CHF 2,409 million.

Figure 2: Dust retention panels

This digital Re-print is part of the January | February 2014 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.
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