Automatic Filling Nozzle for Explosive Materials P. Rayman and M. Fort, Czech Republic Rayman Ltd have developed an ATEX approved filling nozzle for Sokolovska uhelna as. plant in Vresova, Czech Republic, where its used {or loading coal powcier into bulk tanks for road transportation. loading of bulk materials into road and railway ing nozzles are used for dust reduction during Fe material tanks. They are height adjustable de- exhaust system or are equipped with an integrated fiter and. exhaust flow fan, When handling dusty materials, that ~ cogetl cer with ait use a filing nozzle that has been approved by an authorized en tity according to the European directive 94/9/EC ATEX100 a EN 61261 standard. Rayman Led. recently developed such a special fling nozzle, th SPHn 309, for loading dry coal powder into road tanks for the ‘iesove plant of Sokolovske uhelnaas, Czech Republic. This ar- ticle provides some information about the requirements that hhad to be met, how the system is designed and where the new system can be used, Specification of Explosive Environments According to Atex ‘The ATEX comprises two directives of the European Union: 94/9/EC and 1999/92/85, According to the directives, the envi- ronment can be divided into different zones depending on the probability of the formation of an explosive atmosphere and how long this explosive atmosphere prevails: Zone 20: Areas, where an explosive atmosphere with turbulent Clouds of flammable dust occurs permanent or often and for long periods (more than 1000 h per yea. Zone 21: Areas with a probability of occasional presence of an ‘explosive environment with turbulent clouds of fammable dust (10t0 1000 hours per year). 282 Zone 22: Areas where the formation of an explosive environ: ‘ment turbulent is improbable or where it occurs only in excep- tional cases and fora short time (0.1 to 10h per year). Working Conditions for the new Filling Nozzle The new filling nozzle was initially designed for loading dry pow. der lignite coal from the storage silo into che read containers. AC the customers plant, coal dust is stored ina silo under nitrogen atmosphere, The bottom of the silo is equipped with aeration nozzles supplied by pressurised nitrogen. The material is deliv ‘ered from the scorage silo tothe filling nozzle via a rotary feeder with the minimal capacity of 0 «/h and. sliding pipe. The design of the new filing nozzle is based on a previously exst- ing system that consists ofa filing and a filer section, with the filter inserts incegrated between che external and incernal filling,egacgncraane nozzle sleeve. Regeneration ofthe filter insert sured ar for a JET-system. These filing nozzles are generally ‘equipped with a suction fan mounted directly to the socket on its top head. The inital system features a “one rope” design, ‘which means thatthe bottom partis caried bya single rope in the centre axis ofthe nozzle. lin the frst phase of the development project, the customer, to- gether with the general designer and nozzle supplies identified the eifferent ATEX Zones ofthe loading facility, which are: + inside the storage silo - zone 22 + inside the filling nozzle-zone 20 + inside the bulk material container - one 20 + distance up to 05 m from road tank filing socket -zone 21 tance up to 1 m from road tank filing socket -zone 22 + distance more than 1 m from road tank filling socket - zone ‘without danger of flammable dust explosion + “clear” fiterside- zone 22 Filling Nozzle Design ‘The identification of the different ATEX Zones was fully account- ‘ed for during the filing nozzle design, as specified in the order. Fig. 1 shows the location of the different zones. The guarantee protection of the power supply cables of level gauge inside the nozzle against abrasion by falling material, it was decided that the nozzle should be designed as a three rope system with fixed. bell and movable sleeve of the filing head. However, the basic filling nozale design remained unchanged and, thus, the new sys- tem also consists ofa filing and filter section, Fig. 2 shows a cross section of the new SPHFn 300 filing nozzle for explosive materials handling. The outlet part is coated with antistatic rubber. All sleeves, with sewedin steel rings, ate made of the antistatic textile material VINITOL* for a maximum tem perature of +55 °C. The outlet sleeves are also provided with pull-down springs. Plant Engineering and Materials-Handling Technology somponents and ‘Sr your plant snainecring Pant engieesng and malhaingtchalgy ‘thu Lab GmbH 0.20% 0523. 1.94305 StabingGormany Ta 49(0)9421/9256-0 Fax 49 (0) 9421/9258-25 phe rmat@iebinie ener bulk solids handling - Vol 29» 2009 - Ne. 283technical Note Cross section of Rayman's loading nozzle for explosive Materials type SPHEN 300.0 The fileration section comprises a filter cartridge with replacea- bie supporting basket and Venturi pipe (antistatic finish) a re- generating gas dstribucor, he regeneration system (electromag. etic valves with regeneration pipes), and the outlet chamber with a connection to the suction fan, The fan supplied with the orale is mounted on the steel struccure of the storage silo neat the nozzle in an area without explosion hazard. To be able to use a standard fan type, the suction pipe between the fan and the nozzle is provided with a protective filter. les pur Pose is to capture coal dust that could otherwise penetrate ito the fan incase of faulty or damaged filter cartridges in the filing nozzle. For security reasons, the filter is also equipped with 'manostat. In case of filter clogging. asignal rom she manosta ig: 'Sersa nozzle filter failure signal and the loading process is stopped ‘This olution allows for the use ofa standard fan in spite of zone 22 specified for the suetion socket of the filing nozzle. In order to comply with safety regulations, the filing nozzle was designed with additional earthing connections and individual parts of the nozzle were interconnected by copper conductors. ll non-metal lic pares were designed in antistatic finish (fitrating cartridges, sleeves, rubber coating of contact cone), and to eliminate any pos sible sources of explosion ignition, certain parts of the filing nozzle have been manufactured from non-sparking sted. Electrical Equipment The filling nozzle has a cable interface into the terminal barat its bottom head (level gauge, vibrator). The terminal bar has been designed for environment with hazard of flammable dust explo- sion (zone 21). Outlets of all electrical appliances are terminated ina common terminal bar (protection IPSS) placed on the top head of the filing nozzle. Separate cables connect the level gauge and proximity switches. Overhead control designed for zone 21 is used, The distribution board ofthe filing nozzle contains » Sie- mens PLC unit type SIMATIC LOGO 24RCL for working cycle Control. There are two spare outlet contacts left for subsequent 284 Duk sods handling Fig: 5: The loading nozdeinsalled atthe Sokolovses ubilaa as. "plant, Vresova, Czech Repub €quipment contro. The terminal baron the top head ofthe fil: ing nozzle and the distribution board are specified for ervirony ‘ments without flammable dust explosion hazard, Conclu: n 0 far, four filling nozzles of type SPHFn 300 have be supplied to Sokolovska uhelna as. (Fig. 3). The nozales were certified by the authorized test institute FTZU Ostrava - Radvanice and recelved. the compliance certificate No. FTZU 08 ATEX 0035, Successful certification and a year of operation under harsh conditions broved that the filling nozzles of Hn type are capable of heavy duty operation wherever loading of dry, bulk, powder ot fine ‘granulated explosive materials occurs. The filing nozzle can also. be used for loading other expiosive materials, eg coke dust, flours, sugar artificial fertilizers, plastic powders, ete, Classification of explosive zones according to Fig, 1 has to be re- spected ifthe explosive zone 22 spreads more than 1 meter from ‘the container socket, its necessary to use an electric installation With proper protection, certificated pulse fiter valve, and a winch approved for the operation in the appropriate zone. Alter natively the winch can be placed outside the explosive zone and outside the filing nozzle, eg. attached to an adjacent building structure ee Rayman Ltd, ‘Mr Petr Rayman Ocelarenska 1781, 272 01 Kladno, Czech Republic Tel: +42 (0)382522 115 Fax +42(0)382522 117 EMail: petrrayman@rayman.cz Webs wwwerayman.cz WoL 29 - 2009 - wn. §