Exploring the Role of Flow-Aid Devices in Conveyor Systems
What is a Flow Aid?
Flow aid devices are systems designed to enhance the movement of bulk materials. They range from simple impact piston vibrators used on chute walls to dislodge material buildup, to sophisticated multiple air cannon systems that automatically discharge on a timed cycle to prevent such buildup. These devices encompass rotary or linear vibrators, low-pressure air cannons, aeration devices, low-friction linings, and soft-chute designs, and they can be combined in various configurations.
Traditionally, the approach to clearing blockages and removing accumulations from chutes and storage vessels involved pounding the outside walls with a hammer or similar tool. However, this method often worsens the situation by creating bumps and ridges on the walls that lead to additional material accumulation.
A more effective solution involves the application of flow aid devices to chutes. These devices deliver energy precisely where needed to reduce wall friction, break up material, and ensure continuous movement towards the discharge opening.
This discussion focuses on methods to promote material flow in chutes, particularly those used in conveyor loading and discharge. The principles and technologies discussed here are applicable to a wide range of material processing and storage vessels, including silos, bins, hoppers, bunkers, screens, feeders, cyclones, and heat exchangers.
Flow-aid devices such as air cannons supply energy precisely where needed to reduce the friction of the walls and break up the material to keep the material moving to the discharge opening.
Flow Aids on Transfer Points
When dealing with chute flow, it's ideal to design for efficient material movement based on material characteristics and process requirements. However, due to unpredictable factors such as changes in material source or weather conditions altering flow properties, employing flow aids becomes a straightforward and cost-effective solution to maintain consistent material flow.
Flow aids can be integrated into the original equipment design to stabilize flow rates or address anticipated issues. For example, they might be planned into a system to facilitate material movement through a chute with height restrictions that limit steep angles. Alternatively, flow aids can be retrofitted to address unforeseen problems arising from changes in material condition, process dynamics, or equipment performance.
During chute fabrication, it's advisable to include provisions such as channel mountings for vibrators or nozzle mounts for air cannons. This foresight allows for easy installation of flow aid devices if issues arise later due to material changes or unexpected challenges.
Ensuring the structural integrity of steel chutes and support systems is crucial, as operation of flow aid devices can exert significant stress. A well-designed and maintained chute should withstand these stresses without damage.
Proper operation of flow aid devices requires that they are activated only when the discharge is open and material can freely flow from the chute. Activating them when the discharge is closed can compact the material, exacerbating flow issues upon reopening and potentially causing damage to the equipment. It's best practice to control flow aids with timers or sensors to prevent buildup of material that impedes flow. This approach not only conserves energy and reduces noise but also enhances safety by ensuring that flow aids operate only when necessary.