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Blending techniques for systems Blending silo techniques

Blending Reliable performance Experience counts We engineer our pneumatic blending FLSmidth has supplied over 500 applications to maximize the benefits of blenders to industrial customers fluidization and gravity technologies worldwide over the past 70 years. -- Mixing two or more products over mechanical blending. Our technology and commitment to -- Homogenation of individual FLSmidth technologies give you product development and testing have products operating efficiency, low power made us the #1 supplier of air gravity consumption, flexibility and increased blenders. -- Size uniformity productivity. Our product range can combine storage and blending for Materials handled include: -- Color uniformity space-saving plant layouts. Ascorbic acid Carbon black -- Chemical uniformity Scope of supply can include: Cement raw mix • Silos Delrin plastic -- Temperature uniformity • Aerated bin bottoms D.S. nickel • Airslide™ gravity conveyor -- Reduce process variations Edible protein • Solids flow control valves Finish cement • Fan and blower packages -- Recycle out-of-spec material Fly ash • Dust collectors Graphite -- Add trace elements • Pneumatic conveying Ground alumina • Compressor packages Iron powder -- Chemical modification • Pipes and bends Kaolin • Diverter valves Magnesite mix • Control panels Natural gypsum

Material Nickel oxide feed Pigments Vent Polyethylene filter Polyolefin Polypropylene PVC PPO resin Rutile Silica Slag cement Starch Synthetic gypsum TBBA

Load Un-ground alumina cells Vitamin C Zinc dust and more.

Air Air

Material discharge Low power consumption

Central inverted cone: air assisted RANDOM-FLOW™ blender gravity blending Six pie-shaped sectors (each subdivided Multiple outlet gravity discharge combined into six aeration zones) and continuous with central cone construction gives blending in a timed discharge pattern advanced gravity blending and storage with provide the lowest energy gravity a power consumption as low as 0.25 to 0.5 blending silo available. Power kWh/metric ton of cement raw meal. Open consumption on cement raw meal as Airslide™ conveyor sections in the flat low as 0.07 kWh / metric ton. New annulus ensure full clean-out when required. and retrofit installations with minimum Space-saving layout of blowers beneath the silo downtime. Material enters the central bin via multiple Airslide conveyors, blending materials from Features and benefits different areas of the silo floor. • No moving parts • Low pressure air An arrangement of air valves activates • Compact PD blowers sequential discharge and provides a • Gravity withdrawal continuous blending of materials from the • Center or side discharge side of the silo through a funnel effect. • Maximum bottom aeration coverage • Small inverted central cone Features and benefits • Reduced maintenance • Total cleanout • Clean, dry, oil free • High capacity (6,000 ton+) • Low power usage • High discharge rates (150 tph+) • Space on ground floor • Controlled flow withdrawal • No segregation • Reduced silo profile • Flexible plant layout • Discharge equipment located under cone • Maximum cleanout • Minimum dust collection • Low installation cost • No segregation • Maximum storage capacity • Reduced foundation cost

RANDOM-FLOW™ blender

Aeration zones When an aeration zone is activated, layers are mixed through a funnel effect as material in the zone flows to its designated collection point on the gathering Airslide™ conveyor. Aeration zone Collection The inverted cone prevents points material exiting without flowing Gathering side through a collection point.

Discharge point Central inverted cone blender Near-perfect blending

AIRMERGE™ blending Air for fluidization and blending can be Air blending is achieved by use of a supplied from common or separate porous membrane over the entire bin blowers as required. bottom, 4 air plenums and a simple flow control system enable. Together Features and benefits they change the density of material in • No moving parts in contact with the the fluidized bed of material to material generate a gentle folding action and a • Simple operation near perfect blend. • Gentle blending action • Low pressure air AIRMERGE blenders can be designed • ~20° slope on fluid bed for batch or continuous operation to • Steel flange connection meet your requirements. • Batch or continuous working • Standard and FDA fabric option Porous fabric held with binding strips • Low maintenance on top of removable grating panels in • Long life the air plenum allows access for fabric • No complicated controls to be replaced in place. • Little dynamic loading • Usually PD blowers Higher air velocities in the blending • Complete cleanout quadrant lower the bulk density • New or retrofit installations AIRMERGE™ blender cut-away causing the denser material in the • System design flexibility three fluidized quadrants to flow into it • Food applications available and be displaced upward in a continuously circulating bed.

AIRMERGE™ blender Top: complete coverage for maximum fluidizing effect; Top: minimal hold-down points for easy installation Bottom: center or side withdrawal - all material flows and maintenance toward center trough Bottom: quick-disconnect type couplings Blending for difficult materials

Column blender Features and benefits A fully fluidized cone, an upper and • No moving parts lower air plenum and an open-ended • Gravity discharge 60° cone design central column allow the principle of • Simple operation air blending to be applied to even the • Robust design most difficult materials. • Greater flexibility in particle size range The fluidizing air enters the cone beneath the column, reducing the Different batch sizes density of the material within; which is By dividing the central column into displaced upward as the denser two or more separate pieces, the material from the annulus of the cone column blender can accommodate flows inward. different volumetric batch sizes. In the smaller batches, material is lifted up in This “fountain-flow” gives a radial the same way but “fountain-flow” circulation capable of blending into the surrounding fluidized bed is ultrafine powders, coarser sandy via the spaces between the upper and materials and products with a wide lower column. For design purposes, particle size distribution. batch volumes must be known in advance.

“Fountain-flow” gives a radial circulation capable of blending the most difficult materials.

Column blender

The column blender can accommodate different volumetric batch sizes. 900-33-ENG

03-12 Materials testing and research

www.flsmidth.com CM

FLSmidth’s research programs are State-of-the-art computerized data aimed at maximizing the energy-effi- acquisition systems permit continuous ciency and cost-effectiveness of recording of variables including pneumatic conveying systems. pressure drop, air volume, power consumption and material flow. FLSmidth’s world-class R&D facility near Bethlehem, PA enables us to demon- Varying process conditions can be strate both the column and AIRMER- simulated in the laboratory so that the GE™ blenders on your materials prior effect on the conveying system can be to contract, avoiding costly site trials observed prior to actual installation. and possible re-work. Worst-case scenarios can be identified Modular equipment assemblies facilitate test programs. We can perform the following tests: and designed for, thereby eliminating • Size analysis costly downtime. • Moisture content • Bulk density Complete capability of evaluating • Angle of rupture materials to determine the most • Bed expansion energy-efficient and cost-effective • Air flow/pressure system design parameters are also • Airslide™ conveyor angle available. • Conveying tests

Test configurations are designed and equipped to permit field-scale testing under precisely controlled laboratory conditions. Flexibility allows operators Multi-unit receiving and transfer stations allow full-scale testing to go from vacuum to pressure in and material evaluations. combinations of line lengths and pipe diameters.

Project Centre Project Centre USA Project Centre India FLSmidth A/S FLSmidth Inc. FLSmidth Private Limited Vigerslev Allé 77 2040 Avenue C FLSmidth House DK-2500 Valby Bethlehem, PA 18017-2188 34, Egatoor, Kelambakkam Tel: +1 610-264-6011 (Rajiv Gandhi Salai, Chennai) Tel: +45 3618 1000 Fax: +1 610-264-6170 Tamil Nadu – 603 103 Fax: +45 3630 1820 E-mail: [email protected] Tel: +91-44-4748 1000 E-mail: [email protected] Fax: +91-44-2747 0301 E-mail: [email protected]

Copyright © 2012 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.