Context

The customer, who works in the chemical industry, needed to replace their adipic acid loading unit. The unit consisted of four big bag emptying stations, each equipped with a transfer screw that feeds a pneumatic transport lock.

The customer’s request

The customer wants to replace the four emptying stations while keeping the existing screw.

To ensure safety, big bags will no longer be handled by forklift trucks.

The customer also requested a lump breaker for each emptying station to crush any lumps of product and improve screw feed.

Additionally, each station must be equipped with a guillotine valve for regulating emptying.

Finally, ISERCO must be able to offer an installation that guarantees the safety of operators on site.

The purposed solution

Each emptying station is equipped with:

  • A steel frame equipped with a monorail, which is split at ground level.
  • A common footbridge for the 4 emptying stations.
  • A hoist to ensure optimum emptying of the big bags. It is fitted with two detection sensors fixed to the monorail and two safety stops. The hoist is operated by a wired remote control.
  • A lifting cross-member is used to keep tension on the big bag ears while emptying, and anti-return hooks securely fasten the bag to prevent it from coming loose when suspended.
  • A stainless steel hopper equipped with a vibrating motor to extract compacted products or those with poor flow. The hopper is insulated by four silent blocks and operates on demand.
  • A double-skinned, height-adjustable CLEAN CONNECT to ensure a complete seal by pinching the big bag. The unit is height-adjustable using gas cylinders, so it can be adapted to a wide range of bag types and lengths. Adjustment is made by an electro-pneumatic cylinder. A butterfly valve pneumatic actuator is integrated into the Clean Connect outlet.
  • A lump breaker to break up lumps that form during product transport. The inside of the lump breaker can be completely cleaned without having to dismantle the whole assembly. The primary and secondary shafts are accessible via a dismantling flange. Similarly, seals can be replaced without dismantling the entire system.
  • A double-acting guillotine valve was installed on the outlet of the crushers.
  • A screen door and safety lock.
  • A load cell.
  • A PLC program.

Automation and Electrical Systems

These 4 emptying stations are equipped with an automated system.

The automated system enables:

  • Automatic installation and removal of the big bag using the hoist.
  • Sequencing of big bag emptying (end of emptying detected by weight, degassing, start-up of next loading station).
  • Timing of on/off cycles for the vibrating hopper and the lump breaker.

The system includes electrical cabinets with emergency stop buttons, maintenance cycles, and front and rear security keys.

Every station is installed on load cells.

Bulk information

  • Industry: Chemical.
  • Type of product: Adipic acid.
  • Density: 0.67 T/m3.
  • Granulometry: 298,6 – 331,6 μm (50 %).
  • Discharge flow: 2,6 t/hours (instantaneous screw flow)
  • Big Bag features: Models with 4 lifting points, rectangular shape, and inner bag (5 different sizes).