LBIS has accumulated extensive experience over the years with various material processing operations. This experience allows us to design custom solutions for all types of bulk material processing needs. Overall process design can incorporate any one or multiple of these systems. Common systems that we can adapt to your plant include:
LBIS works closely with our suppliers to select, specify and design components required for these material processing systems. Components provided can include:
Classifiers separate processed material into a coarse fraction and a fine fraction based on a selected cut-point. The separation process works by balancing a centrifugal force against an aerodynamic force. LBIS has incorporated both cyclonic classifiers and rotary vane classifiers into our plant installations.
Screeners are used to separate processed material into a coarse fraction and a fine fraction based on a selected cut point. A screener cut-point is more precise and absolute than a classifier since only particles smaller than the holes in the screen deck can get through. A screener can have multiple decks; hence multiple cut-points. Screener capacity is generally lower than for a classifier for the same level of investment. Screeners are usually applied for separating coarse materials at high capacity or fine materials at low capacity. Many types of screeners are available including dry passive or vibratory screeners, trommel screens, wet screens and others.
Hammermills, crushers, or pulverizers are used to reduce the particle size of a bulk material. They are usually paired with a classifier or screener to recycle the coarse fraction back through the size reduction equipment and convert essentially 100% of the feed material to the desired particle size gradation.
Bulk material dryers are designed to reduce the moisture content of feed material for further processing. Dryers can be rotary direct or indirect. They can also be fluidized bed. Natural gas is normally used to provide the heat source. Care should be taken to purge interstitial moisture with dry air and allow the material to cool after drying in order to avoid condensation of atmospheric moisture.
Mixers can be used as conditioners for mixing water with dry powders in order to control dust and provide the correct moisture content for maximum compaction. Mixers are also used to blend two or more dry powders either in a batch or on a continuous basis.
Compressed air systems provide the compressed and conditioned air necessary for various process requirements including operating valves, purging instrumentation, pulse cleaning filter bags and product aeration. Compressors are also used for long distance, dense phase, moving fluidized bed conveying. Compressed air systems usually consist of a compressor, moisture separators, filters, and an air dryer.
Blowers, usually rotary lobe type, are used for low-pressure pneumatic conveying. This can be used in either pressure mode, vacuum mode, or both; such as in a push-pull system. Blowers are also used for fluidization as in an air slide conveyor or silo discharge system.
Fluidization equipment includes airslide conveyors, silo flat floor aeration systems, air pads on cone bottom silos, and air pads on dense phase transporter vessels. The purpose of fluidization equipment is to infuse compressed air into a powder material so that it will flow like a fluid.
Hoppers are necessary as a buffer between various components of a conveying or processing system. LBIS designs and contracts for fabrication of various hoppers as needed for its processing systems.
Hopper discharge equipment is used to facilitate the flow of bulk material out of a hopper or silo. It can take various forms such as fluidizing air pads, vibrators, or an activated bin bottom. Selection of the correct hopper discharge equipment requires thorough knowledge of the material properties being stored in the hopper.
Feeders are used to control the flow of material into a process. Common types include weigh belt feeders or loss-in-weight feeders.
Valves are used in a typical processing, storage, and conveying facility. These could ln include, knifegate, butterfly, ball, check, etc. They could be manually, pneumatic, hydraulic, or electrically operated.
Bag filters, with or without ventilation fans, provide dust collection at mechanical conveying system transition points and provide ventilation of hoppers, silos, and loading spouts.
Mechanical conveying equipment includes belts, screws, bucket elevators, rotary feeders, drag chains, and similar equipment. LBIS will select and size the correct components for each part of your process.
Weighing equipment is used throughout a typical bulk material processing facility; such as in a truck scale, silo level controls, loss-in-weight feeders, or weigh-belt feeders.
Piping can be welded carbon steel or hardened steel piping with bolted fittings.
The process control system will include a PLC, HMI, and appropriate software. The PLC (Programmable Logic Controller) integrates all the instrumentation, process control outputs, and the MCC. The logic software is programmed specifically for your plant to consider all possible operating configurations. The HMI provides an animated graphic representation of your process and is programmed for simple, intuitive control of your process by your operator.
Power controls include MCC, breakers, motor starters, transformers and low voltage distribution panels integrated with the process control system.
Instrumentation is used throughout our systems for measurement of pressure, flow, temperature, valve and equipment position, material level in hoppers and silos, shaft rotation, and other important process variables.
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