The waste wood power boiler uses a wet scrubber to remove ash from the boiler system. The water with unburned carbon, or “char”, and sand with grit is then pumped at a rate of 2300 GPM to the vibratory dewatering screens. The urethane screen panels remove the char and most of the sand and grit from the water. The solids are then removed by conveyor or end loader to the wood yard. The water is sent to the clarifier system for further solids removal. The unburned carbon can be re-injected into the boiler as fuel.

Construction and demolition recycling system that maximizes separation efficiency and volume while reducing manual sorting requirements and maintenance.

This large capacity system is located at a construction and demolition business.  It replaces an existing smaller system which could not efficiently handle the large volume of waste and debris.

Waste and debris are dumped onto a vibrating finger screen that separates the over-sized materials from the “heavies” such as concrete, masonry, stones, rocks and ferrous materials.  The over-sized materials are sent to an existing picking platform that consists of four bunkers.  The heavies are sent to a different part of the system that first removes the ferrous materials using a large overhead magnet.  Then the remaining “heavies” are sorted by size and moved to the collection points using conveyors.

Cement Kiln Dust Mixer under Surge Hopper

Cement kiln dust, or CKD, is the fine material transported by hot gasses inside a kiln to a collection filter.

A Texas Cement producer wanted to replace an existing, inefficient pug mill that was conditioning the collected dust before safe disposal in a landfill.  The producer needed to “wet CKD to a dustless powder” at a rate of 200 Tons Per Hour (TPH).  After testing a sample of the dust, the Dustmaster 200 TPH Series II mixer was selected to replace the existing pug mill.

The 200 TPH Series II is a batch mixer that includes load cells.  A batch of the cement kiln dust is loaded into the Series II from a surge hopper.  Next, a predetermined amount of water by volume is added to the dust at a controlled rate. By adding the water at a controlled rate, the process is able to limit the heat generated by the  exothermic reaction, and does not “over saturate” the dust with water. This also ensures that the ratio of water to cement kiln dust produced is consistent and can be easily reproduced for all future batches.  Since installation, the system has conditioned tens of thousands of tons of dust.

200 TPH Series II - Batch Mixer with Load Cells

vibrating indirect cooling conveyor system

Vibrating indirect cooling conveyor used to cool thermally treated hazardous waste from 600 degrees F to 200 degrees F using water as the cooling medium. The vibrating cooling conveyor is 5 foot wide by 50 foot long.

The conveying trough uses deck plates with convoluted embossing through which the cooling water flows to remove the heat from the hazardous waste. The cooling chamber is totally enclosed and vented. Material of construction is carbon steel and the drive is a natural frequency design with one low HP motor.

What is Indirect Cooling?

In indirect cooling, a hot material is conveyed along a vibratory conveyor trough surface cooled on its underside by a completely segregated cooling medium flow stream such that the cooling medium “Indirectly” absorbs the heat given up by the hot material as it moves along the length of the conveyor trough. (Indirect heating can occur on a similar basis with hot water, steam, or other heated medium.)

Counter-flow of the two flow streams is typically employed to improve heat transfer efficiency. Although water (or steam) is the most common cooling (heating) medium, aqueous solutions of ethylene glycol, heating oils, and other mediums are used as well.

Indirect cooling is usually applied when the material is oxygen sensitive or categorized as a hazardous waste.

Construction may be carbon steel, stainless, or other metals.

Indirect Cooling

Indirect Cooling Vibratory Spiral

These indirect cooling vibratory spirals incorporate very long cooling lengths and large surface areas for extended residence time for cooling of air sensitive granular solids, such as:

• rubber crumb
• granular chemicals products
• food products such as rice

The large spiral vibratory conveyors incorporate the manufacturer’s variable rate, tow mass, natural frequency drive technology to allow for fine tuning of the residence time for optimized cooling.

The cooling chambers can be totally enclosed and conditioned with air or inert gas purged as the application requires. Cooling spiral as shown above is 78 inches in diameter with a over all  lift of 21 feet and is driven by two each 3 HP motors. This unit incorporates 240 square feet of cooling trough and 420 square feet of cooling surface area and uses cooling water flowing under the conveying trough for cooling of the granular solids in the pan.

What is Indirect Cooling?

In indirect cooling, a hot material is conveyed along a vibratory conveyor trough surface cooled on its underside by a completely segregated cooling medium flow stream such that the cooling medium “Indirectly” absorbs the heat given up by the hot material as it moves along the length of the conveyor trough. (Indirect heating can occur on a similar basis with hot water, steam, or other heated medium.)

Counter-flow of the two flow streams is typically employed to improve heat transfer efficiency. Although water (or steam) is the most common cooling (heating) medium, aqueous solutions of ethylene glycol, heating oils, and other mediums are used as well.

Indirect cooling is usually applied when the material is oxygen sensitive or categorized as a hazardous waste.

Construction may be carbon steel, stainless, or other metals.

Indirect Cooling

Indirect Cooling Conveyor for Catalyst

An indirect cooling vibratory conveyor is used to cool regenerated catalyst from 3000 degrees F to 300 degrees F. This is done using 180 degree F cooling water obtained from a previous cooling step in the regenerative process.

The manufacturer developed a curvilinear trough cross section to control relative thermal expansion growth. A series of draped and contoured linked metal curtains of sufficient weight to serve as flow inhibitors and distributors are employed to displace, spread, and mix the granular flow stream frequently, as it proceeds down the length of the cooling chamber. This produces a consistent temperature profile and uniform product discharge .

The conveyor system  is totally enclosed and uses a natural frequency drive system with one low HP motor.

What is Indirect Cooling?

In indirect cooling, a hot material is conveyed along a vibratory conveyor trough surface cooled on its underside by a completely segregated cooling medium flow stream such that the cooling medium “Indirectly” absorbs the heat given up by the hot material as it moves along the length of the conveyor trough. (Indirect heating can occur on a similar basis with hot water, steam, or other heated medium.)

Counter-flow of the two flow streams is typically employed to improve heat transfer efficiency. Although water (or steam) is the most common cooling (heating) medium, aqueous solutions of ethylene glycol, heating oils, and other mediums are used as well.

Indirect cooling is usually applied when the material is oxygen sensitive or categorized as a hazardous waste.

Construction may be carbon steel, stainless, or other metals.

Indirect Cooling

View more information about Open Mouth Bagging Machines

Boiler Ash Handling & Recovery System

Boiler ash handling and recovery system is designed to remove unburned carbon (char), ash, grit and sand from waste water discharged from wood and bark power boiler. Slurry, composed of water and solids, is sent from the wet precipitator to the vibrating Hi-G dryer at rates from 800 to 2200 GPM. The Hi-G dryer uses two, low horsepower, vibrating motors to apply a high G-force on the urethane screen panels.  This separates the water from the solids.

The unburned carbon, or char, is discharged from the Hi-G dryer onto a belt conveyor.  It is also stacked on grade for transfer to the bark or waste wood storage area for re-burning in the boiler. The ash, grit and sand is removed for disposal in a land fill.

This type of ash handling and recovery system can be also be used to remove minerals, green pet coke and other solids from process and cooling water streams.

Coal crusher, single stage, 2 roll

This coal crusher is a single stage, two roll crusher installed in a power plant. It was selected to replace a large hammer mill crusher that was generating too many fines for the coal fired boiler.

The crusher is processing a mix of PRB coal and Eastern Oklahoma coal at a rate of 850 TPH. The feed size to this unit is 3 inches with the occasional 5 inch lump. Product size is 1/2 inch. The coal crusher has only one drive motor and a single gearbox to provide power to both abrasion resistant, replaceable pin tooth rolls. The gap between the rolls is adjustable to allow for in-operation adjustments as needed. The entire unite has tramp metal relief to allow for large tramp metal to pass through the crusher without damage to the rolls or the drive system.

Crusher, gear box and electric motor drive

Single Electric Motor

Abrasion resistant, replaceable, pin-tooth rolls

Close up of coal crusher rolls

vibrating tables for used for powder compaction in boxes

Eight industrial vibrating tables were used for resin powder compaction while filling boxes to desired weight of 55 pounds per box.

Requirement was for a packaging system to increase production in an existing plant. Customer wanted to reuse their existing packaging head to fill the boxes with a powdered resin material to a weight of 55 pounds per box. Eight vibrating tables were manufactured, with each table having a powered roller deck, load cells to weigh each box, and controls to automate the filling process.

Operator places a box on the roller deck and press start button to initiate the filling cycle.  When start button is pressed, controls elevate the vibrating grid deck to compact the powder while filling the box to the desired weight. Once the box has been filled to the desired weight, the vibrating grid deck lowers and the powered roller deck discharges the filled box onto a rolling accumulation conveyor.  Each packaging line has a side by side system to allow one operator to fill two boxes simultaneously.

One operator can control 2 vibrating tables

controls for vibrating table