This self-contained, high-volume bulk material packaging system from National Bulk Equipment, Inc. processes up to 50,000 pounds/hour of combustible materials of varied physical characteristics, including: interlocking flakes and free-flowing, friable rods. Process operations include: material discharge from bulk bags; material introduction from belt flaker units; enclosed, vertical conveying; high-capacity bulk storage; material conditioning; and packaging into bulk bags. Integral to providing a reliable, consistent, high-volume material supply to the downstream bulk bag packaging operation are three, 1,060 cubic-foot capacity storage vessels. Built to ANSI and ASME standards, each 12-foot diameter vessel is constructed of 304 stainless steel, and is internal pressure rated to 116 PSIG. Material is supplied to each vessel from a 50-foot tall bucket conveyor through a 3-way flange inlet that directs material to size reduction units then into the storage vessel. Material is discharged from each storage vessel to the bulk bag filling systems using 12-inch, cast stainless steel rotary airlock valves rated to 150 PSIG and 400ºF material contact. Conditioned material is packaged using three, bulk bag filling stations, each at a process rate of 17,000 pounds/hour. Integrated, NTEP-certified hang-weigh scale systems (Cert. No. 07-108) ensure each filled bulk bag package weighs accurate to +/- .01% of total bag capacity, up to 4,500 pounds.
System-wide process automation and controls communication are managed from the facilities supervisory control and data acquisition system (SCADA). Equipment-level automation and controls are centralized to a single, menu-driven, touch-screen HMI, designed and built by NBE.
Operator exposure to caustic material was eliminated, and operator physical ergonomics were optimized as a result of rigorous NBE risk assessment procedures. NBE expertise in specifying, designing, and manufacturing process systems to application-appropriate codes, standards, and regulations ensured system compliance at start-up.