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-ft. 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-ft. 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-in., 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 lbs./hr. 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 lbs.
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 has been eliminated, and operator physical ergonomics have been optimized as a result of rigorous NBE risk assessment procedures.
