December 2nd, 2011

Equipment Spotlight: Material Handling Conveyors

Understanding the differences between material handling conveyor systems can help you avoid system failures and unnecessary design complexities that can reduce reliability and increase cost.

 

Drag Chain Conveyors

Generally used in dust-tight environments, drag chain conveyors are ideal for handling hot, abrasive and/or corrosive material, and when a shift in elevation is required. There are two common types of drag chain conveyors – single chain strand and multiple chain strand.  Dual strand drag conveyors are effective for handling both solid particles and large particles in a bottom ash removal system.  However, they can present design challenges in the form of uneven drag chain elongation – an issue that can present maintenance and operational challenges.

 

Key features of a drag chain conveyors:

  • Designed for vertically pulling materials such as coal, wood, TDF, lime and other materials while maintaining particle integrity.
  • Engineered with multiple inlets and discharge points for maximum efficiency.

 

Screw Conveyors

Also known as an auger conveyor, the screw conveyor utilizes a flighting (a rotating helical screw blade, usually within a tube) to transfer liquid or granular materials. Ideal for handling a wide variety of materials from biomass to sludge-like substances, screw conveyors typically feature enclosed housing to prevent leakage and compact designs that allows for relatively easy installation.

Key features of a screw conveyor:

  • Can be a very economical method of conveying when space allows.
  • Can be operated with the flow of material inclined upward.

 

Belt Conveyor

Widely known for being the most economical method for conveying solid materials over long distances, a belt conveyor can be constructed to work independently or in tandem with other conveyors as part of a more complex fuel handling system.  Belt conveyors are flexible enough to handle varying elevations and can operate over short or long distances. This type of conveyor is ideal for handling dry materials, as debris from damp or sticky material can stick or clump to system components.

 

Key features of a belt conveyor:

  • Transport a large variety of materials size, composition and capacity.
  • Flexibility for loading and discharging of materials.
  • Improved reliability due to fewer moving parts.

 

Regardless of the specifics of your setup, reliable conveyor solutions must be fabricated with highly-specialized alloys and coatings to withstand a wide array of environmental factors. ProcessBarron designs, fabricates and installs material handling conveyors that reduce maintenance requirements and maximize efficiency – including redesigning or retrofitting existing systems.

 

Contact ProcessBarron to learn more about how our custom fabricated material handling conveyors can improve efficiency and maximize your material handling operations.

Tags: , , , ,
Posted in conveyor systems | No Comments »

October 19th, 2011

Simple Solutions for Ash Handling Systems

Cliff Moss, VP for Materials Handling at ProcessBarron, detailed challenges and simple solutions for ash handling systems in the September issue of Biomass Products and Technology.  His article “Biomass Ash Handling: Simplifying the Challenges” details common pitfalls and simple solutions that can improve reliability, reduce downtime and minimize maintenance costs.  Article excerpt:

 

Bottom Ash and Fly Ash Systems

Some mills have ash systems that collect bottom ash material with their fly ash collection system. Adding the bottom ash to the fly ash collection often requires a cumbersome system to take the bottom ash to the back side of the boiler where the fly ash system is located.  Adding these systems together as one system has proven to be very unreliable and difficult to maintain. The ash particle characteristics and properties of bottom ash and fly ash are very different and therefore have different conveying principles. Trying to incorporate both in one conveyor design creates too much cost, complexity, and tradeoffs in design reliability.

 

The problem these mills encounter with their ash system is that the bottom and siftings hopper material (ash, rocks, sand, clinker, and wood) does not work well in a fly ash system arrangement. When this material is mixed with the fly ash it requires the conveyors downstream to have a more complicated design such as dual strand drag chain conveyorverses single strand drag chain conveyor arrangement.  It also causes difficulties in the ash silo and conditioning system designs due to the solid bottom ash particles entrained with the fly ash particles.

 

The best way to avoid these problems is to treat the bottom and sifting hopper material as bottom ash, and handle it separately from the fly ash. Keeping these systems separate allows for a system that will operate very predictably and reliably for each of these two very different types of material/ash. Additionally, this will require the least amount of conveyors and minimize the total length of the required conveyors…

 

For more insight, download the full article in the ProcessBarron Knowledge Base.

Posted in ash handling, plant maintenance | No Comments »

September 8th, 2011

Five Important Reasons Preventative Maintenance Makes Perfect Sense

Preventative Maintenance. Those two words alone imply the benefit of this practice, but many in the industrial industry abide by the “if it ain’t broke, don’t fix it” rule. Below are five important reasons that Preventative Maintenance makes sense.

  1. Plant Safety

    In order to avoid injuries to your equipment operators, it is important that the equipment used is maintained at the highest standards. Regularly scheduled preventative maintenance can confirm that the machine is working properly and avoid emergency situations and outages, which, in terms of safety concerns, may be too late.

  2. Efficiency

    Preventative maintenance assures the efficiency and speed of your equipment. Over time normal wear and tear can result in diminishing efficiency. By planning for scheduled maintenance, the energy and life of your equipment is conserved. Additionally, any kind of maintenance causes less strain if it has gone through regular maintenance programs.

  3. Immediate Savings

    For many reasons, money can be saved when conducting preventative vs. emergency maintenance. One, preventative maintenance costs less to facilitate than a large repair or replacement. Additionally, knowing when a scheduled shutdown will occur allows you to staff accordingly.

  4. Long-term Savings

    During an emergency shutdown situation, the immediacy required can cause both parts and labor to be priced at a premium, if they are available at all. Preventative maintenance also allows your equipment to run at higher capacities for longer, allowing you to get the most from your investments.

  5. Time Savings

    Preventative maintenance procedures, for the most part, take less time to complete than emergency repairs and replacements. Also, because you can plan for equipment outages during maintenance, you can avoid an outage when you need the machine the most.

For more information on scheduling a routine system of preventative maintenance, contact ProcessBarron.

 

Tags: , ,
Posted in 5 Things to Know, plant maintenance | No Comments »

July 15th, 2011

Three Ways to Streamline Your Shutdown

Scheduled shutdowns can often become a plant’s most expensive project. From the expense of equipment maintenance to the loss of production, downtime can significantly magnify financial strain. However, there are ways you can mitigate the costs of routine maintenance. Here are three tips:

 

1. Plan in Advance Shutdown pre-planning increases your efficiency and productivity. An important component in advance planning is communication. Ensure that everyone involved in the scheduled shutdown is aware of their role and ask for their feedback on each component of the shutdown process. Your shutdown plan should include:

  • Contingency plans for uncertainties
  • Timeline and anticipated outcome for each phase of the project
  • Identification of project roles, shift schedule, and project milestones
  • List of necessary equipment
  • Post-shutdown plan

2. Prioritize Your Activities Take stock of what maintenance activities will be conducted during your shutdown. Prioritize projects that will take longer than others or are pre-requisites for other phases. Strategic thinking can significantly reduce the risk of mid-project scope changes.

3. Outsource When Needed Sometimes outsourcing experienced professionals is the best solution to minimize downtime. Companies that are experts in shutdown management and plant maintenance can exponentially increase your productivity and reduce the impact of production loss.

 

By planning and prioritizing in advance, your shutdown season can be more productive and result in higher longevity for your plant’s equipment. Outsourcing shutdown management to an experienced company like ProcessBarron can lead to greater efficiency for the entire process. Contact us for a consultation on preventive maintenance and shutdown field services.

Posted in plant efficiency | No Comments »

June 3rd, 2011

Three Characteristics of a True Turnkey Service Provider

As the industry trends more toward the utilization of turnkey services, it seems that a lot of companies have begun to hang out their own Turnkey Solutions shingles. How can you tell if you are working with a true turnkey service provider? Here are three things to look for.

 

Process

When evaluating a turnkey provider, consider the process the company uses. Is it comprehensive? At ProcessBarron, we begin with a thorough evaluation and carry it through to execution. We go beyond treating symptoms and work to identify the source of the problem. This detailed evaluation guides us through the engineering, installation and execution phases, providing you with a holistic cure, instead of a band aid solution.

Staffing

Using a turnkey provider should eradicate the need for subcontractors. When you work with a true full-service provider, your life should get easier – your project more manageable. Your turnkey provider should provide and manage all personnel needed to complete a project. This means that you are dealing with one vendor, rather than a different contact for each part of the job.

Resources

A true turnkey provider’s services should also include all the resources necessary to execute a project. ProcessBarron possesses a complete in-house fabrication shop. From engineers to draftsmen to crews on-call, we can handle every nuance of your project at every turn.

 

At ProcessBarron, we take our claim to be a turnkey service provider to heart. It isn’t an industry catch phrase, but our continual commitment to our customers. Contact us today to see why we are the industry’s total systems solutions provider.

Tags: , , ,
Posted in Uncategorized | No Comments »

April 30th, 2011

Equipment Spotlight: Double Dump Valve

Valves are the gatekeepers of the ash handling system. Even the slightest inefficiencies can greatly impact productivity, so it is important to understand the aspects of different valves options.  With Double-Dump Valves, you can expect:

  • Less Deterioration. While rotary valves are a good option for many applications, they also experience constant attrition between the blades and housing.  The double-dump valve design reduces, if not eliminates, this erosion.  Double-dump valves are highly abrasion, heat and corrosion resistant — making them able to handle more abrasive materials in more extreme conditions, with less deterioration. This lack of friction also contributes to a reduction in air or gas leakage, and product longevity.
  • Less Leakage. It is well-known that rotary valves will leak when a system is in operation. In certain situations, this leakage can have great adverse effects on the product flow and system performance. This is not the case with double dump valves. Because of a double dump valve’s dual chamber design, back flow of air or gas is prevented, while material flow is maximized. Thus, leakage is reduced, if not eliminated altogether.
  • Less Downtime. Productivity is a key performance indicator for any plant.  The more you can decrease downtime, the better.  Since removal of the valve is not necessary for cleaning, repair and maintenance tasks, the construction of ProcessBarron’s double-dump valve makes routine maintenance easier and faster.

At ProcessBarron, we engineer Double-Dump Valves to keep ash handling systems operating at maximum efficiency.  Contact ProcessBarron today for an ash handling system evaluation.

Posted in Equipment Spotlight | No Comments »

March 31st, 2011

Three Overlooked Benefits of a Proactive Draft System Assessment

In the quest for improved plant energy efficiency, one of the most often overlooked culprits of energy drain is the draft system. Anything from improper fan installation to extremely dampered operation and especially leaky ductwork can create an inefficient draft system.

These problems and other culprits can be identified through a simple draft system assessment.

With both cost and energy efficiencies high on everyone’s priority list, a proactive draft system assessment can put you ahead of the curve in energy efficiency and provide an even higher ROI than you might expect. Consider the following benefits:

  1. Minor Modifications Instead of New Equipment
    Many times what may be deemed a “fan problem,” that would require a substantial replacement costs, could actually be remedied by a simple de-tip (reduction in effective diameter) to minimize energy drain.  Instead of just focusing on one problematic piece of equipment, ProcessBarron takes an in-depth look at the entire system to understand the true issues that can plague your system.
  2. Easy Increase in Energy Efficiency
    Feeling pressured to optimize energy efficiency within your plant to meet new standards? Poorly designed ductwork can result in substantial pressure drops and leaks that can burden a system’s efficiency.  A draft system assessment can help identify relatively simple changes that can bring about increased performance while minimizing energy costs.
  3. New Eyes = Improved Efficiencies
    “Can’t see the forest for the trees?” The same thing can be true when looking for ways to increase plant efficiency. Sometimes opportunities can be overlooked by those involved in the process every day. Recently, ProcessBarron was called to assess a draft system and discovered that one of the reason the system wasn’t performing up to expectations was because the internal shipping braces had never been removed by the original fan installers, leading to significant pressure loss at that point in the draft system.

ProcessBarron’s highly experienced team can bring a fresh perspective and simple, cost effective solutions that can generate substantial energy savings for your facility.  Contact ProcessBarron today to schedule a draft system assessment.

 

Posted in air handling, plant efficiency | No Comments »

March 1st, 2011

Emissions, Efficiency & Energy: 3 birds, 1 stone

Emission standards are an ever-evolving issue. Fortunately, meeting tighter environmental requirements doesn’t have to result in a loss of productivity or expensive back end equipment. Often small modifications to your air handling system, such as retrofitting fans, damper and expansion joints, can generate big savings.

Air handling retrofits and upgrades can improve energy efficiency and increase productivity – all while decreasing emissions. Three birds. One stone.

Real Life Example:

A utility plant in the Midwest was experiencing problems with thermal expansion on the hub causing the fan to move on the shaft. The plant manager called ProcessBarron to assess the situation. Our investigation identified not only a vibration problem from the loose hub fit but it was also determined that the fan was too large for the application causing flow problems and making it highly inefficient.

After installing a more efficient impeller fan design and new damper, the facility saw not only a significant reduction in power consumption, but also a reduction in carbon emissions of over 2,400 tons/year. The energy savings that this one modification produced was over $48,000 in one year. The plant was able to see an ROI from the new fan design in just over 10 months.

Smart Decisions for Your Plant

To improve the bottom line and stay a step ahead of the emissions standards, plant managers should explore their current air handling systems to look for ways to reduce their emissions. While investing in expensive back-end emission reduction equipment can help to meet emissions standards, thoroughly examining your plant’s power-draining systems and equipment can offer more efficient, tangible energy savings and a rapid return on investment.

For more information on exploring cost effective emission reduction possibilities for your plant, contact ProcessBarron at 888-663-2028.

Posted in energy efficiency, plant efficiency, plant maintenance | No Comments »

July 7th, 2010

Equipment Spotlight: Biomass Reclaimers

Biomass Reclaimer

Biomass Reclaimer

ProcessBarron has been manufacturing & installing rugged, reliable biomass reclaimers throughout North America for over 20 years. From Underpile Drag Chain Reclaimers, Screw Reclaimers & Radial Stacker Reclaimers the ProcessBarron team is well-versed in the unique challenges of handling biomass. Reclaimers vary in fuel storage capability, but ProcessBarron can custom design a system to match power production needs with budget constraints.

Biomass handling can entail harsh conditions.  That’s why reclaimers from ProcessBarron are coated with special abrasion materials to protect from erosion with shafts, bearings & drive components engineered to handle the forces& stress of biomass material. Motion sensors and plugged chute monitors also available to provide reliable operation.

Contact ProcessBarron to learn more about how our biomass reclaimers can improve efficiency and minimize downtime.

Posted in biomass, conveyor systems, energy efficiency, Equipment Spotlight, Rapid ROI, reclaimers | Comments Off

June 13th, 2010

5 Things to Know: Industrial Fan Efficiency

Industrial Fans can be one of the most parasitic pieces of equipment on a system.  Taking simple steps to minimize the fan’s negative impact can make a tremendous difference on a facility’s energy efficiency… and bottom line.

  1. Correctly size your fans. Correctly sized fans are critical to efficiency.  If the system resistance curve is not accurately predicted, fan performance/operating efficiency is likely to suffer:  Too little flow rate leaves the system unable to operate at peak loads, while oversized fans will result in unstable operation.
  2. Industrial Fan - Impeller Tip Out

    Changing the tips on the impeller can create significant energy savings.

    To tip or not to tip. Tipping or de-tipping impellers are good alternatives for improving fan efficiency.  A fan that is being dampered by 40% at peak loads is an excellent candidate for de-tipping.  Conversely, if your fan is not providing enough power, adding tips will increase the overall pressure-generating capacity.

  3. Install or upgrade to the most effective blade. Changing blade design can dramatically improve fan efficiency and capacity.  At one facility, retrofitting a new backward curved impeller into the existing radial blade housing created over $200,000 in energy savings in the first year – creating a one year ROI.  Additionally, many electric networks offer incentives for power savings, making the ROI even better.

    Industrial Fan Efficiency

    Blade effiency varies considerably depending on the application.

  4. Make it adjustable. For variable speed operation, inverter duty electric motors with adjustable frequency drives minimize losses with four to one turndowns.
  5. Request a Draft System Assessment. Draft system assessments, including field flow testing and computational fluid dynamics (CFD), can identify fan performance issues and serve as a guide for implementing changes that will maximize fan efficiency and reduce energy costs.

Posted in 5 Things to Know, air handling, emissions, energy efficiency, plant efficiency | Comments Off

« Older Entries