The Eufaula, Ala.-based manufacturer was performing weekly repairs on the worn elbows of its ceramic bead plant. The company replaced all 12 elbows in their system with HammerTek® Smart Elbow® deflection elbow technology. The Smart Elbow units have lasted at least four years compared to the one- or two-week lifespan of their previous elbows.Read More»
The elbows feature a spherical chamber that protrudes partially beyond the desired 90° or 45° pathway, which causes a ball of material suspended in air to rotate, gently deflecting incoming material around the bend without impacting the elbow wall or generating heat.Read More»
Similar to many manufacturing and production facilities, the Blythewood plant used conventional long-sweep elbows as part of the conveying system, moving the pellets from storage silos to molding machines. The problem? The way conventional elbows function. The design of a conventional elbow changes the direction of conveyed material through deflection off the inner walls, causing friction and heat.Read More»
In reality, however, the standard 316L stainless pipe elbows that made up the pneumatic conveying system were wearing out at an average of every four to six months, resulting in environmentally hazardous and costly spillages. Annual labor costs related to cleanup and repairs soared.Read More»
Each day, approximately 18,000 pounds of the highly abrasive, dusty material are conveyed through the facility using long-radius stainless steel sweep elbows. Long considered the industry standard, these conventional sweep elbows are critical components in any conveying system. Failures at these crucial points can be costly, messy affairs that negatively impact productivity. The powdered limestone was quite literally wearing the sweep elbows away from the inside out.
Moving such a high volume of material non-stop requires high pressure. If even a small leak develops in a sweep elbow (and they occurred frequently), the result would be a huge cloud of dust as the powdered limestone spewed out under pressure. A breach required immediate shutdown of the lines for repair and cleanup — and the clock started ticking: EPA regulations require a complete (and expensive) incinerator shutdown if the line shutdown lasts more than a few hours.Read More»
Plagued by maintenance and housekeeping problems stemming from a single automatic diverter in the grain upload system, Roy Marin, staff engineer at the facility, decided to replace the troublesome component with a more cost-effective piping panel. The original design specifications included a manifold with a dozen 4-foot radius sweep elbows, but therein laid the problem: there wasn’t enough room at the installation point.Read More»
That was exactly the case for Dave Goodwin, Plant Maintenance Superintendent for the Scarborough, Ontario plant of Fiberglas Canada. Goodwin’s plant suffered through as many as 20 wear-related clogs per year — always occurring at the same two refractory elbows in the conveying system connecting the batch house and the furnace hall.Read More»
These line failures were costly. Repairs and cleanups consumed valuable man-hours, and any leaked material potentially subjected the company to EPA fines.Read More»
How much dust? Try 120 tons of dust every 24 hours.
A portion of this dust is sold for use in various industrial and agricultural applications, but the majority must be moved pneumatically and recycled back through the kilns through a process call insufflation.
And that’s where the problems really begin.Read More»
Due to its abrasive nature, pelletized lime was wreaking havoc on the conveying system by literally wearing the traditional long-sweep elbows from the inside out. The never-ending cycle of repair-and-replace began within six months of elbow installation.Read More»
The combination of a small footprint and innovative design make the Smart Elbow deflection elbow an ideal solution for high-wear, high-volume environments.Read More»
Chromalloy’s Drilling Division was experiencing problems every 90 days. The companys Houston plant produces ground barite (barium sulfate), an abrasive compound used in commercial drilling operations. The high-density material was wearing through 4- and 5-inch pipe elbows in the pneumatic system that transported the finished material from the grinding mills to storage tanks.Read More»
Gary Wright, RheTech’s director of Plant Engineering, was convinced there was a more efficient and cost-effective way to keep the conveying systems operational.Read More»
When the grain upload system at Miller Brewing Co.’s Fort Worth, Texas plant needed a complete redesign and equipment upgrade, staff engineer Roy Marin saw an opportunity to eliminate the troublesome automatic diverter, which plugged regularly, with a more cost-effective and efficient solution.Read More»
The Upper Occoquan Sewage Authority (UOSA) wastewater treatment plant in Centreville, VA, handles nearly 30 million gallons per day to provide potable water to more than 300,000 residents in northern Virginia. In order to raise the pH of the water to levels optimal for the efficient removal of bacteria and phosphorus, the chemical treatment system uses pebble lime. This material is conveyed non-stop 24 hours per day, 365 days per year — unless the system malfunctions.Read More»
By eliminating leaks of EPA-regulated materials common in many manufacturing processes, Smart Elbow deflection elbows further eliminate costly fines associated with the spillages.Read More»
According to Greg Sosenheimer, plant manager, 82,000 pounds of the material moves through the system each day, and the ceramic elbows Stonhard used to direct and funnel the flow of silica aggregate from blending vessels to holding silos just couldn’t hold up to the high-wear conditions. In fact, elbows were failing on average every three months, and replacement costs and productivity losses were rising to unacceptable levels.Read More»
Each part of the manufacturing process operates under strict controls, the machinery tuned precisely and using the latest technology.
Despite all the protocols, L.E. Koehler, assistant plant manager, had a persistent headache on his hands: the abrasive nature of the plastic resin was rapidly wearing away the long-radius sweep elbows commonly used in pneumatic conveying systems. Koehler’s team was replacing the elbows every two to four months on average. Maintenance and downtime costs were chewing away at the company’s profits as quickly as the resin was chewing away at the elbows.Read More»
That’s what Dave Goodwin, Plant Maintenance Superintendent for the Scarborough, Ontario plant of Fiberglas Canada, believed. Goodwin’s plant suffered through as many as 20 wear-related clogs per year — always occurring at the same two refractory elbows in the conveying system connecting the batch house and the furnace hall.Read More»