Part 1.

: Vacuum Conveying and the applications for bulk materials in the chemical-, pharma-, and food-industries
Suction/Aspiration, conveying and loading with dusts, powders & granules
Dipl.-Ing. B.Eng.(Hons) Thomas Ramme, Soest

VOLKMANN GmbH Vakuumtechnik Schloitweg 17 D-59494 Soest Phone: ++ 49 (0) 29 21 / 96 04 0 Fax: 900 mail@Volkmann.info

Germany www.Volkmann.info

Table of Contents * Pneumatic Conveying in comparison to mechanical conveying * Vacuum Conveying in comparison to positive pressure conveying * Flexible Configurations and diverse applications of Vacuum Conveying Systems * Powder Transfer Solution Examples, integration into all solids process systems * Silo Loading, big-bag discharging, drum filling, reactor loading, hopper discharging etc. * Examples of materials to be conveyed and powder transfer parameters * Dilute-phase, dense-phase and plug-flow with Vacuum Conveying * Analysis of components (Vacuum pump, receiver vessel, filter systems) * Cyclic powder transfer with Multiple-Jet-Vacuum-Pumps versus electrical mechanical pumps * How to adapt the Vacuum Conveyors to the wide variety of applications

EX-risk overheating

Mechanical Transport

How do you transfer your bulk materials?

Hopefully not like that!

Conveying Screw High friction EX-risk electric sparks EX-risk powder layers (cloud building) Wear

Blockages

Cross contamination because large residuals remain in screw

Flammable materials Back-falling material

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Not dust-free

Open rotating parts

Transfer of bulk materials - pneumatic

Example Positive Pressure Conveying
- Pressure rated vessel necessary - Powder has to be loaded into a pressure rated vessel - Complex installation - Tends to block at higher pressures and longer distances (esp. on fibres..) - Often bypass system necessary - Pressurised system, small leakages lead to large dust clouds - Accumulation of electrostatic charges / blowing into large volumes - For small/medium conveying rates more expensive than Vacuum Conveying - Possible heating of powder at the feeding point Discharging valve Receiving vessel Loading vessel Filter

Pressure rated sending vessel

I
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Material flow in a Vacuum Conveying System with feeding and discharging locations

Various pick-up and loading options

Vacuum Transport System

Powder supply to / Loading Reactors Stirring vessels Weighing containers Tablet presses Mills Mixers IBCs Capsule filling ma. Dosing units Packaging ma. Centrifuges

Suction / Emptying of: Hoppers Big-Bags / FIBCs Silos Sacks Drums Trays Dryers Sieves Mills

Powder Transfer Solutions

Vacuum Conveyors in the pharmaceutical industries

Vacuum Conveyor for the discharging of drums (various powder-like raw materials) and loading of a mixer.
Powder Transfer Solutions

Discharging of Fluidised-bed-dryer and loading of drums with the same, mobile Vacuum Conveyor.

Vacuum Conveyor for dust-free loading of drums with Palladium-oven ash (Catalyst-Recycling)

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Powder Transfer Solutions

Loading of a Toner powderfilling machine Discharging of Big-Bags in the room next door Capacity: 1,100 kg/h Toner powder for photocopiers with fine content up to app. 0.1 m, sensitive against mechanical loads, aggressive to special plastics

Powder Transfer Solutions

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Vacuum Transport System

Silo loading in general bulk industry Conveying of iron sulphate powder Total distance: 20 m Height: 12 m Capacity: 3000 kg/h Conveyor: VR 450

Discharging location

Powder Transfer Solutions

Feeding location

Vacuum Pick-up point

Silo loading in general bulk industry Powder feeding station / hopper Replacement of mechanical conveying system
Powder Transfer Solutions

Big-Bag (partial)unloading, loss in weight dosing & silo loading

Load cell

Feeding Point

Reactor Loading in the pharmaceutical & chemical industries

INEX Inert System for the Loading in zone 0

Pressure rated Vacuum Conveyors APIs (Active Pharmaceutical Ingredients)

Powder Transfer Solutions

Stirring vessel loading in the paint & dye industries

INEX Inert System for the Loading in zone 1

Pressure rated powder locks Double valve powder locks

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Powder Transfer Solutions

Vacuum Conveyors in OEL relevant applications Filling of IBC through split valve to maintain OEL level during container handling

Powder Transfer Solutions

Mixer loading

Tablet press feeding

Mixer loading Vessel loading Powder (raw materials) dosing and charging into IBC (with in-line safety sieving (cone-mill)).

Chemical Chemie
TiO2 Flame soot Sulphur SiO2 Talcum Zinc oxide Silicon carbide Bentonite

Pharmaceutical Pharma
Laxative granule Paracetamol powder Pharma capsules

Food Food
Icing sugar Cocoa Garlic powder

Divers Diverse
Toner powder Aluminium dust Blood powder Al2O3-Powder Magnesium swarfs Casting powder Mussel shell PE-granule Strontium Ferrite powder Colour pigments Palladium ashes Electro waste (shredered)

St. John's wort (drug) Apple sauce Acetylsalicylic acid Ascorbic acid Sterile caps Cellulose powder Cream-fat-powder Bacon pieces "Milk" Wheat starch Desiccated coconut Mixed spices Chanterelles Gelee granule

Activated carbon Plant drugs Resin granule Sodium cyanate Ethylene-Poly. Barium sulphate Magnesium powder Tablets

Powder Transfer Solutions

Influences on the design of a pneumatic Vacuum Conveying System

Powder Transfer Solutions

2. Basic Theory 2.1 General (2) Pressure drop for air flow pL :

l L 2 pL = L w d 2
L = pipe friction coefficient for air flow d = pipe diameter in mm w = air velocity in m/s

[Equation 1]

l = pipe length in m 3 L = density of air in kg/dm

Re =

wd

[Eq. 2] = kinematic viscosity of air in m /s

2

Suspense velocity vS from equation 3. gravity force = lifting force

resistance force

4 g dK vS = 3 cw
dK = corn diameter in mm cw = drag coefficient
Powder Transfer Solutions

K 1 L

[Eq. 3]
2

g = gravity acceleration in m/s 3 K = corn density in kg/dm

Conveying conditions
Dilute phase conveying
w = 18 up to 35 m/s v/w < 1 = 10 (...30)

Dense phase conveying

w < 20 m/s v1 (top) > v2 (bottom) v/w < 0,7

Plug conveying
w = 3 up to 10 m/s v/w < 0,5 = 10 100

w = air velocity v = product velocity Qs = product mass flow Ql = air mass flow = product load = Qs / QL Powder Transfer Solutions

3. Principle design of a
Vacuum generator

modular dense phase / plug flow

Filter

Vacuum Conveyor

Conveying cycles: 1. Suction / Vacuum

Discharge system

2. Filling 3. Aspiration / Filter cleaning

Separator container

4. Discharging

Powder Transfer Solutions

Vacuum generation * Side channel blower (in suction operation) * Oil sealed rotary vane pumps * Multiple stage, compressed air driven vacuum pumps * Liquid ring vacuum pumps * Roots vacuum pumps * Ejectors. The multiple stage, compressed air driven vacuum-jet pumps offer a wide application range because high amounts of suction-air for dilute phase conveying and also big pressure differences for plug flow conveying can be achieved.

Separator container systems * one-piece containers * one-piece containers in pressure rated design * containers consisting of several parts * modular containers consisting of several parts (modular construction system) * separator containers made of special materials: e.g. stainless steels in different qualities and alloys, coatings or special linings, glass containers

Filter systems * Deep filtration: e.g. sintered candle filters, plastics, stainless steel, cellulose, bag filters, tube filters * Surface filtration: Membrane filters, e.g. PTFE coated filters * Primary / secondary filters

Classification of vacuum pumps acc. to DIN 28400, part 2

VAKUUMPUMPEN
(Funktionsprinzip)

GastransferVakuumpumpe
VerdrngerVakuumpumpe
OszillationsverdrngerVakuumpumpe MembranVakuumpumpe RotationsverdrngerVakuumpumpe FlssigkeitsringVakuumpumpe Mechanisch-kinetische Vakuumpumpe DiffusionsPumpe

GasbindendeVakuumpumpe
Kinetische Vakuumpumpe
Treibmittel Vakuumpumpe IonentransferPumpe TreibmittelstrahlVakuumpumpe AdsorptionsPumpe

Getterpumpe

GasringVakuumpumpe

Kyropumpe

HubkolbenVakuumpumpe

KreiskolbenVakuumpumpe

TurboVakuumpumpe

selbstreinigende Diffussionspumpe

Flssigkeitsstrahl Vakuumpumpe

Kondensator

WlzkolbenVakuumpumpe

MolekularVakuumpumpe

fraktionierende Diffusionspumpe

DampfstrahlVakuumpumpe

SperrschieberVakuumpumpe

GasstrahlVakuumpumpe einstufige Ejektorpumpe mehrstufige Ejektorpumpe

DrehschieberVakuumpumpe VielzellenVakuumpumpe

MULTIJECTOR Vakuumpumpe
DiffusionsEjektorpumpe

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Principle design of a multiple-stage, gas-jet driven Vacuum Pump

Compressed air

Suction air Exhaust air

Powder Transfer Solutions

The Laval nozzle

Sonic speed Norm nozzle Subsonic speed Diffusor Supersonic speed

Applications for Multijector Vacuum pumps

MULTIJECTOR
Vacuum Pumps M-RVA / M-RVAC multiple stage compressed air driven completely made out of stainless steel Viton / EPDM gaskets max. Vacuum -96 kPa CIP-able

Vacuum Conveyor with electric-driven, oil-sealed rotary vane Vacuum Pump

continuous energy consumption

Powder Transfer Solutions

Comparison:

- electric - mechanical Vacuum Pumps (here two dry running pumps)

- Multijector Vacuum Pump jet-pump (type G 4500)

Receiver- and collecting containers for Vacuum Conveyors

All ATEX certified by TV

Throughputs from 10 kg/h to up to 8000 kg/h

Pneumatic Pharma Conveyors (PPC): + GMP-suitable, smooth, polished, gap-free, WIP / CIP

Modular container design:

1. Highest flexibility by modular construction system 2. Different flow conditions during suction

Loading of a can-filling machine

Dependency of transfer throughput from bulk density

Conveyors:
For approx. 10 m conveying distance. Attention: Each bulk material may show different behaviour.

Throughput in t/h

Bulk density in kg/dm

Vacuum Conveyor in one-piece design, Pneumatic Pharma Conv. (PPC):

+ GMP-suitable, smooth, polished, gap-free, WIP-suitable

Manual drum discharging by suction lance and loading of a mixer

ETFE (FDA)-coating

Qualification of Vacuum Conveyors

PPC 315 acc. to FDA

Steps of a Qualification / Validation process: 1. User requirement specification (URS) 2. Functional Specification 3. Design qualification(DQ) 4. Installation qualification (IQ) 5. Operation qualification (OQ) 6. Performance qualification (PQ) 7. Validation

Washing in Place: 1. Wetting cycle

Washing in Place: 2. CIP cycle

Modules for CIP Cleaning of a PPC 170 K on top of a tablet press

Loading of tablet presses

Independent institutes, tablet manufactures and contractors confirmed that there is no relevant separation/segregation if VR and PPC Vacuum Conveyors are used.

Filter systems
* Deep filtration: e.g. sintered candle filters, plastics, stainless steel, cellulose, bag filters, tube filters * Surface filtration: Membrane filters, e.g. PTFE coated filters * Primary / secondary filters

Classification - particle air filter

VOLKMANN GmbH -- Vakuumtechnik -- 59494 Soest -- www.volkmann.info
NORM Eurovent DIN 24185 DIN DIN EN 1822
synthetic dust

Test aerosol

Filtration grade [>%] <65 65-80 80-90 90 40-60 60-80 80-90 90-95 95

IEC 60335-2-69 Annex AA

average Test transmittance aerosol grade [>%]

BIA

average Test transmittance aerosol grade [>%]

DIN 24184 EN 779 EU 1 EU 2

COARSE FILTERS

EU 1 EU 2 EU 3 EU 4 EU 5 EU 6 EU 7 EU 8 EU 9 Q R R S (T) (U) (U) (U)

G1 G2 G3 G4
atmospheric dust

Quartz dust

EU 4 EU 5 EU 6
FINE FILTERS

F5 F6 F7 F8 F9 H 10 H 11

Quartz dust

EU 3

0,5

EU 7 EU 8 EU 9 EU 10 EU 11

0,1

0,1

95

HEPA FILTERS
(HEPA = Hig h Efficiency Part iculate Air Filt er)

EU 12 EU 13 EU 14 EU 15

H 12 H 13 H 14 U 15 U 16 U 17

DEHS alt. DOP

99,5 99,95 99,995 99,9995 99,99995 99,999995

0,005

Parrafine oil mist

Paraffine oil mist

Paraffine oil mist

85

0,05

ULPA FILTERS
(ULPA = Ultra Lo w Penet rat io n Air Filt er)

EU 16 EU 17

A direct reference from BIA- and IEC-classes to other

Attention! * DEHS = Di-ethyl-hexyl-sebacat

DOP = Di-octyl-phtalat

class systems is not possible!

Vacuum Conveyor VR 315 with primary filter - secondary filter afterwards (left) - then vacuum pump (middle) - Vacuum control at secondary filter - Replacement of a screw conveyor that often caused production-breakdown

Continuous Vacuum Conveying

4. Application examples
Material to be conveyed Bulk Density [kg/dm3] 0,7 0,4 0,6 0,7 - 0,8 0,8 3,5 0,2 0,85 - 1,4 0,98 1,38 0,2 - 0,8 0,9 Conveying Height [m] 2 3 2 4 1,5 4 5 1,5 5 0,5 4 10 0,5 Conveying Distance [m] 4 3 4 12 3 5 Particle size Material Characteristic Transporting capacity [kg/h] Suction- and loading system

1. Dicyanodiamide powder 2. Activated carbon dust 3. Placebo granule 4. Hexamethylenetetramine 5. Paracetamol powder 6. Ferric powder 7. Flame soot 8. Titanium-dioxide & dyes 9. shredded wheat pellets 10. Sand-limemixture 11. Toner 12. Polyurethane granule 13. Plastic caps

20 up to 100 m fine dust, 5 up to 80 m 100 up to 1000 m > 5 m 40 up to 200 m 50 up to 100 m 0,1 up to 44 m > 2 m

bridging occurs adherent very good flowing hygroscopic adherent & bridging sensitive, abrasive bridging, adherent partial strongly adherent sensitive bad flowing aggressive good flowing sensitive

600 120 5.000 1.400 1.000 180

Thank you for your attention !

15 3 12 32 5 12 10 1.440 600 up to 1.628 3.600 30,0 1.100 1.000 17.100 caps per h dust content, 2 x 8 mm 400 up to 900 m very fine dust > 0,1 m 1 up to 3 mm 40 mm, H=25 mm

VR 315: Weight=19 kg 345 mm, Height=955 mm VR 170: Weight=6 kg 180 mm, Height=450mm VR 450: Weight=39 kg 480 mm, H=1.160mm VR 315: Weight=19 kg 345 mm, Height=955 mm VR 315: W=19 kg 345 mm, H=955 mm VR 170: W=6 kg 180 mm, H=450 mm VR 450 Contivac (continuous conveying) VR 315: W=19 kg 345 mm, H=955 mm VR 450: W=39 kg 480 mm, H=1.160mm VR 170, W=6 kg 180 mm, H=450 mm VR 315: W=19 kg 345 mm, H=955 mm VR 315: W=19 kg 345 mm, H=955 mm VR 315: W=19 kg 345 mm, H=955 mm

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