Polimak linear motion technologies provide a wide range of lifting and positioning solutions for numerous industries. Some of these industries include defence, manufacturing, construction, entertainment, communication, energy and many others. We provide robust and durable screw jacks that guarantee quality and reliable performance. Our experienced and innovative engineering team works with our clients to help them meet their application demands.

In response to the rapidly growing Global Solar Photovoltaic (PV) market – with regard to solar panel tracking systems, Polimak produces linear motion control systems with state-of-the-art components that can be utilised in solar energy systems. A solar tracker must be highly robust so that it may be able to withstand different environmental conditions such as wind forces. We produce screw jack systems that render efficiency, reliability and environmental value to various applications in the energy industry. Our screw jack solutions are ideal for heavy-duty solar trackers as they require little to no maintenance, thereby reducing downtime and making them the best option for solar tracking systems.

The entertainment industry benefits a great deal from our jack screw solutions. Theatre, orchestra, dance and other forms of performed arts typically utilise elevated stages during performances. Because of the high force capabilities and reliable functioning, Polimak linear motion solutions are an excellent choice for stage lifting in the aforementioned performed arts. For improved safety, our power screw jacks are equipped with gear reduction boxes to cease movement in the event of a complete power cut.

Cylindrical wedge barriers, commonly known as bollards, are typically used in a variety of different applications as a security method of preventing vehicular access. For heavy-duty robust bollards like the ones used as vehicle impact barriers which may consist of hefty steel components collectively weighing on the order of a hundred kilograms, the use of translation screw assemblies is ideal. Hydraulic or pneumatic rams are not the best option because they are expensive, consume a lot of power supply and require regular expert maintenance. Our screw jack solutions provide greater advantages for raising and lowering bollards because of their limited maintenance, reduced noise levels, environmentally friendly designs (no contaminants) and reliable functioning in extreme conditions.

The communication industry and other industries benefit from satellite antennas which are typically used for coverage (signal) purposes. Regardless of the environmental conditions, satellite antennas must perform quick, smooth, precise and efficient movements during operation. Our jack screw systems render the high torque control needed to effectively and efficiently handle rapid movements of satellite antennas. We design and manufacture screw jacks with varying capacities, a number of clevis and optional accessories like boots.
The application of screw jacks in satellite antennas is similar to that used in the military industry in their radar systems.

Our screw jack solutions enable machining and metal fabrication clients across the manufacturing industry to attain optimal productivity and high-end quality in tough and demanding industrial setups. Manufacturing machineries have to be able to operate with a high degree of accuracy, precision and dependability in the most demanding conditions. Polimak linear motion solutions have been trusted to address a wide range of machine tool equipment design challenges. Our screw jacks can be integrated with manufacturing machines like rolling machines.

The aerospace industry involves the manufacturing and assembling of large and sensitive parts for flight vehicles such as aircraft, satellites, spacecraft and other related crafts for manned or unmanned flight. Assembly and maintenance platforms are some of the systems used to handle various flight vehicle parts (e.g., engines). Linear motion products are commonly utilised on platforms to enhance safety and increase productivity. Polimak produces innovative worm gear screw jacks with integral safety that can be incorporated into platforms. Our screw jacks can also be used in different Ground Support Equipment (GSE) like airport pallet loaders. Ease and accurate controlled movements without safety risk can be accomplished with our screw jack solutions.

Screw jacks provide robust and quality support in numerous systems used in various industries. Other possible applications of jack screws include the following:

• The opening and closing of penstocks.
• Food processing machineries (e.g., palletizing machines).
• Crank tables height adjustments.
• Missile launching platforms.
• Vehicle ramp and vehicle lifts.
• Scissor lifts.
• Airport passenger walkway (passenger boarding ramp).
• Bath lifts.
• Patient transfer trolleys.
• Construction works.

Downloadable bin activator datasheets and a catalogue are accessible below.

Download Bin Activator Catalogue

Download PTK600 Bin Activator Datasheet

Download PTK900 Bin Activator Datasheet

Download PTK1500 Bin Activator Datasheet

Download PTK1800 Bin Activator Datasheet

Download PTK2350 Bin Activator Datasheet

Download PTK2500 Bin Activator Datasheet

Download PTK2600 Bin Activator Datasheet

A vibrating bin discharger is a conical-shaped equipment that allows dry bulk materials to flow continuously by gravity. It is used to feed downstream equipment such as conveyors, hoppers, rotary feeders etc., installed to its outlet port.

Our vibrating bin dischargers come in a broad variety to meet the economic demands and the diverse industrial application requirements. We deliver our equipment with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel.

The vibrating bin discharger is used in most industries that process dry bulk solids to discharge storage silos, bins etc., and feed downstream equipment such as conveyors, hoppers, rotary feeders etc. It helps prevent bridging, ratholing, or arching during bulk material processing. It is mounted to the upstream equipment’s outlet and the downstream equipment’s inlet.

We provide a wide selection of industrial production vibrating bin dischargers (or bin activators) with innovative options and accessories. These options and accessories ensure smooth and efficient operations as well as safe function over time.

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Companies have been storing finished products or dry bulk raw materials in storage equipment such as silos since the industrial revolution. The extraction of cereals has not possed much of a problem. However, the extraction of other bulk materials such as flour, metal oxides etc., causes problems during extraction from the silo without manual intervention. Bin Activators also known as vibro dischargers are the perfect solution when dealing with such problems. Vibro dischargers impart vibrations to the dry bulk material directly and the vibrations are isolated from affecting the upstream or downstream equipment through the use of flexible seals. Bin activators are used in industries such as mining, food, cement, plastics etc.

Vibrating silo dischargers can be used to facilitate the extraction of dry bulk materials from silos. A flange is welded to the silo cone and the silo discharger is bolted to this flange. During the bulk material discharge from the silo, the bin activator generates vibrations that are transmitted to the bulk material inside the silo, which in turn promotes uniform bulk material flow.

Similar to the way the bin activator is utilised in extracting dry bulk materials from silos, the bin activator is used in the same way with hoppers. It is installed under the hopper. The vibrating bin discharger ensures a continual flow of the bulk material from the hopper to the downstream equipment by using controlled vibrations.

A vibrating bin discharger is a conical-shaped equipment that allows dry bulk materials to flow continuously by gravity. It is used to feed downstream equipment such as conveyors, hoppers, rotary feeders etc., installed to its outlet port.

Our vibrating bin dischargers come in a broad variety to meet the economic demands and the diverse industrial application requirements. We deliver our equipment with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel.

The vibrating bin discharger is used in most industries that process dry bulk solids to discharge storage silos, bins etc., and feed downstream equipment such as conveyors, hoppers, rotary feeders etc. It helps prevent bridging, ratholing, or arching during bulk material processing. It is mounted to the upstream equipment’s outlet and the downstream equipment’s inlet.

We provide a wide selection of industrial production vibrating bin dischargers (or bin activators) with innovative options and accessories. These options and accessories ensure smooth and efficient operations as well as safe function over time.

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Polimak’s bin activators come in different models to meet the economic needs and the diverse industrial application requirements. Our vibrating bin dischargers are delivered with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel. Some of the models that we produce include the following:

Polimak’s standard bin activators are the equipment of tapered-conical shapes that regulate dry bulk material flow from upstream equipment such as silos or bins due to the generated vibrations. The standard vibrating bin discharger consists of a seamless carbon steel cone formed on sheet metal, a polyurethane seal, spring suspensions as well as a single electric vibrator.

Features 

• Material: ST37 Carbon Steel
• A polyurethane seal.
• An inlet skirt.
• A broad range of intern baffles with respect to the application.
• A compact design.
• Durable suspensions and flexible seal.

Our food grade bin activators incorporate the same durable features as those found in the standard bin activators. However, they are particularly designed to meet the requirements of the food industry and other related processing industries. They are mainly produced from stainless steel with high-grade surface finishing. The mating parts are properly welded on both sides, thereby acquiring a perfectly smooth surface that reduces bulk material residue.
The food grade vibrating bin dischargers are an ideal choice where minimal dry bulk residue is required and contamination of the bulk material has to be strictly avoided.

Features

• Material: AISI304 Stainless Steel
• A silicone flexible seal.
• An inlet skirt.
• A broad range of intern baffles with respect to the application.
• A hygienic design.
• High-grade surface finishing.
• Durable suspensions and flexible seal.

Our wear resistance bin activators incorporate the same durable features as those found in our standard bin activators. The wear resistance bin discharger consists of a seamless hardox steel cone, a polymer engineered seal, spring suspensions and a single electric vibrator. Manufactured from hardox steel, the wear resistance bin dischargers are an ideal choice for handling abrasive bulk materials like clinker, silicon carbide, fly ash, alumina etc. Due to the nature of the handled bulk materials, the inlet skirt plays a crucial role in prolonging the usable life span of the seal. This model is primarily used in industries such as mining, aggregate, cement, foundry etc.

Features

• Material: Hardox Steel
• An inlet skirt.
• A polymer engineered seal.
• A wide selection of interns baffles with respect to the application.
• A robust and compact design.
• Wear resistant surface.
• Durable suspensions and flexible seal.

A vibrating bin discharger is a conical-shaped equipment that allows dry bulk materials to flow continuously by gravity. It is used to feed downstream equipment such as conveyors, hoppers, rotary feeders etc., installed to its outlet port.

Our vibrating bin dischargers come in a broad variety to meet the economic demands and the diverse industrial application requirements. We deliver our equipment with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel.

The vibrating bin discharger is used in most industries that process dry bulk solids to discharge storage silos, bins etc., and feed downstream equipment such as conveyors, hoppers, rotary feeders etc. It helps prevent bridging, ratholing, or arching during bulk material processing. It is mounted to the upstream equipment’s outlet and the downstream equipment’s inlet.

We provide a wide selection of industrial production vibrating bin dischargers (or bin activators) with innovative options and accessories. These options and accessories ensure smooth and efficient operations as well as safe function over time.

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Polimak offers a broad selection of industrial production bin activators (or vibrating dischargers) with innovative options and accessories. These options and accessories ensure smooth and efficient functions as well as safe operation over time. Some of the options and accessories that allow enhanced material handling by our bin activators include:

For efficient and smooth discharging of the dry bulk material from the lower portion of the vibrating discharger, an additional baffle plate commonly known as a secondary baffle can be installed in the system. It prevents the jamming and compacting of the bulk material at the bin activator’s outlet, thereby allowing the dry solids to flow steadily through the outlet.

Slide gate valves are designed to render efficient flow control of the free-flowing dry bulk material. They are designed to fit the circular or rectangular/square flange of the equipment they are mounted to. The slide gate is installed to the outlet of a vibrating discharger, where it is used for opening and closing the dry bulk material discharge to downstream equipment. It also makes easier the maintenance operations of the mounted downstream equipment. It can be configured to be operated automatically or manually.

Similar to the slide gate valves, the butterfly valves are also designed to offer efficient flow control of the free-flowing dry solids. The butterfly valve consists of a rotating (up to 90 degrees) disc installed in a hollow body. The valve is mounted to the exit port of a vibrating discharger. It is used to regulate the bulk solid’s flow from a bin activator to installed downstream equipment. This is achieved by the rotating disc. When fully opened, it becomes parallel to the dry solid’s flow permitting minimum resistance. As it gets closed, it gradually becomes perpendicular to the dry solid’s flow, thereby, reducing its flow. It also functions as a shutoff valve and completely prevents the dry bulk material flow.

Flap type diverter valves are connected to the outlet port(s) of a vibrating discharger and are utilised for the redirection of the bulk material flow to two or more downstream equipment. A diverter valve consists of a hinged flap, hence the name ‘flap type diverter valve’. The hinged flap is responsible for diverting the flow of the dry bulk material inside the valve.

A vibration sensor is used to detect the bin activator functionality throughout the operation. The sensor is equipped to the system and it is responsible for perceiving the bin activator’s vibrations. In the case where the system’s operation is started and the vibrations are faulty, the sensor alerts the user and the necessary precautions are taken.

A flexible sleeve is used to cover the gap between a bin activator and upstream or downstream equipment. Typically, a polyurethane sleeve is used as a flexible sleeve connector. Instead of the polyurethane seal, Polimak offers another option which is the use of a silicone connector seal.

This option promotes the flow of the dry bulk material from a single upstream equipment into several separate downstream systems. The multiple outlets design eliminates the demand for using a downstream diverter valve, hence, reducing the overall system cost.

Custom designed internal baffles are available in a wide range of configurations in accordance with industrial applications. They are mainly utilised for damaging bridges, segregation or rathole formation. Our bin dischargers incorporate various internal baffle designs (convex deflector, conical deflector or compound deflector), that promote a continuous flow of the dry bulk material through the system without bridging or jamming.

A vibrating bin discharger is a conical-shaped equipment that allows dry bulk materials to flow continuously by gravity. It is used to feed downstream equipment such as conveyors, hoppers, rotary feeders etc., installed to its outlet port.

Our vibrating bin dischargers come in a broad variety to meet the economic demands and the diverse industrial application requirements. We deliver our equipment with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel.

The vibrating bin discharger is used in most industries that process dry bulk solids to discharge storage silos, bins etc., and feed downstream equipment such as conveyors, hoppers, rotary feeders etc. It helps prevent bridging, ratholing, or arching during bulk material processing. It is mounted to the upstream equipment’s outlet and the downstream equipment’s inlet.

We provide a wide selection of industrial production vibrating bin dischargers (or bin activators) with innovative options and accessories. These options and accessories ensure smooth and efficient operations as well as safe function over time.

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Bin Activators are equipment conically shaped that aid dry bulk material flow from storage silos, or hoppers. Polimak Bin Activators are used in several industrial applications to efficiently discharge dry solid materials in powder or granular form from upstream equipment, thereby, reducing bulk material bridging or ratholing while promoting mass flow.

The fluidity of some dry bulk materials is at times so flawed that material discharge from the upstream equipment (silos, bins, etc.,) with flow aids such as pneumatic hammers, air cannons or even fluidised pads is not possible. The lack of fluidity introduces bulk material processing difficulties such as bridging, arching, or ratholing during the discharge of the material from upstream equipment. Shaking or hammering the bulk container to allow bulk material discharge might seem like something to consider but instead, this is a difficult and sometimes dangerous approach, especially when handling containers with large capacities. However, the bin activator also known as a vibrating bin discharger is one of the best flow aid and discharging equipment for such bulk materials because it renders the possibility of shaking the bulk material through vibrations without agitating the upstream equipment. This possibility is achieved with the help of an engineered polymer seal that forms a flexible connection between the bin activator and the respective upstream unit.

Polimak’s engineering and production teams provide a vast range of industrially manufactured bin activators having different innovative features. Some of the significant design components of the equipment include the following:

An internal tapered-conical shaped baffle plate is positioned at the diameter centre of the bin activator. The baffle is rigidly attached to the body of the equipment using structural steel parts. It facilitates bulk material flow from an upstream equipment by inducing vibrations directly to the material. A secondary deflector plate eases the weight of the bulk material from the lower portion of the bin activator by acting as a wedge below the material and thrusts it around the areas adjacent to the surface of the cone. Our baffle plates come in various configurations (convex plates and cone plates) and angles (15°, 30°, 45°, or even 60°) depending on the flow characteristics of the handled bulk material and type of application.

Special spring suspension links and an engineered polymer seal collectively form a flexible connection between a vibrating bin discharger and an equipment configured above it.
Proper design and installation of the polyurethane seal, prevents the seal from slipping off and the leakage of the dry bulk material. In addition, high-stress resistance and durability over time are guaranteed. These stresses are caused by motor vibrations, pressure conditions etc.

Spring suspensions externally installed to the system offer full resilience to the vibrations of the cone head. They ensure that generated vibrations do not agitate the upstream equipment structure rather than the cone itself.

In order to fit a bin activator, a silo’s cone has to be shorter than usual. This leaves a wide outlet portion. A flange that is provided together with the bin activator is separately welded to an outlet (slightly above the outlet) of the silo on the production site. The vibrating bin discharger is bolted to the flange when installed to the silo.

A vibratory motor is externally mounted to the bin activator. When powered, the electric vibrator causes the bin activator to vibrate which results in a steady flow of dry bulk materials within the system. One or two vibratory motors can be externally installed to the system.

This is an option that we offer to help enhance the life span of the flexible connector sleeve. The skirt’s upper portion is attached to the outlet port of the upstream equipment and dangles down into and through a bin activator’s inlet port. The main purpose of the skirt is to act as a shield and render protection to the flexible connector seal.

Depending on the handled dry bulk material, our vibrating bin dischargers are manufactured from carbon steel, stainless steel or other types of steel. Some of the bulk materials processed using our bin activators include starch, milk powder, wheat flour, sugar, salt, bran, coffee powder, spices, rubber powder, calcium sulphate, cement, aluminium hydrate, carbon black, soot, sodium sulphate, sand, calcium carbonate, dolomite, titanium dioxide, limestone, talcum powder, copper oxide, alumina etc.

Polimak’s bin activators are available in a vast range for handling various types of dry bulk materials stored in different vessels of different capacities. They render many advantages to the user industries. Some of the significant benefits our bin activators offer are:

• Complete resilience to the vibrating dish head provided by special spring suspensions.
• Flexible seal connections at the inlet and outlet to ensure safe connections.
• Excellent performance with low energy consumption.
• Easy to fit and low maintenance.
• High functioning efficiency.
• A housed motor in a single seal enclosure.
• Smooth discharge assurance.

A vibrating bin discharger is a conical-shaped equipment that allows dry bulk materials to flow continuously by gravity. It is used to feed downstream equipment such as conveyors, hoppers, rotary feeders etc., installed to its outlet port.

Our vibrating bin dischargers come in a broad variety to meet the economic demands and the diverse industrial application requirements. We deliver our equipment with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel.

The vibrating bin discharger is used in most industries that process dry bulk solids to discharge storage silos, bins etc., and feed downstream equipment such as conveyors, hoppers, rotary feeders etc. It helps prevent bridging, ratholing, or arching during bulk material processing. It is mounted to the upstream equipment’s outlet and the downstream equipment’s inlet.

We provide a wide selection of industrial production vibrating bin dischargers (or bin activators) with innovative options and accessories. These options and accessories ensure smooth and efficient operations as well as safe function over time.

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Polimak provides all-round solutions to help bulk producers in logistics and warehouse management, covering the three main steps of the process: loading, main carriage, and unloading.

Different components may be used in each application to meet requirements however screw feeders, pump and motor group, rotary feeders, loading hoppers are some of the key components in filling and unloading systems.

When unloading, the output spout of liner bag is connected to loading hopper of the system. The material fallen down into the hopper are then transffered to the storage medium like silos by pneumatic conveying line. Whole system is able to be controlled by installed control panel.

1. Loading 

You can utilize the loading method according to your needs:

• Loading from the plant;
• Direct loading from a silo to a container;
• Loading from a stockpile to a container;
• Loading from bulk bags to a bulk truck.

Our innovative solutions offer a range of loading alternatives tailored to handle even the most challenging bulk materials.

Whether it’s through vacuum technology, conveyors, or specialized equipment, Polimak provides versatile solutions that ensure efficient and reliable bulk solid transfer.

2. Main-Carriage 

The product is then transported via container shipping, short-sea shipping, train, or standard container chassis, by choosing the most efficient mode of transport.

Transport your bulk solid material in standard ISO containers.

3. Unloading

After arriving at the final destination, the product is unloaded safely using mechanical, horizontal conveying. According to the customer’s needs, the unloading can be carried out in the following ways:

• Discharging the container directly to a silo;
• Discharging the container to a further production process;
• Discharging the container to a bulk truck.

The Critical Importance of Containerized Transport for Bulk Solids

Transporting bulk solids in containers provides significant advantages in modern logistics.

• Standardized and Flexible Solution: Containers enable smooth intermodal transfers between different transportation modes, such as ships, trains, and trucks, ensuring a seamless and efficient flow throughout the supply chain.
• Improved Product Protection: Containers help reduce the risk of contamination and material loss, ensuring the safe transport of bulk solids.
• Minimized Handling: By reducing handling, containers speed up loading and unloading processes, leading to lower costs and increased productivity.

As a result, containers prove to be a smart choice for industries seeking cost-effective, safe, and well-organized transportation of bulk solids.

Efficient discharging of big bags and dust-free loading of bulk trucks. The mobile system consists of a mobile platform, big bag discharger, loading screw, telescopic loading chute, and dust collector.

Efficient dumping of materials to built-in loader hopper by wheel loaders. This system consists of a mobile platform, front end loader hopper, loading screw, telescopic loading chute, and dust collector.

Efficient conveying of materials by vacuum system to trucks. The system consists of a mobile platform, flexible suction hose, vacuum receiver, pump, motor, loading screw, telescopic loading chute, and dust collector.

Mobile systems with bigbag discharge, vacuum and large hopper are used for rapid and efficient loading of bulk solids into trucks or other bulk carriers. Our system’s excellent design and robust construction ensures easy management of loading and discharging of free flowing bulk solids.

Technical catalogs, product brochures, installation, operation and maintenance manuals of mobile bulk truck loading systems.

Dust collection systems, baghouse filters and ESP systems are used to remove dust from production lines. Collected dust is discharged from the bottom hopper of dust collectors and sent to containers, trucks and / or silos. Dust discharge and conveying is handled by different types of conveyors. Pneumatic conveying systems provide reliable and safe handling of filter dusts. Mechanical malfunctions caused by screw conveyors, scrapers, bucket elevators, chain gears and similar mechanical conveying equipment are prevented.

Pneumatic conveying system transfers the collected dust from filter or cyclone hopper to silo. Rotary valves are installed below each bag filter hopper. A pneumatic conveying pipeline is installed below rotary valves and collects the dust coming from hoppers. Pressurized supplied from roots type blower is used to transport the dust to the silo through the pipeline. A reverse jet pulse filter is installed above the silo to discharge the pressurized air and keep the conveyed dust inside the silo. Depending on configuration several bag filters, dust collectors can be connected to same pneumatic transport line. System can be designed to run by pressurized air or vacuum air.

Roots Blower:
Used to supply pressurized or vacuum air needed for pneumatic conveying system.

Rotary Valve / Rotary Airlock:
Used to discharge the dust from filter hopper to conveying line. It also prevents some amount of pressurized air to move inside the filter hopper.

Electrical Panel:
Used for controlling whole system. PLC , relays, frequency inverters etc are included in electrical control panel of pneumatic filter dust conveying system

Pneumatic Conveying Pipeline:
Used to transfer the filter dust. Depending on the conveying capacity, pipeline diameter varies generally between 3” -5”.

Silo Top Jet Filter:
Jet filter is used to vent pneumatically filled silo, keeps the dust inside of the silo and lets the pneumatic conveying air to leave it.

Telescopic Truck Loading Spout:
Telescopic loading spout also known as loading chutes are used to automatically discharge the contents of silo into open trucks or tanker trucks without any dust emmission.

• Pipeline can pass through anywhere, it is easier to install the system in tight spaces.
• Filter dust can be conveyed to long distances.
• Pneumatic transport system takes less space with respect to mechanical conveying systems inside the plant.
• AS the filter dust is conveyed within the pipeline, there is no risk for dust emmission through moving mechanical parts.
• There exist low number of rotating or moving equipment. Low risk of malfunctions, unintended stops.
• Maintenance cost of pneumatic conveying systems is generally less than mechanical conveying systems.

Tanker and open truck loading bellows are also known as loading chute and loading spout. Open truck and tanker loading bellows are used for safe and efficient dust free loading of dry bulk solids to tankers and open trucks. As baghouse filter and ESP filter dust have very small particle size, silo discahrging and truck loading should be done by loading bellows to prevent any dust emmission to the environment.

• Iron and steel plants, blast furnace dedusting systems
• Electrostatic Precipitators (ESP) of coal-fired power plants
• Baghouse filters of iron foundries
• Dust collectors of the food industry
• Dust collectors of chemical industry

Bulk material storage silos and tanks are crucial inventory storage units used in wide range of industries. Businesses must maintain their raw material reserves at a level that ensures efficient operation without using unnecessary additional storage. Plant operators are generally aware of what is going on and they have full control over storage facilities. But, there still remains an important challenge: having the right stock volumes at the right times. As storage vessels generally process both inbound and outbound deliveries, it is essential to have both enough available storage volume to accommodate inbound shipments, as well as to have sufficient stock levels to fulfill outbound orders. When one of those criteria are not met, either production will stop due to shortage of stock or extra costs will accumulate due to inadequate storage volume.

Altough checking and maintaining the stock level is the most important concern in bulk material handling, several other aspects should also be considered. Pressure and temperature inside the silo or tank, leaks, dust emmission, health of process equipment, vibration of fan or pump motors, outside weather conditions are some of the important parameters to be monitored for process, plant and operator safety. Condition monitoring of all connected equipment such as pumps, fans and valves provides extra functionality to keep the storage facility running all time without unintended interruptions.

Due to the stated concerns, digital monitoring and automation are quickly becoming essential for maintaining appropriate stock levels and safe operation in wide ranges of industries. Industry 4.0 concept and recent developments in industrial IoT (industrial internet of things) technology have made it possible to achieve efficient management of storage facilities with maximum safety and minimum cost. By integrating intelligent sensors that measure fill levels, process data and environment conditions, silo managers are now able to make better and faster decisions on their operations.

Polimak industrial Iot based silo monitoring system provides one of the most sophisticated solution for bulk material storage challenges using the power of the IoT, wireless connectivity, and smart devices. It provides a 360 degree solution for all storage vessels such as silos, bins, hoppers and tanks used to store powdered or granular bulk solids and liquids. This solution includes remote monitoring of product level, weight, pressure, temperature, moisture, vibration, weather conditions, dust emmission and similar process related variables. Combining and synchronising of all these measuring and monitoring systems and bringing a complete solution from a single source provides 3 important benefits:

 – Efficient stock and inventory control (read more : what is silo monitoring?)

 – Uninterrupted storage service (read more : what is condition monitoring?)

 – Safety of plant and employees (read more : what is silo protection?)

Inventory Monitoring System

Silo and tank inventory monitoring system is developed specifically for tracing the level or weight of liquids and bulk solids in storage vessels and providing meaningful insights to plant operators for managing raw material storage efficiently. Amount of a material inside a storage vessel could be measured by using volumetric or gravimetric measurement methods. Level sensors provide volumetric readings and loadcells provide weight information. These sensors are connected to inventory monitoring platform on the cloud. Sensor values are sent through industrial Iot gateways with increased security. Using the web based user interface, users can keep an eye on their inventories at all times locally and globally. The automated flow of inventory information within the company or between partner companies creates transparency for the supplier and security of supply for the purchaser.

Which Data Are Available ?

Depending on the application and handled material, some or all of the followig data are available:

– Name of the stored raw material

– Material level

– Net weight

– Filling rate

– Discharging rate

– Filling time and dates

– Discharging time and dates

– Name of involved operators

– Health of connected equipment

– Alarms whenever certain thresholds are reached (high level, low level etc.)

– Alarms such as over pressure, high temperature, side winds, leaks, dust emmission etc.

– Maps showing geographic location of monitored silos and tanks together with storage levels

– Current values and historical data

– IoT dashboard providing actionable information

Inventory Monitoring Scenarios , Who is it for ?

Inventory Monitoring for the Enterprises

Polimak industrial Iot enabled silo level monitoring systems let the plant owners monitor and manage their own stocks at one or more locations locally or globally. System provides needfull information to have optimal coordination of raw material deliveries between suppliers, storage facilities, manufacturing sites and processing lines.

Advantages for Plant Owners

– Quick access to current and historical consumption data

– Higher efficiency and confidence in stock levels

– Prediction of run out and consumption prevents costly panic orders

– Security of supply, avoidance of production stoppages

– Cost-effective production and inventory planning in own company

– Information enables plants to deliver more product less often

– Tracing the health of storage vessels ensures process safety

Inventory Monitoring for Suppliers

Raw material suppliers can acquire the responsibility for inventory monitoring and replenishing from customers. Current and historical consumption data is collected by supplier’s system automatically and logistics operations are arranged accordingly. Customers are ensure that enough stock will be available all the time and they can focus on their core business. By using data coming from different customers across geographically dispersed locations, suppliers can optimize production, inventory management, distribution, route planning and logistics operations.

Advantages for Suppliers

– Quick access to current and historical consumption data of all customers worldwide

– Cost-effective production and supply planning

– Cost savings through optimized logistics and route planning

– Reduced delivery cost per tonne by lowering number of trucks on the road

– Improved relationships and long term customer loyalty

Inventory Monitoring for Logistics Companies

Wide range of raw materials are to be used together in same production process. Plant owners have to manage multiple supply chains and make each raw material available at site to prevent production stoppage. Similarly raw material suppliers generally produce different types of bulk products and have to deliver them at the right time to the customer. This brings a complicated problem to solve: managing logistics of multiple suppliers and customers. By monitoring inventories of suppliers and consumers, logistics companies can make a huge impact on their business model. Load consolidation could become a price efficient option, optimized logistics and route planning could bring substantial cost savings.Improved customer relationships and long-term customer loyalty could be achieved by providing security of supply chain.

Advantages for Logistics Companies

– Substantional cost savings through optimized logistics and route planning

– Reduced delivery cost per tonne by lowering number of trucks on the road

– Improved relationships and long term customer loyalty

– Cost savings due to reduced administrative work

Technology and Infrastructure Behind The Platform

Combining long years of experience on bulk solids industry and recent developments in big data technologies, Polimak offers a sophisticated inventory system based on a powerful cloud big data architecture providing insight for process manufacturers to act on. This platform enables following services to achieve complete solution from a single source:

1. Measurement of process values

2. Data collection through secure networks

3. Cloud data storage

4. Visualization of collected data

5. Data analytics

6. Business intelligence

When filling and discharging bulk solids storage silos, several risks that may arise such as overfilling, overpressure and combustable dust explosion. By processing the signals coming from several sensors and taking necessary safety measures, silo control system automatically protects the silo from these risks. Health of critical components are monitored continuously and plant operators are warned if there exist any malfunctuining equipment. System provides a complete silo protection solution for safety of silo, workers and plant.

Silo Overpressure Protection

When bulk material storage silos are being filled by bulk tanker trucks or pneumatic conveying systems, pressurized air is used to fill the silos and it is vented from the top of the silo through jet filters (also named as dust collectors or silo vent filters). If the pressurized air entering the silo is not vented adequately, delivery in this manner may result in pressure build up and consequent rupture of the silo or connected equipment such as filter systems.

Potential Sources of Silo Over Pressurization are:

 – Inadequate flow through the silo top jet filter due to wrong filter selection

 – Inadequate flow through the silo top jet filter due to clogged filter elements

 – Failure of pressure relief valve to vent excessive air inside the silo

 – Sudden increase in air flow rate at the end of bulk tanker discharge

 – Uncontrolled discharge of residual air from the bulk truck

 – Inadequate maintenance of silo protection and safety equipment

Silo overpressure protection systems are used to ensure that storage silos and silo equipment have adequate safety measures to prevent over pressurization. In case of any lack of protection, these systems prevent filling the material to silos. This is achieved by making self tests for the silo equipment before filling and continuous monitoring of silo pressure during filling. Following safety systems are available in silo protection units:

 – Silo inner pressure monitoring

 – Jet filter clogging monitoring

 – Pressure relief valve self test

 – Jet filter self test

 – Automatic closing of silo inlet in case of over pressure

 – Cutting power of bulk truck or cutting signal of pneumatic conveying system in case of over pressure

Silo Underpressure Protection

During silo emptying, powdered material moves downwards and density of air above the material decreases as the empty volume increases if there is no air entrance from outside. This leads to a decrease in pressure and creates vacuum. If the vacuum level is high enough, the silo may collapse inside (implosion).

Main reason of a silo implosion is discharing material in the silo rapidly wihout providing adequate air ventilation.

Silo underpressure protection systems monitor pressure inside the silo and discharge speed of material. If the underpressure safety limit is exceeded, system automatically closes the silo discharge valve or stops the discharging conveyor.

Silo Overfilling Protection

Silo overfilling protection systems are suitable for preventing overfilling of silos and consequential damages or losses. Monitoring the product level continuosly inside the storage silos is the key for successful protection. Silo loading can be done by pneumatic or mechanical conveying systems. Rotating paddle sensors and radar sensors are widely used in storage silos to detect level of powdered and granular bulk solids. Main functions of silo overfilling protection system are as follows:

– Does not allow to start silo filling if it is already full.

– Gives alarm when it becomes full.

– Stops silo filling when it becomes full.

– Operates silo top jet filter (dust collector) during silo loading.

Explosion Protection for Ex-Hazardous Areas

If the handled material has a risk of explosion due to static charge build or the area is an Ex-hazardous area, grounding the truck is imperative. Electrostatic grounding testers are used to check whether the truck is grounded properly or not. Silo protection systems have a signal connection to truck grounding and bonding testers. Silo filling can only start if the safety permission signal is received from grounding and bonding tester.

Explosion vent panels are used to protect the silo, ensure worker and plant safety during handling of combustible dusts such as starch, sugar, coal and chemicals. An explosion vent or rupture panel is a safety device against excessive internal, explosion-incurred pressures, by means of pressure relief. It is designed to open at a predetermined pressure, to allow the fireball and explosive pressure to vent to a safe area. Burst sensors are used to detect if the explosion panels are ruptured due to an internal explosion. The sensors signal the opening of the bursting disc or panel so that equipment such as fans, screw feeders or rotary valves can be switched off and inform the plant operators to take relevant safety measures.

Operator Safety Warning System For Adverse Weather Conditions

Cold weather poses hazards to anybody working outdoors, but the conditions become more intense at higher places in the plants. Workers on the silo top facing different hazards than workers on the ground. What seems like a normal winter day on the ground could be high winds and extreme temperatures at heights. Companies and their workforces must understand what they could encounter to properly prepare for winter conditions.

Air temperature, humidity and wind speeds are measured by sensors at the top of the silo to give warning to workers before climbing to top, preventing any health problems or accidents caused by slippery surfaces, high winds, extreme cold and hot weathers.

Silo Control, Silo Protection and Silo Monitoring Systems

Bulk material storage silos provide a safe and efficient way of storing valuable raw materials. Filling and discharging of silos should be carefully handled to keep plant and operators safe. Polimak silo control and monitoring systems include wide range of powder handling equipment, automation systems and software solutions to operate and protect the silos in most efficient way. Polimak brings one of the most sophisticated silo control, monitoring and protection system to bulk materials handling industry, letting the plant owners monitor and manage their silos at one or more locations locally or globally.

Silo Control System

Silo control and protection systems play an essential role in bulk material storage and handling processes. PLC based systems provide realtime full control over silo while maintaining plant, silo and worker safety. Full control concept includes not only the silo itself, but also the connected upstream and downstream equipment. Silo filling equipment could be any kind of pneumatic or mechanical conveyor like bucket elevator, dilute or dense phase pneumatic conveying system, bulk tanker truck etc. By processing the signals coming from several sensors, silo control system prevents overfilling, overpressurizing and underpressurizing of the silo. Health of critical components are monitored continuously. A self testing system is operated periodically and before each filling operation.

Silo Filling Control System For Bulk Truck Filled Silos

Silos that are filled by bulk trucks (also known as road tankers) have several equipment to be controlled for safe and efficient silo loading. Automatic filling control system has a PLC controlled electrical panel that has full control over silo equipment. Silo top jet filter, silo inlet pinch valve, level sensors, pressure sensors and other components are connected to control panel. The power of air compressor of bulk solid tanker truck is supplied by built in power supply plug. Silo filling control system checks silo before filling for safety, controls the power sent to bulk truck, checks the product level, silo inner pressure during silo filling. System both controls the equipment and protects the silo from overfilling and over pressure.

Read More: How It Works ? Automatic Filling Control System For Bulk Truck Filled Silos

Silo Filling Control System For Silos Filled By Dense or Dilute Phase Pneumatic Conveying Systems

Pneumatic conveying systems that fill silos in industrial plants generally have their own electrical controls with SCADA, DCS or similar systems. Implementing new silo equipment or several safety devices may require substantial effort. Depending on mechanical and electrical configuration of pneumatic conveying system, a local control panel handling all silo functions might be much more convenient. Polimak silo filling control system panels have the capability of connecting to DCS or SCADA units. Start, stop, level, alarm and pressure signals can easily be transmitted between both units, providing cost efficient and practical way of implementation.

Read More: How It Works ? Silo Filling Control For Pneumatic Conveying Systems

Silo Filling Control System For Silos Filled By Mechanical Conveyors.

When silos are filled by mechanical conveyors, there is no pressure build up in silo. Though the system becomes simpler. Mechanical conveying systems such as bucket elevators and screw conveyors that fill silos in industrial plants generally have their own electrical controls with SCADA, DCS or similar systems. Implementing new silo equipment or several safety devices may require substantial effort. Depending on mechanical and electrical configuration of conveying system, a local control panel handling all silo functions might be much more convenient. Polimak silo filling control system panels have the capability of connecting to DCS or SCADA units. Start, stop, level and alarm signals can easily be transmitted between both units, providing cost efficient and practical way of implementation.

Read More: How It Works ? Silo Filling Control For Mechanical Conveying Systems

Silo Discharge Control System

Bulk material silos have several types of discharge equipment such as screw feeders, rotary valves, butterfly valves, slide gate valves, chain conveyors, bulk truck loading bellows and pneumatic conveying systems. Depending on application, there are wide range of receiving points like bins, processing lines, weighing and batching systems, trucks, mixers etc. Silo discharge control systems provide full control over silo discharging equipment for efficient handling.

Read More: How It Works ? Silo Discharge Control System

Silo Safety and Silo Protection System

When filling and discharging bulk solids storage silos, several risks that may arise such as overfilling, overpressure and combustable dust explosion. By processing the signals coming from several sensors and taking necessary safety measures, silo control system automatically protects the silo from these risks. Health of critical components are monitored continuously and plant operators are warned if there exist any malfunctuining equipment. System provides a complete silo protection solution for safety of silo, workers and plant.

Some of the most frequent risks during powder handling in silos and relevant protection systems are as follows:

– Silo overpressure protection

– Silo underpressure protection

– Silo overfilling protection

– Explosion protection for combustable dusts

– Operator safety warning system for adverse weather conditions

Read More: Silo Safety and Protection Systems

Silo Equipment Health Monitoring System

The ability to operate a reliable system requires early and continuous testing from the system level down to the components that make up the system and the ability to deal with failure and malfunction. Bulk solids silos are storage vessels with several equipment running together to ensure safe and dependable raw material storage. Silo Equipment Health Monitoring System is a condition monitoring system that detects the failures of equipment installed on storage silos. Consequently it prevents any damages or losses due to malfunctioning equipment.

Condition monitoring of following equipment is available depending on application and expected safety level:

– Pressure relief valve condition monitoring

– Jet filter (dust collector) condition monitoring

– Pinch valve condition monitoring

– Process air supply monitoring

– Motor vibration monitoring

Read More: Silo Equipment Health Monitoring System

Industrial IOT Based Silo Level Monitoring and Inventory System

Silo level monitoring system is developed specifically for tracing the level or weight of bulk solids in storage silos and providing meaningful insights to plant operators for managing raw material storage efficiently. Amount of powdered material inside a silo could be measured by using level sensors and loadcells to provide level and weight information respectively. These sensors are connected to Polimak-Politrace inventory monitoring platform on the cloud. Sensor values are sent through industrial Iot gateways with increased security. Using the web based user interface, users can keep an eye on their inventories at all times locally and globally.

Depending on the application and handled material, followig data are available for silo monitoring:

– Name of the stored bulk material

– Silo filling level

– Silo Filling and discharging rate

– Filling and discharging dates

– Name of involved operators

– Alarms whenever certain thresholds are reached (high level, low level, overpressure etc.)

– Maps showing geographic location of monitored silos with storage levels

Read More: Silo Level Monitoring and Inventory Systems

Industries Served

Our bulk solids handling solutions have assisted many large and small companies within a variety of industries.  Some of the bulk materials we have been working with include: cement, calcium carbonate, ash, plastic pellets, lime, sand, paints and pigments, gypsum, carbon black, pvc, coatings, fly ash, coal, coal dust, flour, seed, chickpea, rubber, carbon black, bean, sesame, almond, grain cereals, chestnut, coffee grain, coffee powder, sugar, corn, starch, salt, spice, glass powder, marble powder, sawdust pet food, ingredients and extracts, dairy products and industrial products.

Pneumatic conveying systems are broadly used throughout bulk material handling industries to move dry bulk materials through a facility. They move the bulk material in a pipeline generally with air being used as a conveying agent. When it comes to utilising pneumatic conveying systems to transport dry bulk materials, facility owners find themselves in a position to of needing to make a choice between pressure conveying or vacuum conveying. In other operations, a combination of both, vacuum and pressure conveying systems may be the best solution. Ultimately, Polimak experts will have to consider what is feasible given the available resources and suggest which method will best suit the transportation of the bulk material.

The design, production and installation of pneumatic conveying systems for bulk materials require a great deal of know-how and long years of experience. Simple installation, low maintenance need, long years of problem-free service and endurance for harsh environments are key features of quality pneumatic conveying systems. Polimak brings pneumatic conveying solutions and expertise to a variety of industries including chemicals, food, plastics and cement. A well designed pneumatic conveying system is a practical and cost-effective method of transporting dry bulk materials from one point to another.

There are several ways to pneumatically transport dry bulk materials and the key difference in each method is the conveying phase. Conveying phases are modes of how dry bulk materials being conveyed through a conveying pipe. Pneumatic conveying phase mode can be categorised into two, the dilute phase and the dense phase.

Dilute phase pneumatic conveying systems, also known as lean phase conveying systems, involve the transportation of dry bulk materials at velocities above the saltation velocity. These systems generally use air entry pressures below 1bar to move dry bulk materials through conveying pipelines at relatively high velocities. Bulk material particulates are wholly suspended within the airstream throughout the conveying pipe in dilute conveying systems. The material transfer within the system is described as low pressure high velocity, hence the name “low pressure systems”. The particle velocity is paramount in these systems because it affects the material end product, very low velocity may result in the material collapsing to the bottom of the pipe from the airstream and very high velocity may cause particle-to-particle collision and particle-to-wall collision resulting into bulk material degradation. The two methods that can be performed are dilute phase pressure conveying and dilute phase vacuum conveying.

Dilute phase conveying systems are the most common pneumatic conveying systems used in many bulk material handling industries to transport bulk solids. These systems are ideal for transporting non-abrasive bulk materials, products with low bulk density and bulk materials that are hard to break. Some of the dry bulk materials that can be processed using dilute phase pneumatic coveying systems include sugar, flours, pellets, chemicals, polymers (resins and compounds), calcium carbonate, cement and coal dust.

Dense phase conveying systems are pneumatic conveying systems that utilise relatively low velocity gas and rely on high pressure differential, positive or negative, to transport dry bulk materials in pipelines. The velocities in these systems are typically below the saltation velocity. Dense phase pneumatic conveying systems can be referred to as high pressure conveying systems. Low velocities within these systems result in a gentle and efficient transfer of bulk materials. Dry bulk materials move with less wear and impact inside a conveying pipeline and their flow (dense phase transfer form) generally occur in two forms, plug flow or dune (wave) flow. Dense phase transfer form is primarily dependant on the nature of the bulk material and the configuration of the plant. This type of pneumatic transport system is ideal for most abrasive, friable, fragile and mixed-batch dry bulk materials. The two methods that can be performed are dense phase pressure conveying and dense phase vacuum conveying.

These systems are used across many different bulk handling industries to convey bulk products. Higher conveying rates and longer conveying distances are often possible with dense phase conveying systems. Some of the handled bulk materials include sand, limestone, gypsum, fly ash, cement, CaCo3 and many more.

Most bulk material handling industries make use of mechanical conveying systems to handle their dry bulk materials. Industries such food processing industries, pharmaceutical industries and chemical industries need to maintain high levels of hygiene throughout the handling processes of bulk materials. The use pneumatic conveying systems help industries maintain high levels of hygiene during material processing.

Power and Energy Industry

Pneumatic conveying systems are extensively utilised in coal-fired power plants to transport fly ash in its dry form. Glassy droplets of as are produced during the burning of coal. Fly ash is one of the residues produced during coal combustion and comprises fine particles. Pneumatic conveyors offer an ideal choice for handling dry fly ash. Fly ash from various hoppers is evacuated using pneumatic conveying systems up to an intermediate silo.

Designing reliable systems (pneumatic conveyors) is not a trivial task, it necessitates a considerable amount of knowledge of the characteristics of the handled product and the intricate solids-gas-pipe wall interaction. Poorly built systems may result in significant losses in terms of increased energy consumption, decreased delivery, and premature wearing of hardware among other things. Polimak provides versatile, robust and low-maintenance fly ash conveying systems that offer dustless operations and can handle high temperatures.

Cement Industry

Cement is an essential element wherever things are being built, hence the cement industry plays an important role in construction operations as it is responsible for supplying the raw material cement. Pneumatic conveying systems are vital in this industry when it comes to effectively transporting cement in various facilities. Several pneumatic conveying (pressure conveying or vacuum conveying) technologies can be utilised to transfer cement. Finding the appropriate solution for your application can pay dividends, particularly in terms of lowering energy consumption in your plant. Polimak’s qualified and experienced engineers help its clients come up with efficient cement conveying equipment for a specific application. We offer innovative pneumatic technologies for broad cement handling processes.

Mining Industry

Coal mining is one of the mining sectors that utilise pneumatic conveying systems for handling various raw materials including rock dust (usually pulverised limestone). Both dilute phase and dense phase pneumatic conveying systems are applicable in the mining industry.
With the growth of the mining industry, Polimak has taken up an opportunity to supply quality pneumatic conveying systems to this industry. Our products are extremely versatile, reliable and durable even under the most challenging operating conditions. We take pride in offering high-quality pneumatic conveyors suitable for the mining industry to ensure efficient and safe transportation of dry bulk materials within pipelines.

Food Industry

Food production is one of the world’s largest, most diverse and important industries. The food industry is a huge industry that consistently requires higher hygiene and efficiency during bulk material processing. Pneumatic conveying systems provide hygienic and flexible material handling processes. A broad variety of food products such as sugar, rice, corn, spices, grains, cereal, flour and animal feed can be transported using pneumatic conveying mechanisms. The design and production of pneumatic conveying systems and experience-based engineering solutions for any type of bulk material is a challenge. Polimak provides complete solutions of pneumatic conveyors for use in the food industry.

Chemical Industry

The chemical and petrochemical industry is one of the prominent sectors that make use of pneumatic conveying systems to move chemicals through enclosed pipelines from a single or multiple source(s) to a single or multiple destination(s). With the rising usage of virgin polymers in several products, the petrochemical industry is required to generate building block ingredients for the majority of chemicals in large quantities. Bulk materials in this industry may be dangerous, hence the containment of the materials is very crucial to prevent cross-contamination, reduce explosion risks and protect the environment by combating dust emissions.

Plastics Industry

Plastics and polymers industries produce and export a broad range of raw materials and pneumatic conveying systems are suitable for moving plastic pellets and materials in powdered form. Processes such as blending, mixing, extruding and moulding are performed in the plastics industries. Pneumatic conveying systems can be used to feed extrusion machines and mixing machines.

Bulk materials do not pass through fast-moving parts in pneumatic conveying systems unlike other mechanical systems such as belt conveyors, screw conveyors, vibrating conveyors, drag conveyors, bucket elevators, etc. In this way, most contaminations/damages to the transported dry solids are prevented. Some of the dry bulk solids transported with pneumatic conveyors include sugar, spices, salt, flour, maize corn, popcorn, coffee beans, sand, limestone, cement, coal, gypsum, plastic pellets, plastic powders, calcium carbonate and many more.

Pneumatic conveying systems provide numerous benefits to users including the following:

• They can run long distances and the conveying pipes can be installed vertically or horizontally.
• Materials are conveyed in a closed pipeline. In this way, conveyed materials stay clean and dust leakage to the atmosphere is prevented.
• Because of their compact design, it’s easy to integrate pneumatic conveying systems around existing equipment, making them more versatile than mechanical systems.
• A pneumatic system can convey a product at any place a pipeline can run.
• These systems do not occupy a lot of space.
• Pneumatic conveying systems have a few main parts such as a pump/blower, pipeline, feeding device etc., and all parts can be repaired independently, so, they are easy to maintain.

Activated Carbon Injection Systems

In the process of combustion at high temperatures, various gases spread out to the atmosphere. They are toxic and harmful to human health. Powdered activated carbon (PAC) is high performance adsorbent engineered to eliminate such toxic gases like dioxins, furans and other chemicals like mercury. In addition to flue gas treatment, another area of application is the removal of micropollutants in wastewater cleaning and drinking water treatment. Environmental problems affecting air and water are solved through the use of activated carbon.

PAC is commonly used in chemical plants, steel mills, waste disposal facilities, coal-fired power plants and casting plants. Under normal conditions, baghouse filters are not eligible to prevent the spreading of the flue gases produced by the incineration process. Injecting PAC to the pipeline at the baghouse filter inlet adsorbs these gases. PAC within captured flue gases like dioxins, furans are captured by the filter bags and prevent the release to the atmosphere.

Implementation difficulties of PAC in such industries are the storage of raw material (sacks, big bags, silos) , conveying to dosing systems and dosing to the desired process afterwards. However, this is too costly to meet the need for a large space in the plant. Inefficient methods increase operation time, labor and energy costs. Polimak activated carbon injection (ACI) system with its high-efficiency control of gas emissions provides a long-term solution that consists of a packaged system that takes less space in the plant, simple to install and simple to operate. The packaged PAC handling system is designed for PAC delivered in bulk bags and consists of hoist, big bag discharging platform, storage silo, weighing, dosing unit and pneumatic conveying system for PAC injection. It can also be integrated with lime dosing systems to provide better functionality.

Operating Principle of PAC Injection System

Powdered activated carbon (PAC) comes in the big bag and placed to the carrier platform of the unit by the help of forklift or hoist. The FIBC bag outlet connection is released, activated carbon is fed into the powder hopper and discharged into the storage silo. The dosing system below the silo is used to discharge the silo and feed the pneumatic conveying pipeline automatically. PAC is injected into the pneumatic conveying pipeline at the desired speed by the help of a feeder placed under the weighing device. PAC conveying in the pipeline by the help of a roots blower is injected into the process line which is generally another pipeline in the dust collection line. This injection process may operate in the same or opposite direction with the airflow. PLC controlled automation system is used to control the precisely definable amount of injected PAC to the pipeline. Material transfer at desired capacity, speed and time are regulated by the control panel.

Advantages of Activated Carbon Injection Systems for Flue Gas Treatment

• Compact and packageds design for simpler big bag handling, activated carbon storage and injection
• Short delivery times
• Easy installation
• Quick commissioning
• Space-saving design
• Lower investment and operation costs