Rotary airlock valves are essential components in efficient material handling processes & bulk material conveying. Keeping rotary airlock feeders in proper working condition will maximize longevity for your rotary airlock filters and decrease their total cost of ownership.
Whether you’re handling free-flowing powders, wood pellets, or other materials, your system will depend on your rotary airlock feeders correctly functioning.
Due to design, rotary airlock valves typically allow a small amount of conveying air to seep back into the airlock while it is transferring bulk solid material to a conveying system. This rotary valve leakage, if not managed properly, can cause issues such as slowing down the material flow into the airlock or releasing dust into your facility, which could potentially harm the equipment and pose health risks.
To manage this situation, you can use three methods to properly vent the air that leaks from a rotary airlock valve.
Each of these methods is designed to effectively manage and minimize the impact of the leaked air, maintaining the efficiency of the system and ensuring the safety of the facility.
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Option 1: Attach the Rotary Airlock Valve Directly to the Storage Vessel
The rotary airlock valve can be attached directly to the vessel storing the material for the conveyor system. This setup streamlines the handling of the material being transported to the conveyor system. The valve in this setup performs two jobs: it keeps air out and controls how much material is moved.
In the event of a rotary valve airlock leak, the air goes directly into the storage vessel. As the vessel fills with material, the leaked air is forced to move through the stored material and is then vented out from the top of the vessel.
Many storage vessels are equipped with a bin vent filter, designed to exhaust the leaked air efficiently, preventing any build-up of pressure. This solution not only manages the leaked air but also ensures a smooth flow of materials, maintaining the efficiency of the entire conveying process.
Option 2: Equip the Rotary Airlock Valve with a Vented Surge Hopper
Equipping the rotary airlock valve with a surge hopper that has a dedicated vent filter is an effective solution for managing rotary airlock valve leaks. The vented surge hopper, when sized proportionally in relation to the airlock, can handle the air efficiently. Its input can be managed in three ways, providing flexibility depending on the needs of your system.
Firstly, it can be fed by another rotary airlock that is positioned below a storage vessel, effectively creating a chain of airlocks to manage and control the flow of material. Secondly, it can be flood-fed from a storage vessel, where the material is allowed to flow freely into the surge hopper.
Lastly, the surge hopper can act as a transition point to a metered feedpoint, allowing for precise control over the volume and rate of material flow. This multi-pronged approach to feeding the surge hopper allows for a versatile and adaptable solution to industrial airlock valve leaks.
Option 3: Collect the Leaked Air in a Central Dust Collection System
Utilizing a plant’s central dust collection system is another method to manage leaked air from a rotary airlock valve. In this method, the leaked air, along with any particles entrained from the vented surge hopper of the rotary airlock valve, are contained within the dust collection system.
This prevents the particles from dispersing within the facility and maintains the air quality within the plant. The dust collection system fan, designed to create a negative pressure or suction, ensures that the leaked air follows a specific path – from the surge hopper, through its vent, and finally into the dust collection system.
This systematic pathway effectively captures and contains the leaked air, preventing it from causing any disruptions in the plant’s operations.
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Each of these airlock valve leak management methods comes with benefits and risks. Before attempting to handle a rotary airlock valve leak on your own, consult with our team of trained professionals. With their expertise, you can manage the risks and maintain your rotary airlock valves’ efficiency and lifespan.
Additionally, alternatives like double dump valves are available, which are much more resilient and don’t have the same constant leakage issues. Unlike rotary valves, double dump valves are not subject to the same kind of wear, even in extreme conditions.
They allow material to flow while preventing the backflow of air or gas which is critical in many conveying systems, and might be more suitable for your operations.
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