bulk storage & handling
DESCRIPTION
As with most things in life, the basics remain the same although they may become more sophisticated, or complicated, dependent on one’s viewpoint.TRANSCRIPT
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Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872
Digital Re-print - January | February 2012 Bulk Storage & Handling
www.gfmt.co.uk
As with most things in life, the basics remain the same although they may become
more sophisticated, or complicated, dependent on one’s viewpoint.
And so it is with this overview covering the bulk storage and handling of materials in the animal feed and human food industries, from the intake of raw materials through to the discharge of finished products.
It is barely 60 years since a very high proportion of the milling industry was located at the major ports with raw materials in sacks being transported from the docks by horse and cart and then hoisted up to the various floor levels for storage there to be cut and tipped into process bins as and when required.
Gradually, as more home grown grain became available, together with the advent of purpose-built bulk vehicles and an improved road network, there was a move to country mills more conveniently located to service the farming community by buying grain locally, processing it into feed and selling the resultant product back to the farmer.
The use of computers and automation throughout the milling process has reduced what was a labour intensive industry to one controlled by a few technically proficient operators, but to whom the basics of mate-rial handling must still apply, as do health and safety requirements, adherence to DSEAR/ATEX Explosion Regulations, plus health and hygiene control. Hence this résumé.
Interruptions in productionThe interconnection of process plant
is designed to be fail-safe and so prevent chokes and interruption to production.
Intake capacity from bulk tankers has greatly increased over the years and is normally well in excess of 100 tonnes/hour via an intake hopper with safety grid located under cover plus an efficient dust extraction
system, and discharging into a screw or chain type conveyor which may, if wished, be fitted with a variable speed drive so that the intake rate may be varied to suit the characteristics of the particular material being dealt with in order to prevent overloading subsequent equipment.
The conveyor should be fitted with rota-tion control and overfeed detection.
The intake bucket elevator, as with all similar units in the mill, must incorporate explosion relief panels at prescribed intervals, electrically linked to shut down the plant in the event of an explosion occurring.
Because of their inherent design, bucket elevators have a built-in explosion risk factor and, if located within a building, the explosion panels should be ducted to atmosphere. Elevators should also incor-porate tensioning gear at the boot, anti-runback device to cater for a choke or
power failure, rotation sensor to indicate if the belt is slipping and side alignment indication.
Intake points are frequently out of sight of the control room so, to avoid being allowed to run empty for long periods, and a
procedure should be in place to shut down when not in use.
A rotary drum pre-cleaner located at the top of the Mill to remove foreign matter prior to the material being conveyed to raw material bins will protect subsequent equip-ment from being damaged.
The conveyors feeding silos and bins will have multiple outlets and the electri-cal control system must be designed so that only one slide is open at a time in order to prevent the propagation of an explosion from one bin to another. As with the intake conveyor, all conveyors should incorporate overfeed detection and rotation sensing.
To cater for dust laden air displacement at transfer points, small dust units with built-in exhaust fans at convenient locations will ensure a clean atmosphere.
Storing different materialsThe number, location and holding capac-
ity of new material bins is determined by site conditions and the particular require-ments of individual clients, bearing in mind the large number of different materials to be handled and stored in the feed industry. Ranging from free flowing grains to a variety of meals and moisture content, the bins and discharge equipment should be designed to cater for those with the worst flow char-acteristics to ensure maximum flexibility so that individual bins can be used for the stor-age of any ingredients should the need arise.
Level probes are required to prevent overfilling, as are policed explosion panels.
Provision will be required for minerals and other ingredients that are delivered
by bulk tanker and pneumatically conveyed to dedicated bins utilising either a blower mounted on the tanker chassis or, in some cases, by coupling up from a land-based blower. To prevent static electricity causing a spark, the tanker will be connected to an
by Alf Croston, Managing DirectorCroston Engineering, UK
Bulk st
orage
handling
Grain&feed millinG technoloGy12 | January - february 2012
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FEATURE
GFMT12.01.indd 12 02/02/2012 10:13
The color blue, when used in connection with elevator buckets, is a U.S. registered trademark owned by Tapco Inc. Super EuroBucket ™ is a registered trademark ofTapco Inc. © 2012 Tapco Inc.® All rights reserved.
Now available, only from Tapco,the two most popular bucketdesigns in the world! Theseincredible buckets will fit yourelevator no matter where in theworld you operate your facility.
For North American style elevators: the classic CC-HDdesign. For European style elevators: the SuperEuroBucket.
Whatever you want, wherever youneed it, there’s a Tapco bucket.
�900,000 buckets in 93 sizes �15 million bolts, 6 styles�Fasteners, liners & accessories
In stock worldwide, and readyto ship. Contact us today forinformation on getting themost from your elevator. Orvisit www.tapcoinc.com andtap into a world of experience.
Tel.: +1 314 739 9191 • +1 800 AT TAPCO (+1 800 288 2726) • Fax: +1 314 739 5880 • Email: [email protected]
Serving the World by Design
� The most specified style in North America.
� Straight sides provide direct and compact discharge pattern.
� Designed to discharge over thewidest range of speeds andpulley diameters.
� Easily modified to the low profile configuration for high throughputelevators.
� All sizes available in polyethylene,nylon and urethane.
CLASSIC STYLE CC-HD� Direct interchange and replace-
ment of existing pressed steelbuckets.
� Safer – Nonmetallic materials eliminate possible sparking from bent and torn steel buckets.
� Equal or greater carrying capacities of steel buckets.
� Thick walls provide superior impact strength and long life.
� Popular sizes in stock for immediate shipment.
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GFMT12.01.indd 13 02/02/2012 10:13
complies or can be economically altered to comply.
Good housekeeping, regular inspection and maintenance, plus an awareness of potentially hazardous processes or areas, are a requisite for trouble free operation. The Directives combine these aspirations into requirements and apply not only to the sup-pliers of equipment but, in particular, to the users themselves.
Dust classificationIt is the obligation of the user to sat-
isfy himself as to the class or classes of the materials to be handled and to provide this information to the designer or manufacturer of equipment.
These are defined under four Kst classifi-cations (K staube = Class of dust), and relate to rate of pressure rise.
Kst. 0 = Non-explosiveKst. 1 = Weak to moderateKst. 2 = StrongKst. 3 = Very strong
Most materials used in feed mills are covered under Kst. 1 but there are a few to which Kst. 2 could apply.
ZoningIn addition to dust classification, the
user is required to carry out a survey and to designate plant and buildings into zones which will be appropriately signed at points of entry. Zones 20, 21 and 22 are the most likely to apply to feed milling and associated industries.Zone 20 covers an area in which an explo-sive atmosphere consisting of combustible dust in air is present frequently for long periods or continuously. Zone 21 is where an explosive atmosphere
remit covering bulk handling it is a matter that requires attention whether it is for con-ditioning of mashes for direct sales or for pel-leting. The three essen-tials being moisture, temperature and time, whilst bearing in mind the heat sensitivity of some ingredients. For
pelleting, correct conditioning is necessary to ensure starch gelatinisation and pellet quality.
An efficient cooling system is essential prior to finished products being conveyed to packing or bulk out loading bins, the latter discharging either directly to bulk vehicle or via a travelling weigher.
Most of the materials processed in the animal feed, pet and fish food, grain, flour, bakery, sugar, starch and fertiliser industries are subject to the DSEAR/ATEX Explosion Regulations that came into operation on July 1, 2003. There are many misconceptions and confusion as to the requirements of the Directives. It is timely to reiter-ate the general principles relat-ing to the regulations, particu-larly for those who have only recently become involved in one or other of the industries in which potentially explosive
materials are handled.
The DirectivesThe Directives apply from July 1, 2003,
to all new equipment and any existing that is modified or relocated after this date. This has particular relevance in ensuring that, if purchasing any second-hand equipment, it
earthing point prior to starting the discharge process. Care is needed to ensure that the tank-er only couples up to the correct intake line feeding the designat-ed bin and that intake lines are of correct diameter, earthed and routed with minimum horizontal length and number of bends in order to reduce the pressure needed to carry out the convey-ing operation.
As referred to earlier, the configuration of hopper design and type of discharge is all-important in ensuring the free flow of materials from the bins to the blending operation. For accuracy this will include one or more main weigh hoppers, a small weigh hopper for minerals, and a smaller one for micro ingredients.
The blended batch is fed to the grinding plant preceded by a screen to allow meals and minerals to bypass the grinder before re-joining the ground materials and passing to a three tier mixing assembly consisting of pre-mix bin, mixer and dump bin. Molasses and fats are added at the mixer.
Although heat treatment is outside this
Grain&feed millinG technoloGy14 | January - february 2012
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the following may be found helpful as an “aide memoire” towards good housekeeping;• Enforce a strict no-smoking rule, on pain
of dismissal.• Ensure that all electrical equipment,
cabling and control panels conform to relevant standards and regulations, and are kept free of dust.
• Use only totally enclosed, fan-cooled motors, ensuring they are adequately earthed.
• Ensure light fittings are dust-proof.• Test cables and wiring regularly.• Locate switchgear and process control
panels in dust-free rooms under light negative pressure.
• Inspect liquid lines regularly for leaks. Ensure that insulation, if used, has not become impregnated, as this could be ignited by electrical trace heating.
• Bund walls around main storage tanks should be sized to suit.
• Check that bearings, particularly those fitted to elevators and grinders, are not over-heating.
• Detect belt slip and misalignment on elevators – a major source of fires – by rotation and side alignment sensing, and anti-run-back protection.
• Check for possible temperature rise in stored bulk materials, which could result in spontaneous combustion.
• Inspect bin interiors using only battery-operated, non-glass, flameproof inspection lamps, which are suitably secured and never allowed to be in contact with the product. (In the past it was not unusual for naked electric bulbs to be lowered into bins – at best protected with a wire guard).
• Ensure hot work is carried out only on isolated, cleaned-out plant, against Work Permit issued by management, and provision of fire blankets, extinguishers, etc.Many fires have occurred during periods
of repair, renovation or plant modification (as in the case of Windsor Castle a few years ago). During these special periods, in addition to taking fire precautions, it is advis-able to inspect the area closely for at least an hour at the end of each working day.
Adherence to these principles will ensure not only a pleasant environment in which to work but also one that is as intrinsically safe as possible.
About the author:Mr Alf Croston is managing director
of Croston Engineering, at Tarvin, near Chester, which was founded in 1976. His company specialises in the design and building of bulk storage, handling and process plants throughout the UK and Ireland for many household names in industry.
Very often a primary explosion in itself is not dangerous but the vibration it sets up disturbs any dust lying on floors, beams, rafters, into the atmosphere. If a source of ignition is present it can result in a secondary and devastating explosion. So, cleanliness throughout the plant is of first priority with particular attention being paid to “out of sight” areas and cleaning up spillages imme-diately – using one of a variety of vacuum cleaning systems available. Brushing up is definitely out – it only disperses the dust elsewhere.
Despite taking all precautions that one can think of, it is sod’s law that incidents still take place – thankfully not too often in view of increased awareness of the dangers that are always present.
ExamplesThree examples illustrate the variety of
incidents that can happen. The first resulted from smoulder-
ing material entering a bin, setting off a primary explosion which ruptured the explosion panel as it was designed to do. Unfortunately the escaping gases caused a secondary explosion which devastated the top floor of the building. As it was impracti-cal to vent every bin to atmosphere it was subsequently agreed with HSE that the top floor over the bins would in future be a “no go” area whilst the plant was in production and for ten minutes afterwards. A lockable gate was fitted to the access stairs and a warning notice affixed.
The second resulted from a hot spot due to a malfunction in the motor of a dust unit fitted on top of a grinder expansion hop-per. The explosion panel ruptured but had not been vented to atmosphere through a nearby wall.
Unfortunately, two employees were standing nearby at the time and were badly burned. It was interesting to note that a choke had been fitted to the bin discharger beneath the expansion hopper and pre-vented the explosive gases passing into a subsequent elevator and storage bins, otherwise the result would have been even more serious.
The third was caused by welding being carried out on the side of a silo, one of several such accidents over the years, in which the operator was injured. In this case it was not the result of negligence. The silo had been isolated from its feeding conveyor, cleaned down internally and the subject of a work permit. Unfortunately, a small amount of material had remained in an inaccessible spot and on being disturbed created the conditions for an explosion to take place.
The foregoing describes in broad outline the rationale behind the ATEX Directives. Many of the requirements are common sense, but common sense has to be backed up with documentation in this day and age. However,
is likely to occur occasionally in normal operation.Zone 22 is where an explosive atmosphere would not normally occur but, if it does, it would only be for a short period.
Obviously it is the duty of manage-ment to ensure that standards of operation and cleanliness are maintained to meet the requirements of Zone 22 as far as is practical.
In carrying out risk assessments it is natural to concentrate on major processing equipment such as silos, grinders, elevators, dust collectors, etc., and to overlook the myriad range of smaller ancillary items that also need to be checked. Typical items include lighting, electrical fittings, motors, level indicators, solenoid valves, control panels. In fact, anything that can generate a spark.
It is well known that three elements are required to cause an explosion – dust in suspension at a critical level, oxygen, and a spark or hot surface. The first two are always there, so it is against the third item that every precaution must be taken, including satisfac-tory earthing throughout the plant.
Bear in mind that dust in suspension appearing as a light fog provides the condi-tion in which a spark can cause an explosion. The finer the dust particles the greater the danger because of the increased surface area exposed to atmosphere.
The duties of the user having been described in general terms, what about the supplier of the equipment? Firstly, he has to satisfy himself that the user has provided him with all the necessary details concerning clas-sifications of materials to be processed and the areas in which equipment is to be located, together with any other relevant information.
The supplier then has to ensure that the equipment he supplies is designed, manufac-tured and installed to satisfy requirements by taking all precautions to prevent an explosion but also, and most importantly, to mitigate against an explosion should such an event occur.
Equipment can be manufactured in such heavy construction that an explosion would be contained but this is so expensive as to be impractical. The alternative is to fit a certi-fied explosion panel vented to atmosphere through a nearby wall or roof.
Due to the location of plant within a build-ing venting may not be practical and so the fitting of expensive flame quenching or explo-sion suppression equipment may be required.
To prevent the propagation of an explo-sion, items of equipment should be isolated from each other. An example being to incor-porate valves or slides so that only one bin can be filled and exhausted at a time. Bin dischargers and screw conveyors can be designed with chokes incorporated.
The installation of a rubble separator on the intake system and magnets at appropri-ate points throughout the plant are obvious precautions.
Grain&feed millinG technoloGy16 | January - february 2012
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Grain&feed millinG technoloGy January - february 2012 | 17
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The reclaiming of bulk products from silos, bulk carriers, railroad cars, hoppers, etc … is made easy by
Vibrafloor, says the company.
“This proven technology is ideally suited for either new-build or retrofitted storage structures,” it adds.Vibrafloor performs the recovery and clean-up of residual piles on slightly inclined floors, typically 8 to 12°. Most commodities can be efficiently handled, such as cereals, meals, sugar, flour, fish feed, cotton seed, sulphur prills, wood chips, wood pellets, saw dust, ores and aggregate.Vibrafloor is made of independent vibrating modules, customised to suit the shape and dimensions of the storage. Modules are laid side-by-side and end-to-end to cover a given area.Modules are typically 2.2m wide, 3m to 4m long and 50mm thick. They can also be of trapezoidal shapes into a conical design. A three-phase electric vibrator of 700W unit power powers each module.Lower modu le s are triggered first, to destabilize and c a r r y r e s i d u a l piles into a central conveying system o r a c e n t r a l h o p p e r . T h e n upwards rows or circles of modules a r e t r i g g e r e d successively from bot tom to top , u n t i l c o m p l e t e c l e a n u p o f t h e s t o r a g e i s completed.Advan t a ge s for operators include:
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The exhibition features technological meetings and seminars promoted
by the industry’s representative trade associations
Technologies for packaging, processing and industr ia l logistics, the three pillars of IPACK-IMA 2012, all have a high degree of automation as their common characteristic. The upcoming edition of the exhibition on schedule from February 28th to March 3rd at Fiera Milano will host over 200 exhibitors active in the industry of automation systems and components. 215 companies representing a sector capable of creating strong synergies with the ten exhibition areas and nine business communities of IPACK-IMA, thus attracting
the interest of the vast majority of professionals visiting the event. The increase in ef f iciency, p roduc t i v i t y and s a f e t y s t andards for mach iner y and equipment is largely the result of innovations brought about by manufacturers of automat ion systems. The latest advances showcased at IPACK-IMA go hand in hand with technical meetings
organized by major trade associations. A N I E ( t h e F e d e r a t i o n representing the electro-technica l and e lec tronic companies in Italy) will hold a seminar intended for all industry profess iona l s , des igners , manufacturers and assemblers titled “Electrical Cabinet for Human Interfaces Machines: design, application and energy efficiency”. The meetings (on schedule for Friday March 2nd) will discuss requirements and features of in-field control panels and will provide an outline of the main national and international regulations, the materials employed according to different uses as well as specific applications and the legislation connected to them.Another prestigious association
that has chosen IPACK-IMA 2012 as the venue to meet the specialist public is ANIPLA (Italian Automation Association) with a meeting focused on next-generation t e chno log y t o improve ef f iciency and productivity ( scheduled for Thursday March 1st): “Automation in the Packaging: from innovation to Efficiency”.L as t l y, t he ob jec t i ve o f increasingly comprehensive, w ide l y a cce p t ed g l ob a l standards will be discussed during a specific meeting on Friday March 2nd organized by PLCopen, a global association of manufacturers and vendors of automation systems aiming at becoming global leader in the regulation of automation control systems.
Efficiency, productivity and safety increase through the use of automation systems- As many as 215 automation companies to exhibit at IPACK-IMA- As many as 215 automation companies to exhibit at IPACK-IMA
News January - February 2012 NEWS
Grain&feed millinG technoloGy January - february 2012 | 11
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Dr John Schillinger is acknowledged as one of the most accomplished
soybean breeders of the past century and a father of GMO soybeans, but today his research centres on non-genetically modified (non-GMO) varieties.
For the past decade Dr Schillinger has specialised in creating high protein soybeans with low anti-nutritional factors, tailored for specific feed uses.Dr Schillinger has devoted over 40 years of his distinguished career to working with soybean genetics. His research programs have emphasised the function of various compositional factors of soybeans and their impact on nutritive value in feed and food. His developments of soybean varieties for the food industry in United States, Japan and Korea are well recognised. Currently, four of Schillinger
Genetics’ food grade varieties (240.RY, 389.FYC, 3520.FHPC and 448.FHPC) are among the most popular varieties for tofu, soymilk, soy snack and miscellaneous production. All of these varieties were selected for high protein content.For the past 10 years, John Schillinger and his team at Schillinger Genetics have turned their attention to animal and aquatic feed use. In 2007, John and his team began supporting feeding trials with swine, poultry and turkeys followed by aquaculture feeding trials with trout, salmon and shrimp – all with great success.Thanks to Dr Schillinger, novel soybean varieties are now commercially available with oligosaccharide levels (stachyose and raffinose, oligos) significantly reduced from a normal value of 5.5 to 0.5 percent. Similarly, unique soybean cultivars have been developed
which significantly reduce trypsin inhibitors from 55,000TIU/g present in regular commodity beans to a low of 7000TIU/g.From a practical perspective, the value added advantage in using these improved soybean varieties is highlighted by savings in processing costs since there is no need for heat-deactivation of protease inhibitors, improvement of nutritive value as there is no nutrient deterioration and the elimination of potentially detrimental effects of excessive oligosaccharide concentrations. For the growing aquafeed market , soybean cult ivars have been selected with 15-20 percent higher protein content and with the difficult-to-digest carbohydrates raff inose and stachyose, as well as trypsin inhibitors significantly reduced. The defatted meal derived from these cultivars exceeds 56
percent in protein content and with further gentle processing will surpass 60 percent in crude protein (CP). Feeding trials comparing protein digestibility, metabolisable energy, mortality, FCR and growth per formance have been conducted with Atlantic salmon, rainbow trout, Pacific white shrimp, European sea bass, cobia, yellowtail and red drum. Additional trials with other aquaculture species will be conducted in 2012. Dr Schillinger’s team will describe how redesigned soybean varieties are opening up opportunities for animal and aquafeed manufacturers at the feed conferences FIAAP Asia Conference and Aquafeed Horizons, taking place February 15 and 16, 2012, during Victam Asia 2012 in Bangkok.
More inforMation:Website: www.feedconferences.com
Tailored non-GMO soybeans create new opportunities in animal and aquafeeds
News January - February 2012 NEWS
Grain&feed millinG technoloGy January - february 2012 | 7
At AFIA’s Pet Food Conference in Atlanta, Ga, AFIA announced
a new third-par ty faci l ity certification program designed specifically for manufacturing p e t f o o d a n d p e t f o o d ingredients.
AFIA’s petfood and quality committees developed the Pet Food Manu f ac tur ing Facility Certification Program (PFMFCP) and the Pet Food Ingredient Facility Certification Program (PFIFCP) with input
from third-party food safety experts. These two programs build upon AFIA’s domestic Safe Feed/Safe Food program and are designed to monitor the process controls specifically related to the manufacturing of pet food.“AFIA sees this as a model program for the entire petfood industry,” according to Joel G Newman, AFIA’s president and CEO. “ I commend the pet food committee for developing this
program to help ‘raise the bar’ for their own industry.”The PFMF and PFIF certification programs were designed to meet and in some parts exceed the requirements of the Food Safety Modernisat ion Act regulations. AFIA is seeking FDA recognition of these programs and is encouraged that FDA may use these programs in their risk assessment of the industry for inspection priorities.“In 2004 AFIA launched the first third-party feed facility
certif ication program, Safe Feed / Safe Food program, addressing the needs of the feed industry. And then in 2010 the International Safe Feed/Safe Food program was added to provide a tool for companies that wish to meet the EU requirements. “Now today, adding the Pet Food Facility program to the family of third-party certification program makes sense not only for our members, but for the petfood industry,” says Mr Newman.
New Third-Party Facility Certification Program for petfood manufacturers and petfood ingredient processors
GFMT12.01.indd 7 02/02/2012 10:12Grain&feed millinG technoloGy January - february 2012 | 27
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Phone +49 (0)571 95580www.jacob-pipesystems.eu
Original Quality to a Modular DesignThe QUICK CONNECT® pull-ring makes the acclaimed
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for installation. In new plants for animal feed,
pharmaceuticals, chemicals, food, glass, semi-
conductors or environmental technology as
well as for upgrading existing layouts user-
friendly system installation becomes precise
and easy due to the great versatility of
mass-produced pipe components.
Request a
catalogue!
Hotline
+49 (0)571 95580 or at
www.jacob-pipesystems.eu
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FEATURE
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In this issue:
• Increasing storage capacity
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January - February 2012
• Bulk storage & handling
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