Dewatering Feeder Slide Gates
Mt. Vernon Transfer Terminal Testimony (ref. 189213)
PEBCO® recently assisted Mt. Vernon Transfer Terminal (MVTT) in Mt. Vernon, Indiana by providing dewatering feeder slide gates and chutes (See Photo 1) for handling -2” coal at 55 pcf in a gravity flow application within a reclaim tunnel. The feeder gates were installed to provide product flow control onto a conveyer belt below open stockpiles. Coal flow regulation onto the conveyer belt is controlled at ~4,200 TPH.
Dewatering feeder slide gates were provided to replace the original feeder gates PEBCO® installed when the terminal was originally constructed in 1983. The PEBCO® dewatering feeder gates and chutes had the following design enhancements to increase the operational life and overcome maintenance issues that were identified during the discovery phase of the project.
Significant features of the PEBCO® equipment are:
- All stainless steel feeder gate construction including assembly fasteners
- Enhanced structural supports to assure both product and dozer support capability
- Dewatering feature to eliminate water draining onto the conveyer belt
- High force, accurate positioning hydraulic operation to include a new hydraulic power unit, which utilizes static o-ring connections and integrated circuit designs to eliminate fluid leakage
Dewatering Feature: The PEBCO® Dewatering Feeder Slide Gates were constructed with 304-stainless steel. The front dewatering design includes a sloped drain trough with a drain pipe connection and two clean water flushing connections.
The gate was designed with a front dewatering trough and pipe connections to direct free-water from the coal above into a drainage system rather than dripping onto the conveyer belt. MVTT has decided that at present time, the drain piping and connections to the dewatering trough were not necessary. During an interview with an employee of MVTT, the employee stated, “[…] because the gates are so tightly sealed; there is no need for the dewatering feature [to be connected into the drain piping]”.
Hydraulic Actuation: Gate actuation is achieved by a heavy-duty, front head-mounted hydraulic cylinder. PEBCO® included a hydraulic power unit for operating the gates. The gates are typically open two at a time to control coal feed rate onto the belt below.
Electrical Controls: Control of the dewatering feeder slide gate is through a touch screen panel (See Photo 2) located in the MCC room, remote from the reclaim tunnel. The controls provide infinite blade positioning of each dewatering feeder slide gate as well as control of the HPU. The feed rates can be set manually or an auto-function will modulate the feeder gate opening to maintain a set flow rate.
Blade Position Feedback: Feeder blade position feedback is accomplished through the use of a linear potentiometer that is integral to the hydraulic cylinder. This design provides high resolution and a rugged and robust installation.
Chute Work: The gates were mounted above chutework designed to extend down past the skirt-boarding for the reclaim conveyer belt. These chutes were a bolt-together design and constructed of carbon steel with 304-stainless steel liners (See Photo 5).
Spliced Gate: The PEBCO® dewatering feeder slide gates were designed and built in two separate modules. Because of the size of the reclaim tunnel, the full-sized gate could not be taken into the tunnel as a single unit. The feeder gate frame was designed with a splice plate connection near the interface of the retract area bonnet and the product flow area; essentially dividing the gate into two halves (See Photo 6).
The gate was easily transported into the tunnel and reassembled using the splice plate connection to form the complete gate assembly. Stainless steel fasteners were used throughout the gate construction to resist corrosion associated with the moisture-laden coal and high humidity common in reclaim tunnels.
Blade Supports: PEBCO® used internally lubricated polymer blade supports (See Photo 7) rather than the more traditional roller bearing supports. The polymer blade supports were selected because they provide:
- High resistance to wear, providing longer operational life than roller bearing supports
- No lubrication required, reducing maintenance and providing consistent, long-term performance
- Extremely high resistance to moisture and corrosion, increasing operational life
Anchors, Rockers, Beams: The design of the support structure for the feeder slide gates were part of PEBCO®’s scope of supply. Heavy structural beams were provided to carry the load exerted by the stockpile and the load associated with the dozers used to push the coal to the flow openings over the dewatering feeder slide gates (See Photo 8 and 9).
A special design was used to connect the beams to the concrete walls of the reclaim tunnel. The end connection design was similar to that used in bridge construction to reduce stress in the concrete connections due to thermal and mechanical loads on the beams.
The support plates are rigidly fixed to the concrete walls of the tunnel. Pinned connections between the support beams and the support plates are used in conjunction with a rocker on one end of the beam.
The combination of the pinned connections and the rocker support on one end of the beam allows the beam to deflect and the beam ends to rotate about the pinned connections; thereby reducing the stress on the support plates and the moment applied to the concrete tunnel walls.
The design also allows for the thermal expansion and contraction of the support beam without transferring stresses into the concrete walls of the tunnel.
MVTT personnel reported that the installation of the equipment went exactly as planned and without any problems. The dewatering feeder slide gates have now been operating for over one year flawlessly. Personal at the sight report complete satisfaction with the quality and performance of the PEBCO® provided equipment.
PEBCO® was approached by a local municipality for assistance correcting a safety issue with a roof rack that was installed on one of their trucks.
The road sign crew had a new truck and newly installed rack to carry multiple sign post. There was one problem with their new rack – sign posts could slide forward in the event of a sudden stop.
They contacted PEBCO® to design and build a rack addition, to help prevent this from happening.
PEBCO® designed a symmetrical rack addition that eliminated the possibility of improper installation; mounting could be attained properly regardless of which way it was attached.
It also provided additional tie-down points providing increased flexibility of use. These additional points could also be used to mount accessories such as lights.
Feedback from one of the municipal workers was the rack addition had already paid for itself. A car pulled in front of him and the rack attachment prevented the sign post from slipping from the rack and into the back windshield of the car.
“The added safety provided by the rack addition was well worth the investment.”
For more information, let us know at email@example.com.
PEBCO®’s Double Blade Mass Flow Feeder (DBMFLO) offers a number of features and benefits unique to its design; such as, it performs as a volumetric feed rate control device which has the capability of adjusting to varying material flow characteristics.
This feeder promotes:
- mass flow
- handles large volumes of material
- is ideal for blending
- feeds centerline of conveyer belt
Because the DBMFLO has no vibrating parts, it requires less power and operates at a low noise level.
Mass flow feeders are used in conjunction with mass flow silos. They can provide flow rate in excess of 8,000 TPH and can be manufactured in sizes ranging from 24” to 60”.
The SBDX diverter was developed with exceptional sealing performance and easy seal replacement.
THE SBDX diverter provides:
- Ability to perform seal replacement without removing the diverter from the process installation
- Long life, wear compensating seals that offer tight sealing of process materials
The SBDX diverter is built with long-wearing, polymer seals that provide edge of blade sealing. The seals are pressure loaded to compensate for wear throughout the life of the seal.
Blade tip sealing is accomplished using an elastomer body seal that is easily replaceable.
A removable access cover allows full access to the blade and all seals used in the SBDX diverter.
The SBDX design is ideal for virtually all material sizes. Powders, grains, and large product sizes are all within the range of materials that can be diverted without leakage.
- Methods of actuation: manual, pneumatic, electric, and hydraulic.
- Materials of construction: carbon steel, abrasion resistant steels, stainless steels, and aluminum.
- Flow surfaces: polymers, stainless steels, AR steels, chrome carbides, and ceramic.
The diverter blade is supported by anti-friction bearings. Shafts seals are provided to prevent exposure of the bearings to the product handled.
Contact PEBCO® at firstname.lastname@example.org for information
PEBCO® manufacturers more than a 12 categories of equipment – placed in almost twice as many locations – within the sand processing plants and transfer terminals. Years of experience in building a wide array of bulk material handling equipment gives us a tremendous capability for providing efficient, reliable equipment and systems based on the latest technology. It all comes down to innovation, advanced engineering tools, and experience. PEBCO® can provide the equipment and application assistance to solve your bulk material handling problems.
- Bins, Hoppers, and Chutework
- Clamshells, Simplex, with metering capabilities
- Collection Boxes
- Deceleration Boxes and Chutework
- Diverters and Flow Splitters (i.e., Bucket Diverters, Winged Single Blade Diverters, Flop Gates)
- Dustless Loading Spout
- Dustless Loading Spout Positioner
- Maintenance Slide Gate
- Self-Contained Dustless Loading System
- Slide Gate, with/without metering capabilities
- Undercut Gate, with/without metering capabilities
- Control Packages, Motor Starter Packages, Loading Point Controllers
- Rail and Truck Scales
PEBCO®’s deceleration box is designed to feed sand onto a screen vertically at a controlled rate. This assures an even distribution of sand onto the screener.
Sand can be fed into the deceleration box from any angle; however the preferred angle is through a sloped chute located on the same side as the outlet.
An adjustable v-notched blade allows for fine tuning of the flow rate.
The inlet is offset from the outlet, creating a product-on-product flow path for minimum wear and maximum operational life.
PEBCO® manufacturers more than a 12 categories of equipment – placed in almost twice as many locations – within a coal-fired power plant. From the coal yard to the powerhouse, PEBCO® provides rugged, reliable and long life equipment for essential areas within the coal fired power generation process.
Years of experience in building a wide array of bulk material handling equipment gives us a tremendous capability for providing efficient, reliable equipment and systems based on the latest technology. It all comes down to innovation, advanced engineering tools, and experience.
PEBCO® can provide the equipment and application assistance to solve your bulk material handling problems.
- Bottom/Bed Ash Valves
- Burner Isolation Valves
- Coal valves
- Diverters and Flow Splitters (i.e., Basket Diverters, Bucket Diverters, Winged Single Blade Diverters, Flop Gates)
- Double Bladed Mass Flow Feeders
- Dustless Loading Spout
- Dustless Loading Spout Positioner
- Fluidized Conveyers and Conveyer Slide Gate
- Hoppers and Chutework
- Hydraulic Power Units
- Maintenance Gates
- Self-Contained Dustless Loading System
- Telescopic Chute (including Spray Rings)
- Blower Package for Aeration
- Fluidized Bin Bottoms
Another Successful Project!
PEBCO® was recently invited by the Spencer Group in the UK to be part of a “project that employs multi-disciplinary engineering expertise to [its] best effect; rail, civil, structural, electrical, and mechanical engineers were all involved”.1
The impressive facility at the Port of Hull, showcasing the multi-disciplinary engineering expertise, is a biomass handling, storage, and railcar loading facility. A silo is part of the system and will handle a million tonnes per year of biomass imported from the United States and Canada by sea to the Port of Hull in the form of wood pellets created from forestry residues. 1
After unloading at the port, biomass is stored in warehouses until it is transported by truck to the new facility. The silo is 50 meters (164 feet) tall with a storage capacity of 3000 cubic meters (105,944 cubic feet) of wood pellets. 1
The biomass is unloaded from trucks into feeders to the 250- meter (820 ft.) long conveyor. This conveyer moves the biomass to the railcar loading facility where it is discharged into railcars as they pass through the base of the structure. The railcars do not stop during the loading process. This ensures an accurate and even load, without spillage. The loading system will load up to 30 railcars with 1,950 tonnes (2,149 tons) of material in just 45 minutes. 1 2. According to the customer, “The [loading] facility will accommodate up to four trains per day, loading through a state-of-the-art system that complies with all environmental and safety standards;” for the safe, reliable and efficient handling and loading of bulk biomass.” 1
PEBCO® worked in conjunction with the Spencer Group LTD to design and manufacture the railcar loading gate and loading chute.
During the Humber Renewables Awards, a prestigious green energy awards event held on March 6, 2014, Spencer Group was granted the award of Best Renewable Energy Project for the design and construction of this biomass handling and loading facility at the Port of Hull.
According to the judges, this project:
• “provides safe, reliable and efficient handling of fuel for one of the UK’s leading power supplier
• “was a ‘milestone’ for the renewables industry”.
• “was a ‘showcase for the technical and engineering skills available in our region’.”
Congratulations, Spencer Group and thank you for allowing PEBCO® to be a part of it!