Pneumatic Conveying

2altmayerBTD GmbH & Co. KG is the right partner for system, bin, energy and environmental technolo-gy. Our tradition-rich companys product portfolio ranges from bin and reservoir technology to heating

and drinking water systems and solar technology, to storage and transport of bulk solids.

Pneumatic conveying allows bulk solids to be transported simply and hygienically through pipelines.

The right choice of a conveying system is based on many different criteria and is the prerequisite for the

systems operational safety, energy efficiency and cost effectiveness.

Regardless of whether universally applicable air conveying or sophisticated dense-flow conveying is

adopted, the product line offered by altmayerBTD GmbH & Co. KG has the right system for every con-

veying process.

Our decades of experience in this field are the best guarantee of sophisticated expertise and process

reliability.

As a result of our own production, experienced engineers and installation and service technicians, we

guarantee maximum customer benefit combined with innovative, efficient technology.

Pneumatic Conveying

AIRDOS

AIRDOS

Continuous Gravimetric Metering with Direct Input of Material into Pneumatic Conveying Systems

The increasing quality demands on technological processes require metering devices that, during mete-

ring, offer optimal conditions when it comes to metering accuracy, operational safety, compact construc-

tion and simple operation and maintenance. If, in addition, direct product feed into pneumatic conveying

systems is necessary, the AIRDOS metering system offers the required characteristics at the same

time.

Benefits

Pulsation-free metering

High short- and long-term accuracy

Not affected by taring changes; no taring adjustment

Dispensing results independent of the devices feed conditions and the solids flow

characteristics

High control dynamics

Pre-homogenization of the solid in the fluidized bed

Increased control range through multi-flow conveying to a single receiver

Energy savings with pneumatic transport through multi-flow conveying to a single

receiver

Closed system, dust-proof exterior, suitable for transferring inert gases

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Pressure-shock-resistant design

Direct integration into a pneumatic conveying system

Leakage air does not affect the pneumatic transport system

Trouble-free product discharge of fluidized solids from the metering disk

Low energy consumption

Designed for easy service

Modular construction

No uncontrolled product entry into the feed pipe

Precise volumetric dispensing through constant fluidized bed tightness

Optional batch operation with pre-homogenization

Optional pneumatic feed to the AIRDOS dispensing system

Operation

Fluidization of the solids through the AIRDOS metering systems aeration floor causes a homogeneous

fluidized bed that possesses liquid-like characteristics. The metering disk is completely immersed in the

homogeneous fluidized bed and has several coaxial hole circles with bores that determine the metering

volume. As a result of the liquid-like characteristics of the fluidized bed, the bores fill completely with the

solid to be metered. By the rotation of the disk around the horizontal axle of the metering disk drive, the

solid is moved through two slide ring seals and fed into the pneumatic feed pipe.

Metering is pulsation-free because at any given time of the disks rotational movement, the same number

of metering holes is immersed into the feed pipe. The type of slide ring seals used limits the amount of

leakage air and effectively prevents uncontrolled entry of material into the feed pipe. The mixing of an in-

homogeneous solid accumulating in the fluidized bed, the complete filling of the metering disk bores and

the constant density of the solid in the fluidized bed are the reasons for the constant, pulsation-free mete-

ring with an almost linear relationship between driving speed and dispensing performance. Therefore, the

AIRDOS metering system can also be used in many ways as a volumetric operating device.

When the minimum fill level is reached, the device is filled through the filling nozzle to the upper fill

level. The displaced air as well as the fluidization air and the leakage air are discharged into atmosphere

through an integrated filter that is cleaned by compressed air. Multi-flow designs of the conveyor tube

arrangement are used to increase the metering performance.

In that case, the blow-through openings on the metering disk have the same distance from each other. If

the lines outside the AIRDOS metering system are brought together again, the metering performance

increases according to the number of blow-through openings.

AIRDOS

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If the pipelines are not brought together, two separate processors can be fed with the same or propor-

tional output. If separate pipelines are brought to one processor, allocation of the maximum metering out-

put into sub-quantities and a corresponding adjustment of the amount of conveying air allow a significant

increase in the metering control range. At the same time, adjusting the amount of conveying air to the

metering performance allows considerable energy savings.

In the case of gravimetric dispensing, the AIRDOS dispensing system works according to the principle

of a loss-in-weight feeder. Continuous determination of the weight loss per time unit allows determination

of the metered quantity. After the metered quantity is compared to the pre-set reference quantity, the con-

trol variable for the subordinate control circuit of the metering disks drive motor is established.

During the short refilling phase, the AIRDOS metering unit is switched over to volumetric metering

operation. Variations from the gravimetric operation in this phase are barely measurable as a result of the

operation with fill-level-dependent RPMs that have been stored during gravimetric operation.

1 Weighing frame 2 Aeration floor 3 Aeration blower 4 Bin 5 Metering disk 6 Metering disk drive 7 Conveying air inlet 8 Product outlet 9 Level sensor10 AIRDOS controller 11 Filling nozzle 12 Filter 13 Sight glass 14 Butterfly valve

AIRDOS

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Principle of the loss-in-weight feeder Weight loss per time unit

Structure and Designs

The simple, compact structure that is independent of additional equipment allows installation also in

existing systems. AIRDOS metering devices come standard in a pressure-shock-resistant design for

pressure of 10 bar.

The solids are fluidized by an adjustable side channel blower above a sintered metal floor. The metering

disk is driven by a frequency-controlled three-phase motor. The metering disks very low friction against

the fluidized solids allows low drive powers. The metering disks low moment of inertia makes possible

high control dynamics that can be seen in the AIRDOS metering systems extremely short response time

to changes of the reference value.

Using a highly wear-resistant material for the metering disk and slide ring seals easily allows a lifetime of

several thousand operating hours, depending on the solids. As a result of the resilient mounting of the

slide ring seals on the metering disk, reworking of the disk is possible even after longer operating periods.

The leakage air occurring with every air lock system is extremely low. It amounts to about 5% of the leak-

age air of a new rotary feeder, but the resilient seal keeps it constant even after long operating periods.

All seals and bearings of the drive shaft are accessible from outside. The interior of the AIRDOS metering

system can be monitored constantly through the two sight glass openings. If necessary, the metering disk

and slide ring seals can be removed easily through these openings. The built-in, compressed air acti-

vated cartridge filter cleans the air displaced during filling and discharges it into the atmosphere.

AIRDOS

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Butterfly valves on the conveying air side allow alternative or simultaneous operation of several feed

pipes. The AIRDOS metering unit can be filled through a downpipe or pneumatically, as desired.

The pressures necessary for safe operation of the metering system, such as delivery pressure, bottom

aeration pressure and differential filter pressure, are displayed both in analogue and digital form. The

AIRDOS metering unit can optionally be built in standard or stainless steel. For coarse-grained solids

that are difficult to fluidize, a special design of the AIRDOS metering system is available. As a measure-

ment, control and regulation system, the AIRDOS controller is based on modern technology. It is dis-

tinguished by its compact, modular construction, flexibility and robust design. Use of the loss-in-weight

system allows metering independent of possible taring changes due to fouling or caking.

Due to the loss-in-weight systems working principle, an upstream silo fill level or the type and design of

the filling pipe has no influence on the quality of the metering result. If several AIRDOS metering systems

are set up underneath a silo, using a ROTAFLOW solids activator is recommended. The AIRDOS me-

tering system is internationally patented.

AIRDOS with ROTAFLOW solids activator

AIRDOS

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AIRDOS double metering system

Application Samples

Coal dust metering for rotary kilns, hot gas generators, drying drums, lime shaft kilns and

tunnel kilns

Metered absorbent input and activated carbon input for dry flue gas cleaning

Metered fly ash input and clinker powder input in cement mills

Metering of copper concentrate into a burner

Metering of a lime-carbon mixture into a fluidized bed boiler

Metering of cleared ash into a burner

Metering of coal dust into a metal bath

Technical Data

Metering capacity range: 0.01 to 30 t/h

Gravimetric long-term accuracy: +/- 0.5% to 1%, based on the actual value in the metering range 1:20

Volumetric long-term accuracy: +/- 1.5% to 3%, based on the actual value in the metering range 1:20

Control range: max. 1:20 with one pipe to a single receiver

Max. temperature of solids: 120C

Max. conveying pressure: 1.8 bar (abs) in the standard design

AIRDOS

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AIRDOS C

AIRDOS C

Continuous Conveying with Direct Input of Material into Pneumatic Conveying Systems

The increasing quality demands on technological processes require conveyor devices that, during con-

veying the solids, offer optimal conditions when it comes to operational safety, compact construction and

simple operation and maintenance. If, in addition, direct product feed into pneumatic conveying systems

is necessary, the AIRDOS C conveying system offers the required characteristics at the same time.

Benefits

Pulsation-free conveying

Conveying results independent of the devices feed conditions and the solids flow

characteristics

Increased conveying range through multi-flow conveying to a single receiver

Energy savings with pneumatic transport through multi-flow conveying to a single receiver

Closed system, dust-proof exterior

Direct integration into a pneumatic conveying system

Leakage air does not affect the transport system

Low energy consumption

Designed for easy service

Modular construction

No uncontrolled product entry into the feed pipe (no risk of clogging)

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Operation

The metering disk is completely immersed in the bulk material and has multiple coaxial hole circles with

bores that determine the metering volume. As a result of the solids gravitational force, the bores fill com-

pletely with the solid to be conveyed.

At the same time, an agitator contributes to a steady discharge of solids. By the rotation of the disk around

the vertical axle of the metering disk drive, the solid is moved through two slide ring seals and fed into the

pneumatic feed pipe.

Conveying is pulsation-free because at any given time of the disks rotational movement, the same num-

ber of metering holes is immersed into the feed pipe. The type of slide ring seals used limits the amount

of leakage air and effectively prevents uncontrolled entry of material into the feed pipe. The conveying

output is almost linearly dependent on the metering disks driving speed.

1 Bin 2 Metering disk 3 Metering disk drive 4 Conveying air inlet 5 Product outlet 6 Level sensorr 7 Filling nozzle 8 Filter 9 Sight glass 10 Hand lever valve 11 Check valve 12 Agitator

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AIRDOS C

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1 Bin 2 Metering disk 3 Metering disk drive 4 Conveying air inlet 5 Product outlet 6 Level sensorr 7 Filling nozzle 8 Filter 9 Sight glass 10 Hand lever valve 11 Check valve 12 Agitator

Technical Data

Conveyor output range: 0.1 to 60 t/h

Control range: 1:20 with one feed pipe

Max. temperature of solids: 120C max.

Conveying pressure: 1.8 bar (abs) in the standard version

Drive power: 3 to 7.5 kW

Three different sizes are available.

Multi-flow design available.

Typical Solids and Applications

Industry Solid

Cement industry Raw coal, petroleum coke, cement, clinker, gypsum, marl, clay,

slag sand

Rocks and soils Cement, gypsum, limestone, marl, silica sand

Power plants Fly ash, ground limestone, hydrated lime, furnace ash

Steel industry Blast furnace slag, raw coal, coke, bauxite

Aluminium industry Foundry sand, aggregates

Waste incineration plants Ash, slag

Chemical industry Plastic, granules, chalk, titanium dioxide

Water treatment Ground limestone, hydrated lime, activated carbon

Glass industry Aggregates, sand, glass batch

AIRDOS C

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CONTIPULS / CONTIDENSE

CONTIPULS / CONTIDENSE

Gentle Pneumatic Dense-Phase Plug Flow Conveyor

The CONTIPULS pneumatic dense-

phase plug flow conveyor works with

plugs.

As a result of selectively clocked air

injections into the feed pipe, the pro-

duct is slowly, gently conveyed as

plugs. These plugs remain compact

until the end of the conveying pipe.

The CONTIPULS system can be re-

gulated well and is suitable for cohe-

sive, powdery products.

The CONTIPULS can also be used for

fine and coarse granulates. Advan-

tages of the CONTIPULS include high solids to air ratios and gentle conveying at a low speed of about

1-5 m/sec. In case of mixtures, segregation-free conveying is guaranteed.

For products that are difficult to convey with a tendency for plug slowdown in the pipeline,

the CONTIPULS system is equipped with pulsating activator groups. The activator groups are installed

only at critical places in the pipeline. The so-called critical plug length is measured, and if the plugs have

reached this critical length, they are cut into smaller pieces. This provides gentle conveying for products

that cannot be conveyed with plug flow conveyors.

Air velocity

Pre

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Plug flow conveying

Bed flow conveying

Dilute-phase conveying

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CONTIPULS Plug Flow Conveying

Benefits of the CONTIPULS System

Gentle plug flow conveying

Low gas consumption

Filter and compressor stations with smaller dimensions

Sensitive products are not destroyed

Abrasive products cause barely any tube wear

Segregation-free movement of mixed materials

Long life, because there are no rotating parts

Low investment, operating and maintenance costs, good total cost-effectiveness

Single and double vessels1 Material feed2 Clocked conveying air3 Closing flap4 Fill level limit switch5 Pressure vessel6 Outlet elbow7 Conveying pressure manometer with pres- sure switch8 Load cells9 CONTIDENSE controls

Fields of Application:

Plastic granulates up to 300 m and 100 t/h Sensitive, coated products

Metal dust mixtures Abrasion free plug flow conveying of sand

Sugar conveying, gentle up to 100 m Conveying of various metal oxides

Sewage sludge granulate Cocoa beans and instant products

Sulphate and carbonate Various chemical products

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CONTIDENSE Dense-Phase Conveying

Benefits of the CONTIDENSE System

Safe dense-phase conveying, the conveying pressure can be raised as desired

High solids to air ratios, reasonable gas consumption

Long conveying lines are possible

Tubes do not need to be purged

Long life, because there are no rotating parts

Can be upgraded to gravimetric metering

Low investment, operating and maintenance costs, good total cost-effectiveness

Single and double vessels 1 Material feed 2 Clocked conveying air 3 Closing flap 4 Fill level limit switch 5 Pressure vessel 6 Outlet elbow 7 Conveying pressure manometer with pressure switch 8 Load cells 9 CONTIDENSE controls

Fields of Application:

Lignite dust up to 400 m

Pressure-shock-resistant systems with silos for lignite dust, sugar, etc.

Cement and filter ash dense-flow systems

Potato starch and corn starch up to 400 m

Carbonates and metal oxides

Aluminium oxides and titanium oxides

Various chemical products

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Operation

The continuous feeding of the solids into the feed pipe happens without rotary motion. This process is

gentle to the product and low on wear. If in the left pressure vessel of the CONTIPULS or CONTIDENSE

the minimum fill level is reached, the outlet valves are gently opened or closed. This allows switching

between the two sending vessels without pressure loss.

For gravimetric metering tasks, the CONTIDENSE can be produced in a double or single version with ad-

ditional rotary feeders instead of the outlet valves. In that case, the pressure vessels are set on load cells.

As a result of the metered product discharge, several CONTIDENSE double vessels can load a common

pipeline. This allows conveying lengths up to 1,000 m.

Structure and Designs

The CONTIPULS and CONTIDENSE pneumatic conveyors come in single and double versions in various

sizes from 20 to 4,000 litres. The pressure range is 4 10 bar. They are produced in standard steel and

stainless steel for the food industry. A large number of our systems were realized using our algorithm de-

sign method. It allows the systems to be calculated with great certainty without conveying tests. The gen-

tle CONTIPULS process thus has an output limit from 0.5 to 120 t/h and conveying lengths up to 300 m.

The CONTIDENSE process has an output limit from 1 to 150 t/h and conveying lengths up to 1,000 m.

CONTIPULS CONTIDENSE

conveys fills

CONTIPULS / CONTIDENSE

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MONODENSE mobile unit

MONODENSE

Variable Pneumatic Transport in Your Plant

The MONODENSE mobile unit was developed to ful-

fil various conveying tasks with one device. For this

purpose, the pneumatic conveyor is built on a roller

frame. This makes it easy to transport the MONO-

DENSE mobile unit to the production area where it is

currently needed.

The device is built completely ready to run and has

its own controls, so that only power and compressed

air connections are necessary to put it into operation

in a new location.

Its technical equipment allows a variable application

range for dilute- and dense-phase conveying. For

customers whose production lines are quite varied,

we offer the possibility to store the various product-

specific settings in the controls, and when nece-

ssary call them up automatically through the control

elements.

Benefits

Variable range of applications for dilute- and dense-phase conveying

High solids to air ratios with low compressed air consumption

Long life, because there are no rotating parts

Low investment, operating and maintenance costs

Ready to plug in, with its own controls

Only power and compressed air connections are needed

Structure and Designs

The MONODENSE mobile unit comes in various sizes from 300 to 1,000 litres (or in even bigger cus-

tom-built sizes). The pressure range is from 4 to 10 bar, so that output from 0.5 to 25 t/h and conveying

lengths up to 150 m can be covered.

Conveying lengths: 40-150 m

Conveying outputs: 1-25.3 m3/h

Temperatures: up to 200C

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INJECTOR CONVEYOR

INJECTOR CONVEYOR

Safe Feeding of Material into Pneumatic Pressure Conveying Systems

Feeding material into the conveying flow of pneumatic pressure conveying systems requires feeders that

overcome the pressure difference between delivery pressure and the pressure of the material feed bin.

The INJECTOR CONVEYOR should be used particularly with hard-to-handle solids, such as long-grained,

abrasive, cohesive or hot materials.

Benefits

No mechanically moved parts

Continuous material feed

Low maintenance cost

Low space requirement

Use in high temperature zones

No leakage air discharge

Dust-free operation

Support of the material feed at the air lock chamber

OperationNarrowing of the propellant nozzles cross-section turns the pressure of the conveying air into kinetic

energy. This generally causes a pressure in the air lock chamber that is below the ambient pressure.

The vacuum draws the conveyed material and a supplementary quantity of air out of the material feed

area, accelerates it and feeds it into the conveying pipe without an additional mechanical seal. The sub-

sequent deceleration of the air flow in the mixing tube creates a static pressure. The acceleration of the

conveyed material in this area reduces the pressure increase.

In the diffuser, the air speed to the feed pipe is decelerated. This increases the pressure up to the end

of the INJECTOR CONVEYOR to the feed pipes operating pressure.

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INJECTOR CONVEYOR

Structure and Designs

The INJECTOR CONVEYOR has no mechanically moved parts and low maintenance requirements. The

geometric dimensions depend on the material load, the material characteristics, the material flow rate and

the feed pipes operating pressure.

Exact knowledge of the INJECTOR CONVEYORs functional contexts and of the pneumatic conveyor sys-

tem allows optimal dimensioning to the specific application. The INJECTOR CONVEYOR can optionally

be built in standard or stainless steel. For abrasive materials, the mixing tube is supplied with a collecting

nozzle and diffuser as a replaceable ceramic insert. For solids that tend to adhere or crust onto the pipe

walls, the special version of the INJECTOR CONVEYOR ring nozzle shall be used.

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1 Material feed 2 Conveying air supply 3 Propellant nozzle 4 Air lock chamber 5 Aeration bottom 6 Nozzle pressure manometer 7 Aeration pressure manometer 8 Collecting nozzle 9 Mixing tube 10 Diffuser11 Conveyor pressure manometer

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INJECTOR CONVEYOR

Applications

Dusty or granular solids

Conveying capacity up to 15 t/h

Conveying distance up to 200 m

Solids to air ratio below 5

Sample applications

Filter ash removal

Fluidized bed boiler coatings with hydrated lime

Absorbent input for dry flue gas cleaning

Powdered coal firing systems

Activated carbon input in waste incineration plant gas lines

Transport of returns in packing systems

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Pressure gain in relation to the dynamic pressure of the propulsion jet

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altmayerBTD GmbH & Co. KGHeadquarters: System technology: Representatives: Brckenstrae 1 Sdstrae 14 Santa Sanayi Mamulleri TIC. Dearborn Mid-West Conveyor Co.72135 Dettenhausen 66780 Rehlingen ve San. Ltd. Sti. 4220 Shawna Mission Parkway Germany Germany Ankara/Turkey Suite 301 BTel.: +49 (0) 71 57 5 62-0 Tel.: +49 (0) 68 35 91 93-0 Tel.: +90 3 12 3 42 52 50 Fairway KS 66205/USAFax: +49 (0) 71 57 6 10 00 Fax: +49 (0) 68 35 91 93-29 Fax: +90 3 12 2 95 97 26 www.santa.com.tr info@altmayerbtd.de www.altmayerbtd.de

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