NEW TECHNOLOGY IN ASH HANDLING PLANT

A
Seminar Report
Submitted
in partial fulfillment
For the award of the Degree of
Bachelor of Technology

in Mechanical Engineering
2015-2019

SUBMITTED TO SUBMITTED BY

DR. DEEPAK PALIWAL VINAY KUMAR YADAV

(Head of Department) ROLL NO. 15EGIME115
Mechanical Engineering
GITS, Udaipur

Department of Mechanical Engineering

Geetanjali Institute of Technical Studies, Dabok Udaipur

i
 CERTIFICATE

This is to certify that the Seminar report entitled “NEW TECHNOLOGY IN ASH
HANDLING PLANT” for the award of Degree in Mechanical Engineering at
Rajasthan Technical University (Kota) has been prepared and submitted by MR.
VINAY KUMAR YADAV (15EGIME115) as per the guidelines under my
supervision and guidance.
Date:

Under the Guidance by

Supervisor Name: MR. RAM DAYAL KUMAWAT

Head of Department
(Department of Mechanical Engineering)

Date

ii
 STUDENT DECLARATION

We hereby declare that the Seminar report entitled " New technology In Ash
handling Plant" is the work done by us during the academic year 2018-2019 and is
submitted in partial fulfillment of the requirements for the award of Four Year
Degree in MECHANICAL ENGINEERING from RAJASTHAN TECHNICAL
UNIVERSITY (KOTA).

Signature
VINAY KUMAR YADAV
15EGIME115

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 ACKNOWLEDGEMENT

Success is epitome of hard work, cogency for fulfilling the mission, indefatigable
perseverance and most of all encouraging guidance and Steering.

It gives us an immense pleasure to express our gratitude to MR. RAM DAYAL

KUMAWAT, Assistant Professor of Department of Mechanical Engineering for his
esteemed guidance and able supervision during the course of the project. His constant
encouragement and co-operation made this project a success.

We are also thankful to our head of department and Assistant Professor, Dr.
DEEPAK PALIWAL for needful support whenever required during execution of our
project.

Name of Student
MR. VINAY KUMAR YADAV

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 ABSTRACT

The seminar report for an engineering student plays an important role in developing
as a well-groomed professional. It allows a student to give theoretical concepts a
practical stand in the field of application. It gives the candidate an idea of dynamic
and versatile professional world as well as exposure to the intricacies and
complexities of corporate world.

Doing summer training at Ultratech Cement Works, UCW was a great experience.
An opening experience to the concepts of engineering which helped me a lot in
understanding the concepts that are applied in the organization. This organization,
since its inception has progressed a lot and is walking on the guidelines of success. As
the organization is marching with the tenacious speed towards the horizon.

This report is an attempt made to study the overall production system and related
action of Gypsum and Lime stone, Shambhupura, Aditya Cement a unit of Ultratech
Cement Works.

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 Table of Contents
CHAPTER NO. TOPIC

1 Introduction 1
2 Cement Manufacturing Process 2

2.1 Working Method Mines 2

2.1.1 Overburden Removal 2
2.1.2 Drilling 3
2.1.3 Loading &Transportation 3
2.2 Raw Material preparation 3
2.3 Crusher 3
2.4 Stacker & Reclaimer 4
2.4.1 Stacker 4
2.4.2 Reclaimer 4
2.5 Raw mill & Coal Mill 4
2.6 Continuous Blending & storage 5
2.7 Pre-heater 6
2.8 Kiln 7
2.9 Clinker Cooling & Clinker 8
2.10 Cement Mill 9

3 Packing Plant 11
4 Ash Handling plant 12

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5 Conclusion 14

6 Research Paper 15

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CHAPTER 1

INTRODUCTION

Aditya Cement is a unit of Grasim Industries Ltd of Aditya Birla group. Aditya
cement the plant with 1.75 million tons per Annum capacity was commissioned in a
record time in March 1995. Aditya Cement shas install second unit having the
capacity of 8000TPD along with 2x25MW thermal power plant. Unit II project starts
from 05Sept.2006. The total project cost of Aditya Cement Unit I was Rs.430 Crore.,
& Unit II project cost is expected to be 1500 Crore.

Fig 1.1 Company location

In Unit –I major equipments supplied by the world major and renowned Krupp
Polysius of Germany and Quality Control systems by Gamma Matrix of USA. It has
already been accredited with ISO 9001:2001, ISO -14001 and OHSAS Certifications.
It has the owner of first Cement Plant to get ISO 9001:2001 certifications in India.
Highlights of this plant also include energy efficient operations and it has marched
towards excellence by taking up World Class Manufacturing (WCM) in March, 2001.
The plant has proximity to limestone deposits and has an on-line Cross-belt Analyzer
to ensure limestone of consistent quality.

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CHAPTER 2

Cement Manufacturing Process

There are four main process routes in the manufacturing of cement the dry, semi-dry,
semi-wet and wet process.

Common to all these processes are the following sub-processes -

1) Working method in mines

2) Raw materials preparation.

3) Fuels preparation.

4) Crusher

5) Stacker & reclaimer

6) Raw mill & coal mill

7) Storage silo

8) Preheater

9) Kiln

10) Clinker cooling and clinker cooler

11) Cement mill

2.1 Working Method In Mines

2.1.1 Overburden Removal

For winning limestone, at first area is to be cleared from overburden. This operation is
done by scrapping through dozer. Hydraulic excavators load the heaped up OB
material to dumpers and it is transported to the dumpsite by dumpers. Overburden in
Aditya Limestone Mines is very less, as such no supporting equipment are engaged
and this operation is carried out during shutdown period of crusher.

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2.1.2 Drilling

After clearing the area from overburden, drilling operation is carried out. Drill holes
are normally done at 7.0 Mtr spacing and 5 Mtr burden. The depth of the hole is 9.0
Mtr.

2.1.3 Loading & transportation

Heaped up limestone is then loaded by hydraulic excavators and is transported by

dumpers upto crusher. In each working shift, normally two excavators and 6 dumpers
are engaged for feeding limestone to crusher.

2.2 Raw Materials Preparation:-

After intermediate storage and pre-homogenisation, the raw materials are dried and
ground together in defined and well-controlled proportions in a raw mill to produce a
raw meal for the dry (and semi-dry) process. The resulting intermediate product – i.e.
raw meal– is stored and further homogenized in raw meal silos, storage bins or slurry
basins to achieve and maintain the required uniform chemical composition before
entering the kiln system.

2.3 Crusher

Crusher is used to crush big limestone into useable size for raw mill at plant.

In Aditya Cement single impact type of crusher is used. The advantages over jaw type
crusher are –

A. Low maintenance cost

B. More capacity than Jaw type crusher.

Crusher Set-up and Crushing procedures:-First the dumpers fed limestone into
bunker of capacity 850 ton from the bunker limestone with the help of apron goes into
the crusher when limestone goes on apron the low size stone and clay is separated by
going through the way in apron and after coming in crusher section stone strike over
rotor which have bleeds on it because of its rotary motion stone strike on impact plate
where it get crusher and come out with a specific size and it is fed to belt conveyor for
stacker and Reclaimer with help of cross country belt.

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2.4 STACKER & RECLAIMER:-

2.4.1 STACKER: Various types of stacker are used in the cement plant but some of
them are given below: -

A. Linear luffing non slewing stacker

B. Linear luffing and slewing stacker

In Aditya Cement linear luffing non-slewing type of stacker is used. this stacker
makes roof type stockpile.

2.4.2 RECLAIMER

Limestone Reclaimer (Bridge Type):- By reclaimer we loosened the material of pile

& transport to the hopper by belt conveyor. Materials loosened by the harrows slides
down the pile slope. At the base of the pile it is scrapped by the shovels of the scraper
and carried away to the belt conveyor. Reclaimer are volumetric machines and are
rated in m3/h (cubic meters per hour) for capacity, which is often converted to t/h
(tonnes per hour) based on the average bulk density of the material being reclaimed.
Reclaimers normally travel on a rail between stockpiles in the stockyard.

2.5 Raw Mill & Coal Mill :-

Lime stone & laterite are reclaimed and stored in respective hoppers, weighted
quantity of material through weigh feeder is fed to Vertical Roller Mill (VRM). The
material gets grind by VRM in powder form.

In Aditya Cement we use vertical type of roller mill, in past ball mill for grinding of
limestone were in use but as the efficiency of ball mill was less so VRM are used
nowadays.

Vertical Roller Mill (VRM) :-

Here VRM is of KRUPP POLYSIUS and is for particularly hard substance. The
polysius VRM is ideally suited for combined grinding and drying.In polysius grinding
mills two pairs of roller run on a rotating grinding bowl. The principle of the two
rollers units leads to a lower speed differential between the roller and grinding bowl.

4
Operation Of Raw Mill :-

First hot air comes to raw mill through nozzle ring and crushed limestone from chute
as the limestone come in contact with the table due to the rotary motion of table a
centrifugal force act on the limestone and it goes outwards and come under the roller
due to pressure and motion of rollers it gets grind but some limestone does not grind
to its required size and through nozzle ring bucket elevator again it come between
rollers. Hot air from P.H. Fan gives motion to the limestone grind particles and due to
the vacuum, ereated by the raw mill fan these particle moves upward and when this
particle come in contact with dynamic separator due to centrifugal force coarse
particle again grind for required size.

Coal Mill:-

The main parts of coal mill are grinding bowl, the roller pairs & the housing with
static or dynamic separator the roller pair moving on the grinding bowl. The power is
given by motor, which rotates the grinding table, planetary gear is attached between
motor & table. Hydroneumatic arrangement transfers the grinding pressure to the
roller & the rollers are in permanent contact with grinding bed. The separator
separates the ground material in finish material & tailings. The tailings fall back on
the center of the grinding bowl, while the finished material is conveyed by the gas
flow. The grinding is carried by the four rollers, which are arranged bin two pairs.In a
case of fire accident, the pressure of burnt gases opens explosion flap valve so that
they may exit atmosphere this will prevent the damage of bag house. Inert gar purging
system is also provided at different places to prevent fire accidents & N2 gas is used
as inert gas.

2.6 CONTINUOUS BLENDING AND STORAGE SILO (CBS) -

The continuous blending silo is simultaneously used for blending of the raw mix as
well as for its storage.

Description Of Aditya Cement Silo :-

The multiflow silo is a large capacity silo made has reinforced cement. The O/L are
arranged at the floor of the central chamber.

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It can be made free flowing by means of aeration. The silo consists of: -

1.Silo

2.Material distribution

3.Central chamber

4.Outer chamber

Functional Description:-The silo discharge systems consists of the aeration boxes in

the discharge channels & on the silo surface in connection with the right & left of it
from one aeration sector. Always two aeration systems in opposite position are
aerated for a fixed period of time. The blower aerates aeration sectors. The air
quantity can be controlled by means of hand valves. Cement can be stored in different
types of Silos like Horizontal Mobile Silos, Concrete Silos, Steel Panel Silos etc.
depending upon the requirement of the end user. While Mobile Silos come in a
relatively small storage capacity of approximately 90MT of Cement, Concrete Silos
can store practically thousands of MT of Cement. A majority of Silos that store more
than 5000 MT of Cement are constructed from Concrete. A good compromise
between cost, construction time and ease of operation is Steel Panel Silos. These silos
can be manufactured in a factory, and then erected at site using small panels that are
bolted together to form a Silo that is watertight because of a sandwiched layer of
special rubber seals

Specification –

SILO HEIGHT 76 m

SILO DIAMETER 22m

CAPACITY 26,000T

BLENDING EFFECT 1:1

2.7 Pre-Heater:-

The kiln system is most essential part of a cement plant and has to be operated
continuously for as long as possible.

The major components of the kiln system are:

A. Preheater

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B. Pre calciner

Pre heater & Pre- CalcinerSystem :- The main function of the Preheater cyclone is
the preheating of the raw meal, from outlet hot gases of kiln. 6-stage double string in
line calciner preheater system is used for this purpose. In this system the process is as
follows. Raw meal entering the kiln from the last stage of the PH the material feed
between 6th & 5th stage then it goes to 6th cyclone by hot air. Here calcination of
material is completed upto 90%. Then material passed to 1st stage & then enters to
kiln.

2.8 KILN:- The rotary kiln consists of a steel tube with a length to diameter (L/D)
ratio between 10 and 38, supported by two to seven or more support stations. The
inclination of 2.5 to 4.5% together with a drive to rotate the kiln about its axis at 0.5
to 4.5 revolutions per minute, allows for a slow internal material transport. In order to
withstand the very high peak temperatures (gas: 2000° C, material:1450° C), the
entire rotary kiln is lined with different types of heat resistant bricks (refractories).
Most hazardous substances are either destroyed (organics) or integrated into the
product in concentrations in the range of the earth surface.

Fig. Rotary Kiln

The major environmental impact of cement kiln systems can be summarized as

follows:-

 emission of combustion gas, CO2, vapour, dust, air pollutants and noise;

 consumption primarily of combustibles, but also of power, refractories and steel;

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 environmentally sustainable elimination of a large variety of hazardous waste.

Aditya Cement Kiln:- The rotary kiln is designed for the burning of pulverized small
size materials. Kiln design kiln has these parts:

1. Rotary kiln tube

2. Rotary kiln inlet with pneumatic seal

Rotary Kiln Tube:-

Specification:-

a) Kiln diameter 4.4 meter

b) Kiln length 65 meter

c) Kiln slope 3.5 degree

d) Kiln shell temp max. 35000

e) Kiln RPM 4.17-15rpm

Kiln Type - (High quality, alloyed cast steel) The tyre transmits the loads cause by
the rotary kiln into the foundations via the roller station. The rigidity of the type must
be great enough so that the liner supporting loads in particular on the rollers only have
a very minimum effect on the rotary kiln tube.

2.9 Clinker Cooling & Clinker Cooler –

Clinker leaving the rotary kiln at a temperature around 1200-1250° C has to be cooled
down rapidly to allow further transport and handling. This process also recovers heat
from the clinker back to the kiln by preheating the air used for combustion in the main
burner and in any secondary firingCooling of clinker is necessary because –

 Hot clinker is difficult to convey.

 Hot clinker has a negative effect on the grinding process.

 The reclaimed heat content of the hot clinker of about 200 kcal/kg is an important
factor lowering the production cost.

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 Proper cooling improves the quality of the cement.

2.10 Cement Mill -

In the cement mill various equipment’s are used for various purpose in cement mill
area we first mix gypsum in clinker and then effeminate the mixture to make cement,
the various main equipment used in the cement mill are : -

(1) Weight feeder

(2) Belt conveyor

(3) Polycom

(1) Weight feeder: - Weigh feeder is used to make a known flow of material so that
according to requirement we can add gypsum in clinker. For mechanical point of
view the main bottlenecks are free movements of belt and pulley and lubrication
check in bearings.

(2) Belt Conveyors –Belt conveyors are used for conveying clinker + gypsum to the
Polycom. Main mechanical problem in belt conveyors are misalignment in belt,
jamming of roller and lubrication check.

(3) Polycom–Polycom is a pre-grinding stage situated before cement mill, clinkers

coming from the hopper first come into diverter. The line of falling the material
should match exactly with the line of rollers in polycom for grinding of clinker two
rollers are used and material pass through them .

Separator:-Separator is used for separating the coarse particle of cement from a

desired size particle, the separator is dynamic type, crushed clinker from polycom A
schematic diagram of cement mill is shown below. In cement mill, fine particle of
mill, fine particle of cement comes from spol through cyclone and than air slide.

These particles when go into cement mill due to rotary motion of cement mill it takes
up the grinding media to a certain height and then all media fall suddenly due to
weight of grinding media.

A impacting force is given to cement and they get more fine and by this concept when
cement go at outlet screen its Blaine size is 300 m2/kg. Gypsum is added in the
cement the temp. should not be given higher than a certain limit if it does happen

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gypsum get converted in plaster of pairs. So to prevent this condition or maintaining a
certain temp. in the cement mill water spray is done other main of important feature of
cement mill is grinding media for grinding steel ball of different diameter basis are
placed inside the mill, in Aditya Cement the ball size is 30mm,25mm,20mm,12mm
etc.

Fig. Cement Mill (Vertical Mill)

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CHAPTER-3

PACKING PLANT

Description -

The EEPL HAVER ROTO PACKER, is rotating valve bag filling machine for
packing easy flowing powdery material and granular bulk material into bags with
simultaneous weighing of the bulk material from 10 – 50 Kg.

Filling through impeller -

The bulk material is passes through a filling impeller into a valve bag with coarse &
fine flow control. Simultaneously weighing of filling process ensure a very high
output of each filling station; The bag rests on a saddle during filling. It is therefore
possible to use paper bags with only two layers without special valve reinforcement.

Material inlet –

The material inlet is connected below the rotary feeder outlet. The filing level detector
connected to the stationary cover, which consists of travelling lever. When cement is
filled up to a particular level, the detector gates activated, which in turns stops, the
rotary feeder. Similarly when the level falls the travelling activates the limit switch
which in turn energies the motor of rotary feeder.

Coarse flow -

After tarring, the coarse flow slide gate is open and the filling turbine started, during
the filling process the weight increase is continuously measured and the dynamic load
derived from these measurements. If the weight increases, the coarse flow is negative,
i.e. the bag is loosing material and the current weight is above the empty limit, the
filling process is interrupted and the bag discharge the error output is set. The same
procedure applies to bag whose weight does not increase the empty limit at the
discharge position, or those bags, where the filling time increase the max filling time.
The same also applies if the bag slippage of the filling pipe but remains on the bag
stool.

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CHAPTER-4

Ash Handling plant

In a cement industry a large quantity of dust is produced during production, somewhat

it is due to grinding or any other reason. This is when allowed to go freely, causes
environment pollution. So that the dust must be treated or separated, from the dust
laden gases, before it allows freeing..

Cyclones- Cyclones consist essentially of two sections. A cylindrical & conical

section. At the top of the cylindrical section, the gas enters tangentially &U moves in
a spiral motion along the walls of the cyclone, in down ward direction into the conical
section. From here it starts to occupy the center space of the cyclone & spiral upward
to the outlet thimble. The particles fall down to the bottom into the hopper from
conveyors. The efficiency of the cyclone depends upon the internal diameter of the
cyclone. The gas after separation is exit from saleron pipe here they are carried away
by the rotary valves & screw .

Bag filter - This type of filters essentially consists of numbers of bags, which are
mounted, in a series. These bags are made up of natural or synthetic fiber, so it is
called fabric filter also. These bags can handle small particles in the sub-micron
range. Depending upon the fabric kind, its efficiency changes. The bags are mounted
in a chamber, which has two sections. One is the upper section, & another is lower
section.

Fig. Bag filter

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The upper part is connected with an air suction pipe, & lower is connected with dusty
air duct. The dust laden air enters from the lower section & fresh air exits through
upper section. In the central part of the bag filter, the gas passes through the bags,
leaving the dust in the voids present in the fabric bags. When the dust layer becomes
too thick on the bags, then a reverse air pulse is passes through the bags to drop down
the dust.

Electrostatic precipitator –

The working of ESP is based on effect of ionization of a gas in a strong electric field.
It consists of number of electrodes, one is discharge electrode & another is collecting
electrode. These are arranged alternatively, in a series.

A high electrical voltage (50 to 110 kV) is developed on the discharge electrode, so
that it begins to emit electrons. When dust-laden gas enters the Electro static
precipitator, the dust particles get charged, & get attached to collecting electrode.
These dust particles are then wrapping out from the electrode by using the hammers.
which are located below the electrodes.

This dust is then falls down in a hopper, from where it is conveyed further.

Fig. electrostatic precipitator

In an ESP, where particle charging and discharging are key functions, resistivity is an
important factor that significantly affects collection efficiency. While resistivity is an
important phenomenon in the inter-electrode region where most particle charging
takes place, it has a particularly important effect on the dust layer at the collection
electrode where discharging occurs.

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CHAPTER 5

CONCLUSION

By doing this internship training at ADITYA CEMENT I came to know much a

cement firm and how the production of cement is done. Each and every department of
the company has its own duties and responsibilities which should be followed by each
staff members of the firm. The marketing department plays a very important role in
sales activities and by increasing the market of the firm. The marketing mix such as
product, place, price, promotion is maintained well effective. Due to the good quality.
cement has got good brand name and demand.

According to demand and supply theory – As the demand of the product increase the
supply remains constant due to the decreased production. Beside learning, It is one of
the wonderful experience for me.

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RESEARCH PAPER

THE CONTROL OF ELECTROMAGNETIC VIBRATORY ACTUATOR

FOR EFFICIENT FLOW OF DUST PARTICULATE FROM THE
COLLECTING HOPPERS OF ELECTROSTATIC PRECIPITATORS

Željko V. Despotović and Aleksandar I.Ribić

Institute “Mihajlo Pupin” , University of Belgrade, Serbia,

zeljko.despotovic@pupin.rs

Abstract: In addition to the high voltage power supply and drive electrostatic
precipitator rappers, very important is the system to remove precipitated dust from
the collecting hoppers which are located directly below the electrode system.
Vibration of collecting hoppers appropriate amplitude and frequency can
significantly improve the removal of precipitated dust. The vibratory actuators
having electromagnetic drive are commonly used in these systems as a source of
vibration. They are a standard controlled by thyristor converters. This converter is
provided amplitude control of vibration and through it control of the flow
collecting particles. Since these converters are synchronized to the 50Hz network,
frequency of generated vibrations can be at 50Hz (single thyristor) or 100Hz (two
thyristor in ant parallel). For the efficient flow and transport of separated particles
is needed in addition to amplitude control to provide and frequency control of
collecting hoppers. This paper presents one possible solution to the switching
control of vibration actuator through IGBT converters which provided their
amplitude and frequency control. Based on a simulation model of the system was
developed experimental model, which shows the characteristic oscilloscopic
records and confirmed the effectiveness of proposed solutions

1. INTRODUCTION
The separation of particles of coal dust and ash significantly reduces the negative
impact of waste materials that are the products of combustion in thermal power
plants and heating plants. World standards that are becoming more accepted in our
country require emission limit values (ELV) less than 50mg / m3 , a tendency in the
world is to reduce the level of the value of 25mg / m3 .
Prevention of waste particles of coal dust and fly ash from the chimneys the
mentioned plants, or their "collection" is achieved by electrostatic precipitator
(ESP). The separation of the mentioned types of solid products is achieved by
strong electrostatic field that forms in precipitation chamber of ESP.
In the precipitation chamber, there are two types of electrodes: collecting
and emissions, as well as devices for rapping of separated particles. Periodic
shaking of deposited material in the mentioned electrodes to exercise its
accumulation in host hoppers (bunkers) which are located just below the
precipitation chamber.
A typical distribution of ash in a percentage of a typical thermal power plant
is shown in Fig.1. Approximately 10-15% of the ash is separated into the
reception bunkers of boiler. On the exit of boiler, precisely from the bunker of

15
economizer extract 5-10% of the ash. In a system for heating air extract about 2-
5% of the ash. The ash from economizer and air heater is in fact on the fly ash and
it is about 20% of the total quantity of ash. The rest of the ash in the flue gas
passes
through a system of high voltage electrode system of ESP, so that most of the ash
75-80%, is allocated in hoppers which are placed directly below high voltage
precipitation chambers of ESP. A very small portion of ash, much less than 1% is
extract at the bottom of the output chimney.

Fig.1. Typical distribution of ash in thermal power plant

From the reception hoppers of ESP, separated particles are continuously

drain to different types of systems for evacuation and transport of ash. Depending
on the fluid through which it transports these particles are different hydraulic and
pneumatic transports. Hydraulic transport was done by water and pneumatic
transport was done by gas, usually air.
Hydraulic transport is, in fact, a tubular transport of mixture deposited ash
(particulate matter) and water. Hydraulic transport in case of removal of ash from
ESP makes sense to use, considering that the ash does not change the physical
properties or chemical reaction in contact with water. This is off the creation of
compounds that could lead to a clogging of the pipeline.

2. THE PHENOMENOLOGY OF VIBRATORY HOPPER

DISCHARGE
Vibrating hoppers and bin are commonly used for transportation, processing or
storage of bulk materials such as coal, grain, ashes, etc. Although hoppers are
common, the internal flow of the material is not well understood, relying heavily
on empirical information to maintain operation. For example, when a batch of
material is introduced into a hopper for the first time, the material at the exit may
arch and prevent flow. To remedy the situation, vibration may be used, sometimes
in the crude form of a hammer, to perturb the material and initiate the flow [1].

16
Fig.2. Typical types of ash and particulate material conveying; (a) pneumatic transport, (b)
hydraulic transport

Alternatively, the hopper may be equipped with a bin activator to

continuously shake part of the hopper wall. These bin activators must be carefully
designed to enhance the flow and not result in further settling or clogging of the
material.
The discharge of granular material from a hopper subject to vertical
sinusoidal oscillations was investigated using experiments and discrete element
computer simulations. With the hopper exit closed, side-wall convection cells are
observed oriented such that particles move up along the inclined walls of the
hopper and down at the center line. The convection cells are a result of the
granular bed dilation during free fall and the subsequent interaction with the
hopper walls .

3. ELECTROMAGNETIC ACTUATOR FOR EXCITING OF

VIBRATORY HOPPER

Different drive types can achieve mechanical vibrations of the vibratory hopper.
The very first drives were originally mechanical (pneumatics, hydraulics, and
inertial). Today, most of the common drives are electrical.
When a reciprocating motion has to be electrically produced, the use of a
rotary electric motor with a suitable transmission is really a rather round-about
way of solving the problem. It is generally a better solution to look for an
incremental-motion system with magnetic coupling, so- called “electromagnetic
vibratory actuator” (EVA), which produces a direct “to-and-from”
Electromagnetic drives offer easy and simple control for the mass flow of
particulate and bulk materials. In comparison to all previously mentioned drives,
these have a more simple construction and they are compact, robust, and reliable

17
in operation. The absence of wearing mechanical parts, such as gears, cams belts,
bearings, eccentrics, or motors, makes vibratory conveyors, hoppers, feeders etc.
most economical equipment

Fig.3. The electromechanical system for exciting vibratory hopper for efficient dust
particulate flow

(a) mechanical construction , (b) armature of EVA on active side, (b) armature EVA on
reactive side

The material is transported into the hopper is in fact fly ash obtained by rapping of
the collecting ad emission plates of ESP. Vibrating actuators are mounted on the
sides near the bottom of the vibrating hopper, forming a triangular shape. In this
way, the entire mechanical construction becomes oscillatory system with two-
masses: one consisting of vibrating hopper filled with ash, the total mass M and the
other consisting of a moving part of EVA, whose mass is m .
All main types of vibratory hoppers can be seen as two-mass systems. The
majority of them generate harmonic excitation forces, while some types generate
transmitting impact pulses. The EVA can be single- or double-stroke construction.
In the single-stroke type, there is an electromagnet, whose armature is attracted in
one direction, while the reverse stroke is completed by restoring elastic forces. In
the two-stroke type, two electro-magnets, which alternately attract the armature in
different directions, are used.
These reactive vibrators can also operate on interrupted pulsating (DC)
current. Their frequency in this case depends on the pulse frequency of the DC.
Mechanical force, which is a consequence of pulsating current and created by
electromechanical conversion in the EVA, is transmitted through the elastic
springs to the outer wall of the hopper.

18
 REFERENCES

C.R.Wassgren, M.L.Hunt, P.J.Freese, J.Palamara and C.E.Brennen, Effect of vertical

vibration on hopper flows of granular material, Physics of Fluids, Vol.14, No.10,
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