Ubon India Air Blaster Service And Intallation

Air blasters are an essential tool in cement plants to resolve material flow problems. Also known as air cannons, they prevent material build-up in equipment and storage vessels.

Air cannons have two vital parts – a pressure tank (vessel) and a triggering mechanism. They release a high-flow of compressed air to clear obstructions in silos, hoppers, and chutes.

Working

Air blasters are used to prevent material build-up or blockages in various equipment and vessels throughout the cement production process. These devices can remove clogs in silos, hoppers, and chutes, as well as dislodge clinker from cooler grates and riser ducts in kilns and preheaters. They can also help maintain consistent flow of materials and aerate the contents of bins and hoppers to reduce dust build-up.

These devices are powered by plant air and are controlled by a Programmable Logic Controller with a graphic Human Machine Interface (HMI). They can be programmed to fire at specific intervals or in sequence, depending on the conditions of the chute and the materials being conveyed. In addition, they can be programmed to automatically clear the clogged chute and then shut off the firing sequence. This will allow plant personnel to carry out other maintenance tasks without needing to manually monitor the system.

Air cannons are available in different sizes with a choice of nozzles that provide the desired blast effect. The nozzles are positioned to direct the blasts towards sensitive clogging zones. They can be made of steel or refractory stainless steel and are designed to operate at high temperatures.

A large Caribbean cement plant experienced issues with a chute that was difficult to open due to the sticky nature of the material. Several different air cannons were used, but they weren’t able to break up the hardened material that was causing the blockage. The plant was forced to stop production and manually clean the chute every five hours. After the installation of a Ubon India air blaster, the problem was resolved and manual cleaning no longer needed to be performed.

Accessories

An air blaster can be a critical tool in cement plant operations. It can help dislodge materials from silos, hoppers and chutes by releasing bursts of compressed air. It can also help keep material flowing through conveyor systems by promoting proper mixing and homogenization. Regardless of the application, however, it is essential to have the right accessories in place for optimal performance and safety.

Cement plants often face challenging operating conditions, including high temperatures and humidity. These factors can accelerate the wear and tear of equipment, causing nozzles to wear out faster and other components to fail sooner. Taking steps to monitor the condition of the blaster regularly and performing routine maintenance can help avoid these problems.

Various accessories can improve the operation and performance of an air blaster, helping it to perform at peak efficiency for longer periods of time. These include a stainless steel bush, a quick exhaust valve (QEV), and an adjustable hose whip that allows the operator to vary airflow direction. The hose whip also helps prevent sudden pressure spikes that can damage the nozzle and impact operational performance.

In addition, an OEM-designed moisture separator and a blast metering valve can significantly enhance the performance of an air blaster. These accessories, available from Clemco, are designed to be compatible with the manufacturer's original specifications and provide the optimal media-to-air mix for maximum productivity.

Pneumatic Control Panel

The pneumatic control panel needed for air blaster installation is used to regulate the flow of compressed air to different parts of the system. It can be made up of various parts, including air cylinders, valves, and pressure gauges. These parts are connected by an airline that is fed from a compressor to the pneumatic control panel. The control panel then controls the movement of the cylinders during rotations and streamlines machine function. It also helps protect the cylinders from damage caused by over-extension and prevents sudden pressure spikes.

Pneumatic systems use compressed air to control engineering equipment and are often more reliable and economical than electric/electronic devices. Compressed air flows through copper or plastic tubing to the device being controlled, where sensors and thermostats are located. The air then passes through an actuator, which is either pneumatic or electric. Pneumatic actuators are the most durable and economical, as they require fewer mechanical linkages than their electric counterparts. They are also less expensive than similar-sized electric actuators and reduce electrical power loss.

An industrial air cannon, or blaster, is an air-expansion type flow aid that quietly supplies a powerful blast of compressed air into bulk materials handling storage or process vessels, bins, silos, chutes, and ducts. Its eruptive force cleans, de-clogs, or dislodges bulk solids and eliminates blockage that chokes production and hampers flow. It also increases safety and plant efficiency by reducing dust and contamination.

The control panels for air blasters help them to operate smoothly, efficiently, and safely. They are essential in maximizing performance, promoting free flow of materials, and preventing blockage. They are also useful in minimizing maintenance and repair costs and prolonging the lifespan of the air blaster. Pneumatic control panels come in a variety of configurations and sizes, and are available with different features and capacities. Depending on the application, they can be installed as front-panel units or in a cabinet. Some are even portable, allowing them to be relocated easily.

Air Blaster M.S Band

Air blasters are used to remove material blockages and promote flow in equipment, preventing costly downtime. They do this by releasing a powerful blast of compressed air into the blocked area, breaking up and dislodging material that has collected. The resulting stream of clean air then clears the obstruction and allows for continuous production. Air blasters also contribute to energy efficiency by ensuring that equipment is not impeded by blockages and that the proper amount of fuel is being burned during combustion in kilns.

In cement plants, air blasters are used to prevent material build-up and blockages in silos, hoppers, bins, and chutes. They are especially useful for addressing problems in high-heat areas like preheaters and kilns, where blockages can lead to unexpected production shutdowns.

Air blasters also promote flow in clinker coolers by removing any accumulated gypsum and limestone, which can cause clogs and slow down cooling processes. They are also helpful in cleaning filter bags, which can become clogged with dust and need to be cleaned periodically to maintain their function.

Using an air cannon to remove obstructions in cement plant equipment is cost-effective and safe, since it eliminates the need for manual tools that can damage the equipment. Moreover, timed air cannon activation prevents material build-up from forming in the first place, reducing downtime and improving production efficiency. In addition, air cannons are available with a variety of nozzles that optimize their performance for different applications. They can even be mounted on a mobile platform to reach hard-to-reach areas.

Sequential Timer

Cement plants require continuous flow of material to ensure optimum production and prevent a variety of costly problems. These include blockages in preheat towers, cyclones, riser ducts and grate coolers. Air blasters help solve this problem by dislodging material buildup in these areas. They also reduce energy consumption by preventing waste and allowing better heat transfer.

Conventional air cannon systems use excessive compressed air and are prone to wear and tear, but new technology is changing this. Advanced air cannons feature valves that increase efficiency and reduce compressed air consumption by a significant margin. This enables you to achieve significant savings on your plant’s operating costs.

Air blaster installation is simple and straightforward, and you can even use a sequential timer to create sequences that repeat at a specific interval. These devices are ideal for addressing material arching and blocking in storage silos, as they can be used to improve the flowability of hard-to-move materials and reduce the need for manual cleaning.

A cement plant experienced problems with its raw material chute due to a sticky, hard-to-move substance that would clump together and block the chute. Previous air cannon solutions were not effective, and the company was forced to stop production for manual cleaning every five hours. This reduced production and lowered the plant’s overall productivity by over 900 tons per day.

A new air cannon solution was installed and combined with a pusher to address the issue of blocked chutes. The IGS Big Blue Air Blaster system was able to break up the hardened substance and shove it away, eliminating the need for manual cleaning. The system also requires no special compressed air and operates at a modest pressure of 4 bar (60 psi or 400 kPa) with two firings per hour.