Grain elevator dedusting system and its environmental safety

Grain elevator dedusting system and its environmental safety

Increasing requirements to environmental safety require from agrarians modern dedusting systems.

Ukraine's active agricultural policy has led to a significant increase in grain production. Most grain elevators and grain marine terminals, both the newest facilities and those built back in the 80's, have met this challenge with obsolete dedusting equipment. Traditional dust collectors, such as cyclones, are unable to fully meet modern requirements for environmental safety of grain production.

Insufficient efficiency of dedusting systems is often associated with outdated methods of their calculation and design. Previously, important aspects such as the induction properties of gravity equipment were not taken into account, the amount of air required for dedusting was not taken into account taking into account the dependence of the length and height of the gravity flow as well as the transported product into the bulk chute, which may not provide the necessary sanitary standards.

In addition, the optimum size and location of dust collectors is an important factor. Grain Capital solved these problems by developing state-of-the-art design methodologies that take all factors into account for efficient and trouble-free dedusting systems.

Any dedusting starts with design

The design ideology is fundamentally different from the approaches of other machine builders. Grain Capital has developed and actively uses a complex system of design automation, which allows to create an optimal dust suppression system in accordance with specific requirements and the ratio of price, quality and reliability.

The dedusting system project, adapted to aerodynamically variable parameters of dust emission sources for a particular enterprise, fully complies with fire, explosion and environmental safety standards in force in Ukraine.

Dedusting systems for equipment and personnel safety

Production activities of grain enterprises, bread receiving stations, feed mills and other similar institutions provide a wide range of production processes, such as receiving and shipment of raw materials, transportation, cleaning, drying, grinding, etc. All these processes are accompanied by the formation of a large amount of dust, which can reach explosive concentrations, as well as emitted into the environment.

During vertical and horizontal transportation of grain, its reloading by transport equipment, as well as during the loading of silos and bins, a large amount of dust is always generated. As a result, dust clouds are formed, which are hazardous. If measures are not taken to remove them, the consequences can be catastrophic.

Dusting of grain processing complexes

In order to effectively dedust each process unit, it is essential that the dedusting equipment complies with all regulations and environmental safety requirements. This includes not only ensuring high dust collection efficiency, but also optimizing processes taking into account the specific operating conditions of each production element. Only an integrated approach to the design and implementation of dedusting systems makes it possible to achieve the required level of environmental safety and compliance with modern standards.

Dedusting equipment we design

• Sanitary and hygienic efficient. Our dedusting equipment provides a high level of environmental protection against pollution. It creates normal sanitary and hygienic working conditions in work areas and provides the necessary efficiency for dust extraction from the air when it is released into the atmosphere. This helps maintain optimum cooling capacity in the working areas, which is critical for the health of workers and the long-term performance of the equipment.
  
• Technologically efficient Our equipment ensures stable and highly efficient operation of the entire shop floor process. This increases the overall productivity and reliability of the processes, which directly affects the quality of the final product and reduces maintenance costs.
• Ensures explosion safety: dedusting systems are designed to comply with all current recommendations and standards for the prevention of dust explosions. This ensures the safety of both equipment and personnel and minimizes the risks associated with potential explosions.
• Economically beneficial. Our products are characterized by optimum initial cost as well as minimum energy and operating costs. This ensures economic benefits during use and reduces overall equipment maintenance costs.

New filter generation or smart dedusting systems

The basis for the development of new generation equipment is advanced dedusting systems, which are implemented in the design by Grain Capital specialists in cooperation with leading professors of Odessa National Technological University. Our approach includes the principle of complex impact on dust emission sources, which allows to achieve maximum results in dust control.

The development of the new range of filters is based on four main directions and utilizes 145 patents and copyright certificates:

• Designs of units and mechanisms are protected by 70 patents of Ukraine, which confirms their innovativeness and efficiency.
  
• Control systems take into account the regularities of dust emission sources and use combined methods of dust suppression, which ensures high efficiency in various conditions.
• The components are supplied from European manufacturers with high quality guarantee and long service life, which ensures reliability and durability of the systems.
• An efficient in-house service system ensures fast and quality maintenance, which increases the reliability of the system as a whole.

Features of the use of dedusting systems in Ukraine

The main challenge of implementation was to adapt the high-tech system to the operating conditions at Ukrainian grain processing enterprises. Our line of filters reflects the interests of grain terminal owners, offering an optimal price-quality ratio.

The use of new dedusting equipment can significantly reduce energy costs for dedusting of transport and processing equipment. By replacing complex, complex, energy-intensive centralized networks with local, highly efficient dedusting networks, significant savings are achieved.

Grain Capital's line of dedusting equipment includes both traditional modernized units (4BCSH (ZEO-C4), ZEO-C1) and the latest innovative equipment: breathing filter ZEO-FB, filter cabinet ZEO-FW.

Each filter developed by our specialists is the result of long research and tests carried out in cooperation with Odessa National Technological University. These filters meet all necessary requirements and have numerous technical advantages, which makes us undisputed leaders in the Ukrainian market.

Technical characteristics of filters

We are always one step ahead!

Grain Capital is constantly expanding its range of services and adopting the latest technologies. Our design office, through the development of computer-aided design and modern techniques, offers:

• Modeling of dust emission sources and development of integrated dust suppressors, which allows for maximum control and reduction of dust levels in production facilities.
• Creation of multi-chamber shelters, which provide additional protection from dust and contribute to the improvement of the environmental situation at the facility.
• Justification of optimal mode and design parameters for combined dedusters, which allows achieving the best results in dust control.

This project allowed to achieve significant dust reduction up to 93% at autodusting.

• Design of the dust suppression system for the backfill pit.
• Calculation and layout of the most efficient dedusting system.

Lubashevsky elevator Ltd.

The management of Lyubashevsky elevator was one of the first to ask us for help in dedusting of the over-silo floor.

Dedusting of the unloading carriage of the over-silo conveyor was performed with two local ZEO-FG filters. The dust collection ratio amounted to 96-98% of the total dust content. The cleaning factor of dusty air after the catcher reached 99.5%.

In June 2011, an aspiration and automation system for the unloading cart was also installed at Stepnoy elevator LLC.

Implementation of the dedusting system for the unloading cart at these enterprises allowed:

• Reduce energy consumption.
• Eliminate human error during operation.
• Improve qualitative indicators of work.
• Improve the sanitary condition of the elevator.

Grain Capital provides free consultations on modernization and reconstruction of dust suppression systems. If you have any questions or need advice, please call: tel: +38 (048) 786-83-00 mobile: +380 (067) 558-58-37, e-mail: info@zeo.ua.