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Flow problems are prevalent in the large scale storage bins of processing plants that move and store powdery materials such as kaolin clay, cement, wheat flour and several others. In dairy powder manufacturing plants for instance, powder particles typically coat the walls of a baghouse and its bag filter that make maintenance in these hard to reach spaces difficult. Flow problems are compounded in facilities that produce an extensive line of powder formulas and liquid blends. Know that processing facilities need to be kept clean and sanitized between changeovers. Contaminants leave an after taste which adversely affects the quality of the final product.
What causes material buildup?
Powdery materials move through a sophisticated network of twists, elbows and U-turns that are predisposed to material build-up. These create tight spaces within the installation that would later constrict material flow. Material build-up occurs because humidity levels cannot be controlled in tight spaces. Moreover, the difference in temperature allows the powdery material to coat and stick to inner walls, particularly in tight spaces. These surfaces cannot be accessed for regular cleaning and maintenance so that flow devices are routinely installed to prevent materials to cake-in, clog, and reduce system efficiency. Nonetheless, non-acoustic flow aids cannot fully resolve this nagging processing problem the way sonic horn can.
What are sonic horns and how do these devices operate?
Sonic horns are flow aids typically attached to pipes and ducts as well as to hoppers, bins and silos. Top mounted sonic horns are installed on the loading hatch of a storage facility to disintegrate ratholes and fluidize particulate buildup. Meanwhile, bottom mounted horns are attached near the discharge bin to eliminate bridging and dissolve compacted materials.
Each sonic horn is built to produce as much as 120 decibel-blasts. Continuing 12-second blasts from both acoustic horns, occurring at 13-minute intervals will be sufficient to clean hard to reach and tight spaces.
How useful are sonic horns to manufacturing?
Acoustic cleaners are indispensable to any powdery manufacturing process. For one, it eliminates expensive maintenance procedures without the risk of installation damage and moisture contamination that is inherent in air blast devices and vibrating flow aids.
Furthermore, sonic horns are efficient maintenance devices since these rely solidly on increased acoustic pressure that prevents particulates from clinging on duct walls and tight spaces. Acoustic pressure also forces compacted materials forming near loading and discharge outlets to disintegrate or even fluidize.
Material buildup predisposes manufacturing facilities to flow problems that eventually lead to reduced system efficiency and even system failure. Acoustic cleaners like sonic horns are therefore critical to keeping clean, free flowing installations that can sustain production quotas each time.
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