Blending Silo Techniques for Bulk Material Handling Systems

Fuller® Random Flow™ System Central Inverted ConeAirmerge™ BlenderColumn Blender

www.fls-pt.com

Up-to-date addresses of worldwidesubsidiaries and sales offices are available from our website

DENMARK USA INDIAFLSmidth A/SVigerslev Allé 77DK-2500 ValbyCopenhagenTel:+45 36 18 10 00Fax:+45 36 30 18 20

FLSmidth Inc.2040 Avenue CBethlehem, PA 18017-2188Tel:+1 610-264-6011Tel:+1 800-523-9482Fax:+1 610-264-6170E-mail: info-us@flsmidth.com

FLSmidth Ltd.Capital Towers180, Kodambakkam High RoadNungambakkamChennai 600 034Tel:+91 – 44-52 191234Fax:+91 – 44-2827 9393E-mail: indiainfo@flsmidth.com

06-2

007-

BLEN

DSI

LO

Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for generalreference only and may change at any time. Please contact us for specific information or data that may relate to your interests.

FLSmidth’s research programs are aimed at maximizingthe energy-efficiency and cost-effectiveness ofpneumatic conveying systems.

Test configurations are designed and equipped topermit field-scale testing under precisely controlledlaboratory conditions. Flexibility allows operators to gofrom vacuum to pressure in combinations of linelengths and pipe diameters.

Computerized data acquisition systems permitcontinuous recording of variables including pressuredrop, air volume, power consumption and materialflow. Complete capability of evaluating materials todetermine the most energy-efficient and cost-effectivesystem design parameters also exist. Varying processconditions can be simulated in the laboratory, so thatthe effect on the conveying system can be observedprior to actual installation. Worst-case scenarios can beidentified and designed for, thereby eliminating costlydowntime.

Column BlenderMaterials Testing

FLSmidth’s world-class R&D facilitynear Bethlehem,PA enables us todemonstrate both the Airmerge™

and Column Blenders on yourmaterials prior to contract.

• Size Analysis• Moisture Content• Bulk Density• Angle of Rupture• Bed Expansion• Air Flow/Pressure• Airslide Angle• Conveying Tests

Come to FLSmidth and avoidcostly site trials and possible re-work.

The fluidizing air enters the conebeneath the column, reducing thedensity of the material within which isdisplaced upward as the denser materialfrom the annulus of the cone flowsinward.

This “Fountain-Flow” gives a radialcirculation capable of blendingultrafine powders, coarser sandymaterials and products with a wideparticle size distribution.

• No moving parts• Gravity discharge 60° cone design• Simple operation• Robust design• Greater flexibility in particle size range• Design for different batch sizes

available*

Features:

A fully fluidized cone, an upper and lower air plenum and an open-ended central column allowthe principle of air blending to be applied to even the most difficult materials.

* Different Batch SizesBy dividing the central column into two or moreseparate pieces, the column blender canaccommodate different volumetric batch sizes.

In the smaller batches, material is lifted up in thesame way but “Fountain-Flow” into thesurrounding fluidized bed is via the spacesbetween the upper and lower column.

Batch volumes must be known for designpurposes in advance.

Column Blender, Catasauqua, PA

Materials Testing and Research

Multi-unit receiving and transfer stations allowfull-scale testing and material evaluations.

FLSmidth Airmerge Blender

Modular equipment assemblies facilitate test programs

• Reduced maintenance

• Clean, dry, oil free

• Low power usage

• Space on ground floor

• No segregation

• Flexible plant layout

• Maximum cleanout

• Low installation cost

• Maximum storage capacity

Six pie-shaped sectors (each subdivided into six aeration zones) andcontinuous blending in a timed discharge pattern provide the lowestenergy gravity blending silo available. Power consumption oncement raw meal as low as 0.07 kWh / metric ton! New and retrofitinstallations with minimum downtime.

BLE

ND

ING

SIL

O T

ECH

NIQ

UES

Blending Silo Techniques

• Mixing two or moreproducts

• Homogenation ofindividual products

• Size uniformity

• Color uniformity

• Chemical uniformity

• Temperature uniformity

• Reduce processvariations

• Recycle out spec material

• Add trace elements

• Chemical modification

BLENDINGAPPLICATIONS

• No moving parts

• Low pressure air

• Compact PD blowers

• Gravity withdrawal

• Center or side discharge

• Maximum bottom aeration coverage

• Small inverted central cone

Features

Space-saving layout of blowers beneath the silo

Fuller® Random-Flow™

Open Airslide™ sections in the flatannulus ensure full clean-out whenrequired.

Material enters the central bin viamultiple Airslide blending materialsfrom different areas of the silo floor.

An arrangement of air valvesactivates sequential discharge andprovides a continuous blending ofmaterials from the side of the silothrough a funnel effect.

Features include:• Total cleanout• High capacity (6,000 ton +)• High discharge rates (150 tph+)• Controlled flow withdrawal• Reduced silo profile• Discharge equipment located under cone• Minimum dust collection• No segregation• Reduced foundation cost

Airmerge Blenders™

At FLSmidth we engineerall our blending silos tomaximize the benefits offluidization and gravitytechnologies overmechanical.

Technologies that give youoperating efficiency,flexibility and increasedproductivity. Our productrange can also combinestorage and blending forspace-saving plant layouts.

AerationZone

GatheringSlide

CollectionPoints

Discharge Point

Benefits

When an aeration zone is activated, layers aremixed through a funnel effect as material inthe zone flows to its designated collectionpoint on the gathering Airslide™ conveyor. Theinverted cone prevents material exiting withoutflowing through a collection point

Central Inverted ConeCentral Inverted Cone—Air Assisted Gravity Blending. Multiple outlet gravity dischargecombined with central cone construction gives advanced gravity blending and storage with apower consumption as low as 0.25 to 0.5 kWh / metric ton of cement raw meal.

Experience countsFLSmidth has supplied over 500blenders to industrial customersworldwide over the past 70 years.

Our technology and commitment toproduct development and testinghave made us the #1 supplier ofair/gravity blenders.

Materials handledinclude:Ascorbic AcidCarbon BlackCement Raw MixDelrin PlasticD.S. NickelEdible ProteinFinish CementFly AshGraphiteGround AluminaIron PowderKaolinMagnesite MixNatural GypsumNickel OxidePigmentsPolyethylenePolyolefinPolypropylenePVCPPO ResinRutileSilicaSlag CementStarchSynthetic GypsumTBBAUn-Ground AluminaVitamin CZinc Dust

ReliablePerformanceWhether you need a completesystem or just a component, letthe engineering team at FLSmidthput its resources to work for you.

Our attention to detail will makeit work.

Scope of supplycan include:SilosAerated Bin BottomsAirslide™ Gravity ConveyorSolids Flow Control Valves Fan & Blower Packages Dust CollectorsPneumatic Conveying Compressor PackagesPipes and BendsDiverter ValvesControl Panels

Airmerge Blenders can be designed for batchor continuous operation to meet yourrequirements.

Porous fabric held with binding strips on topof removable grating panels in the Air Plenumallows access for fabric to be replaced inplace.

Higher air velocities in the blending quadrantlower the bulk density causing the densermaterial in the three fluidized quadrants toflow into it and be displaced upward in acontinuously circulating bed.

Air for fluidization and blending can besupplied from common or separate blowers asrequired.

• Low maintenance• Long life• No complicated

controls• Little dynamic loading• Usually PD blowers• Complete cleanout

• New or retrofitinstallations

• System designflexibility

• Food applicationsavailable

Benefits:• No moving parts in contact with the

material• Simple operation• Gentle blending action• Low pressure air• ~20° slope on fluid bed• Steel flange connection• Batch or continuous working• Standard and FDA fabric option

Features:

Air blending is achieved by use of a porous membrane over the entire bin bottom, 4 airplenums and a simple flow control system enable . Together they change the density ofmaterial in the fluidized bed of material to generate a gentle folding action and a near perfect blend.

VentFilter

Materialfeed

Loadcells

Air AirMaterial

discharge

Typical support arrangementshowing loadcell option

• Reduced maintenance

• Clean, dry, oil free

• Low power usage

• Space on ground floor

• No segregation

• Flexible plant layout

• Maximum cleanout

• Low installation cost

• Maximum storage capacity

Six pie-shaped sectors (each subdivided into six aeration zones) andcontinuous blending in a timed discharge pattern provide the lowestenergy gravity blending silo available. Power consumption oncement raw meal as low as 0.07 kWh / metric ton! New and retrofitinstallations with minimum downtime.

BLE

ND

ING

SIL

O T

ECH

NIQ

UES

Blending Silo Techniques

• Mixing two or moreproducts

• Homogenation ofindividual products

• Size uniformity

• Color uniformity

• Chemical uniformity

• Temperature uniformity

• Reduce processvariations

• Recycle out spec material

• Add trace elements

• Chemical modification

BLENDINGAPPLICATIONS

• No moving parts

• Low pressure air

• Compact PD blowers

• Gravity withdrawal

• Center or side discharge

• Maximum bottom aeration coverage

• Small inverted central cone

Features

Space-saving layout of blowers beneath the silo

Fuller® Random-Flow™

Open Airslide™ sections in the flatannulus ensure full clean-out whenrequired.

Material enters the central bin viamultiple Airslide blending materialsfrom different areas of the silo floor.

An arrangement of air valvesactivates sequential discharge andprovides a continuous blending ofmaterials from the side of the silothrough a funnel effect.

Features include:• Total cleanout• High capacity (6,000 ton +)• High discharge rates (150 tph+)• Controlled flow withdrawal• Reduced silo profile• Discharge equipment located under cone• Minimum dust collection• No segregation• Reduced foundation cost

Airmerge Blenders™

At FLSmidth we engineerall our blending silos tomaximize the benefits offluidization and gravitytechnologies overmechanical.

Technologies that give youoperating efficiency,flexibility and increasedproductivity. Our productrange can also combinestorage and blending forspace-saving plant layouts.

AerationZone

GatheringSlide

CollectionPoints

Discharge Point

Benefits

When an aeration zone is activated, layers aremixed through a funnel effect as material inthe zone flows to its designated collectionpoint on the gathering Airslide™ conveyor. Theinverted cone prevents material exiting withoutflowing through a collection point

Central Inverted ConeCentral Inverted Cone—Air Assisted Gravity Blending. Multiple outlet gravity dischargecombined with central cone construction gives advanced gravity blending and storage with apower consumption as low as 0.25 to 0.5 kWh / metric ton of cement raw meal.

Experience countsFLSmidth has supplied over 500blenders to industrial customersworldwide over the past 70 years.

Our technology and commitment toproduct development and testinghave made us the #1 supplier ofair/gravity blenders.

Materials handledinclude:Ascorbic AcidCarbon BlackCement Raw MixDelrin PlasticD.S. NickelEdible ProteinFinish CementFly AshGraphiteGround AluminaIron PowderKaolinMagnesite MixNatural GypsumNickel OxidePigmentsPolyethylenePolyolefinPolypropylenePVCPPO ResinRutileSilicaSlag CementStarchSynthetic GypsumTBBAUn-Ground AluminaVitamin CZinc Dust

ReliablePerformanceWhether you need a completesystem or just a component, letthe engineering team at FLSmidthput its resources to work for you.

Our attention to detail will makeit work.

Scope of supplycan include:SilosAerated Bin BottomsAirslide™ Gravity ConveyorSolids Flow Control Valves Fan & Blower Packages Dust CollectorsPneumatic Conveying Compressor PackagesPipes and BendsDiverter ValvesControl Panels

Airmerge Blenders can be designed for batchor continuous operation to meet yourrequirements.

Porous fabric held with binding strips on topof removable grating panels in the Air Plenumallows access for fabric to be replaced inplace.

Higher air velocities in the blending quadrantlower the bulk density causing the densermaterial in the three fluidized quadrants toflow into it and be displaced upward in acontinuously circulating bed.

Air for fluidization and blending can besupplied from common or separate blowers asrequired.

• Low maintenance• Long life• No complicated

controls• Little dynamic loading• Usually PD blowers• Complete cleanout

• New or retrofitinstallations

• System designflexibility

• Food applicationsavailable

Benefits:• No moving parts in contact with the

material• Simple operation• Gentle blending action• Low pressure air• ~20° slope on fluid bed• Steel flange connection• Batch or continuous working• Standard and FDA fabric option

Features:

Air blending is achieved by use of a porous membrane over the entire bin bottom, 4 airplenums and a simple flow control system enable . Together they change the density ofmaterial in the fluidized bed of material to generate a gentle folding action and a near perfect blend.

VentFilter

Materialfeed

Loadcells

Air AirMaterial

discharge

Typical support arrangementshowing loadcell option

• Reduced maintenance

• Clean, dry, oil free

• Low power usage

• Space on ground floor

• No segregation

• Flexible plant layout

• Maximum cleanout

• Low installation cost

• Maximum storage capacity

Six pie-shaped sectors (each subdivided into six aeration zones) andcontinuous blending in a timed discharge pattern provide the lowestenergy gravity blending silo available. Power consumption oncement raw meal as low as 0.07 kWh / metric ton! New and retrofitinstallations with minimum downtime.

BLE

ND

ING

SIL

O T

ECH

NIQ

UES

Blending Silo Techniques

• Mixing two or moreproducts

• Homogenation ofindividual products

• Size uniformity

• Color uniformity

• Chemical uniformity

• Temperature uniformity

• Reduce processvariations

• Recycle out spec material

• Add trace elements

• Chemical modification

BLENDINGAPPLICATIONS

• No moving parts

• Low pressure air

• Compact PD blowers

• Gravity withdrawal

• Center or side discharge

• Maximum bottom aeration coverage

• Small inverted central cone

Features

Space-saving layout of blowers beneath the silo

Fuller® Random-Flow™

Open Airslide™ sections in the flatannulus ensure full clean-out whenrequired.

Material enters the central bin viamultiple Airslide blending materialsfrom different areas of the silo floor.

An arrangement of air valvesactivates sequential discharge andprovides a continuous blending ofmaterials from the side of the silothrough a funnel effect.

Features include:• Total cleanout• High capacity (6,000 ton +)• High discharge rates (150 tph+)• Controlled flow withdrawal• Reduced silo profile• Discharge equipment located under cone• Minimum dust collection• No segregation• Reduced foundation cost

Airmerge Blenders™

At FLSmidth we engineerall our blending silos tomaximize the benefits offluidization and gravitytechnologies overmechanical.

Technologies that give youoperating efficiency,flexibility and increasedproductivity. Our productrange can also combinestorage and blending forspace-saving plant layouts.

AerationZone

GatheringSlide

CollectionPoints

Discharge Point

Benefits

When an aeration zone is activated, layers aremixed through a funnel effect as material inthe zone flows to its designated collectionpoint on the gathering Airslide™ conveyor. Theinverted cone prevents material exiting withoutflowing through a collection point

Central Inverted ConeCentral Inverted Cone—Air Assisted Gravity Blending. Multiple outlet gravity dischargecombined with central cone construction gives advanced gravity blending and storage with apower consumption as low as 0.25 to 0.5 kWh / metric ton of cement raw meal.

Experience countsFLSmidth has supplied over 500blenders to industrial customersworldwide over the past 70 years.

Our technology and commitment toproduct development and testinghave made us the #1 supplier ofair/gravity blenders.

Materials handledinclude:Ascorbic AcidCarbon BlackCement Raw MixDelrin PlasticD.S. NickelEdible ProteinFinish CementFly AshGraphiteGround AluminaIron PowderKaolinMagnesite MixNatural GypsumNickel OxidePigmentsPolyethylenePolyolefinPolypropylenePVCPPO ResinRutileSilicaSlag CementStarchSynthetic GypsumTBBAUn-Ground AluminaVitamin CZinc Dust

ReliablePerformanceWhether you need a completesystem or just a component, letthe engineering team at FLSmidthput its resources to work for you.

Our attention to detail will makeit work.

Scope of supplycan include:SilosAerated Bin BottomsAirslide™ Gravity ConveyorSolids Flow Control Valves Fan & Blower Packages Dust CollectorsPneumatic Conveying Compressor PackagesPipes and BendsDiverter ValvesControl Panels

Airmerge Blenders can be designed for batchor continuous operation to meet yourrequirements.

Porous fabric held with binding strips on topof removable grating panels in the Air Plenumallows access for fabric to be replaced inplace.

Higher air velocities in the blending quadrantlower the bulk density causing the densermaterial in the three fluidized quadrants toflow into it and be displaced upward in acontinuously circulating bed.

Air for fluidization and blending can besupplied from common or separate blowers asrequired.

• Low maintenance• Long life• No complicated

controls• Little dynamic loading• Usually PD blowers• Complete cleanout

• New or retrofitinstallations

• System designflexibility

• Food applicationsavailable

Benefits:• No moving parts in contact with the

material• Simple operation• Gentle blending action• Low pressure air• ~20° slope on fluid bed• Steel flange connection• Batch or continuous working• Standard and FDA fabric option

Features:

Air blending is achieved by use of a porous membrane over the entire bin bottom, 4 airplenums and a simple flow control system enable . Together they change the density ofmaterial in the fluidized bed of material to generate a gentle folding action and a near perfect blend.

VentFilter

Materialfeed

Loadcells

Air AirMaterial

discharge

Typical support arrangementshowing loadcell option

Blending Silo Techniques for Bulk Material Handling Systems

Fuller® Random Flow™ System Central Inverted ConeAirmerge™ BlenderColumn Blender

www.fls-pt.com

Up-to-date addresses of worldwidesubsidiaries and sales offices are available from our website

DENMARK USA INDIAFLSmidth A/SVigerslev Allé 77DK-2500 ValbyCopenhagenTel:+45 36 18 10 00Fax:+45 36 30 18 20

FLSmidth Inc.2040 Avenue CBethlehem, PA 18017-2188Tel:+1 610-264-6011Tel:+1 800-523-9482Fax:+1 610-264-6170E-mail: info-us@flsmidth.com

FLSmidth Ltd.Capital Towers180, Kodambakkam High RoadNungambakkamChennai 600 034Tel:+91 – 44-52 191234Fax:+91 – 44-2827 9393E-mail: indiainfo@flsmidth.com

06-2

007-

BLEN

DSI

LO

Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for generalreference only and may change at any time. Please contact us for specific information or data that may relate to your interests.

FLSmidth’s research programs are aimed at maximizingthe energy-efficiency and cost-effectiveness ofpneumatic conveying systems.

Test configurations are designed and equipped topermit field-scale testing under precisely controlledlaboratory conditions. Flexibility allows operators to gofrom vacuum to pressure in combinations of linelengths and pipe diameters.

Computerized data acquisition systems permitcontinuous recording of variables including pressuredrop, air volume, power consumption and materialflow. Complete capability of evaluating materials todetermine the most energy-efficient and cost-effectivesystem design parameters also exist. Varying processconditions can be simulated in the laboratory, so thatthe effect on the conveying system can be observedprior to actual installation. Worst-case scenarios can beidentified and designed for, thereby eliminating costlydowntime.

Column BlenderMaterials Testing

FLSmidth’s world-class R&D facilitynear Bethlehem,PA enables us todemonstrate both the Airmerge™

and Column Blenders on yourmaterials prior to contract.

• Size Analysis• Moisture Content• Bulk Density• Angle of Rupture• Bed Expansion• Air Flow/Pressure• Airslide Angle• Conveying Tests

Come to FLSmidth and avoidcostly site trials and possible re-work.

The fluidizing air enters the conebeneath the column, reducing thedensity of the material within which isdisplaced upward as the denser materialfrom the annulus of the cone flowsinward.

This “Fountain-Flow” gives a radialcirculation capable of blendingultrafine powders, coarser sandymaterials and products with a wideparticle size distribution.

• No moving parts• Gravity discharge 60° cone design• Simple operation• Robust design• Greater flexibility in particle size range• Design for different batch sizes

available*

Features:

A fully fluidized cone, an upper and lower air plenum and an open-ended central column allowthe principle of air blending to be applied to even the most difficult materials.

* Different Batch SizesBy dividing the central column into two or moreseparate pieces, the column blender canaccommodate different volumetric batch sizes.

In the smaller batches, material is lifted up in thesame way but “Fountain-Flow” into thesurrounding fluidized bed is via the spacesbetween the upper and lower column.

Batch volumes must be known for designpurposes in advance.

Column Blender, Catasauqua, PA

Materials Testing and Research

Multi-unit receiving and transfer stations allowfull-scale testing and material evaluations.

FLSmidth Airmerge Blender

Modular equipment assemblies facilitate test programs

Blending Silo Techniques for Bulk Material Handling Systems

Fuller® Random Flow™ System Central Inverted ConeAirmerge™ BlenderColumn Blender

www.fls-pt.com

Up-to-date addresses of worldwidesubsidiaries and sales offices are available from our website

DENMARK USA INDIAFLSmidth A/SVigerslev Allé 77DK-2500 ValbyCopenhagenTel:+45 36 18 10 00Fax:+45 36 30 18 20

FLSmidth Inc.2040 Avenue CBethlehem, PA 18017-2188Tel:+1 610-264-6011Tel:+1 800-523-9482Fax:+1 610-264-6170E-mail: info-us@flsmidth.com

FLSmidth Ltd.Capital Towers180, Kodambakkam High RoadNungambakkamChennai 600 034Tel:+91 – 44-52 191234Fax:+91 – 44-2827 9393E-mail: indiainfo@flsmidth.com

06-2

007-

BLEN

DSI

LO

Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for generalreference only and may change at any time. Please contact us for specific information or data that may relate to your interests.

FLSmidth’s research programs are aimed at maximizingthe energy-efficiency and cost-effectiveness ofpneumatic conveying systems.

Test configurations are designed and equipped topermit field-scale testing under precisely controlledlaboratory conditions. Flexibility allows operators to gofrom vacuum to pressure in combinations of linelengths and pipe diameters.

Computerized data acquisition systems permitcontinuous recording of variables including pressuredrop, air volume, power consumption and materialflow. Complete capability of evaluating materials todetermine the most energy-efficient and cost-effectivesystem design parameters also exist. Varying processconditions can be simulated in the laboratory, so thatthe effect on the conveying system can be observedprior to actual installation. Worst-case scenarios can beidentified and designed for, thereby eliminating costlydowntime.

Column BlenderMaterials Testing

FLSmidth’s world-class R&D facilitynear Bethlehem,PA enables us todemonstrate both the Airmerge™

and Column Blenders on yourmaterials prior to contract.

• Size Analysis• Moisture Content• Bulk Density• Angle of Rupture• Bed Expansion• Air Flow/Pressure• Airslide Angle• Conveying Tests

Come to FLSmidth and avoidcostly site trials and possible re-work.

The fluidizing air enters the conebeneath the column, reducing thedensity of the material within which isdisplaced upward as the denser materialfrom the annulus of the cone flowsinward.

This “Fountain-Flow” gives a radialcirculation capable of blendingultrafine powders, coarser sandymaterials and products with a wideparticle size distribution.

• No moving parts• Gravity discharge 60° cone design• Simple operation• Robust design• Greater flexibility in particle size range• Design for different batch sizes

available*

Features:

A fully fluidized cone, an upper and lower air plenum and an open-ended central column allowthe principle of air blending to be applied to even the most difficult materials.

* Different Batch SizesBy dividing the central column into two or moreseparate pieces, the column blender canaccommodate different volumetric batch sizes.

In the smaller batches, material is lifted up in thesame way but “Fountain-Flow” into thesurrounding fluidized bed is via the spacesbetween the upper and lower column.

Batch volumes must be known for designpurposes in advance.

Column Blender, Catasauqua, PA

Materials Testing and Research

Multi-unit receiving and transfer stations allowfull-scale testing and material evaluations.

FLSmidth Airmerge Blender

Modular equipment assemblies facilitate test programs