In 2016, Palmer purchased Klein Technology Group.
This entire line includes pneumatic conveyors, batch mixing, and cooling/classification for the foundry and rail sand industry.
More info: www.albkleinco.com
Little Known Facts about Sand Handling that
can Slash Your Operating Costs by up to 45%
by Chris Doerschlag.
Klein Equipment Brochure
Klein PLUG FLO® Sand Pneumatic Transporter
Transporter Application Sheet.
This form will help us better understand your
conveying systems come in two broad
categories: Dilute Phase and Dense Phase.
works by vacuum or low-pressure air (up to
20 psi) with velocities in the pipe of 4,000 feet per minute and
works by medium to high-pressure air (10 to 60 psi) with
velocities in the pipe of 2,800 to 5,000 feet per minute. Dense
Phase systems fluidize the sand for transport and use booster
(injection of additional air along the pipeline) to keep the
sand in the pipeline fluidized.
However, the high velocities of the sand grains traveling in the
pipeline, with either the dilute or the dense phase system, wear out
pipes and bends prematurely, even when Schedule 80 pipe is used –
literally sand blasting the pipe walls – causing degradation of the
sand and generating excessive fines/dust. It is not uncommon to see
dilute and so called dense phase fluidized systems with transport
velocities approaching 3000 feet per minute and more.
The success of these systems depends entirely on keeping the
material in suspension at all times by installing boosters along the
line, and because of the excessive velocities required a portion of
the material is always pulverized during transport.
Waste of a good product, increased fines, higher resin usage,
useless downtimes and repetitive expensive repairs.
Unlike conventional transporters,
the KLEIN PLUG FLO® operates with:
No fluidization requirement eliminating product segregation
No boosters required, system efficiency is increased and
installation costs are lower.
Lower transport velocities - Only 40 to 450 feet per minute
transport velocity resulting in less material degradation and
drastically reducing pipe wear.
The lowest air consumption per ton, resulting in smaller
collectors and considerable energy savings (up to 45%).
Standard Schedule 40 pipe, which lowers system operation and
Minimal maintenance due to reduced wear and moving parts
Rated for sand up to 125°F
The unique features of the KLEIN PLUG FLO® system make it
possible to transport sand through pipelines with practically no
degradation. Unlike dilute and dense phase conveying systems where
grain fineness reduction of 5 points and more can be experienced the
KLEIN PLUG FLO® system typically stays within one half point or
less. Naturally, this can mean a great deal for your operations
where grain fineness must be maintained to meet quality tolerances.
Lower air pressure, lack of fluidization air boosters and the KLEIN
PLUG FLO® principle result in lower air consumption and therefore
smaller dust collection requirements system at the receiver. All system components are
completely enclosed for dust free operation. The KLEIN PLUG FLO®
system is especially suitable for granular, free flowing materials
and offers lower wear and abrasion as well as minimum material
separation or reaction during the transport phase.
- Operating rates up to 20 Tons per Hour per Unit
- 3", 4", 5" diameter systems available
- Multiple transport receiving bins
- System engineering assistance
Construction and Operation of the Transport Vessel
Material Inlet Valve
The material inlet valve
consists of an air-spring fixed in the center of the vessel holding
a cast iron cone in position. When ready to fill the vessel the air
spring is deflated and the cone drops down by gravity allowing sand
to flow into the vessel. When the vessel is full (timed interval)
the air spring is inflated, raising the cone, thereby closing the
inlet opening. As the cone travels vertically up, a small amount of
compressed air is injected sweeping the peripheral surface of the
cone and keeping the sand away from the surface as it seals cleanly
against the main seal.
Alb. Klein PLUG FLO® pneumatic
sand transporter system:
No fluidization – resulting in:
- up to 45% lower air consumption;
- less compressor energy required;
- fewer parts to install and maintain;
- lower operating costs;
- Schedule 40 pipe is standard. Schedule 80 pipe is not required.
2. No boosters – resulting in:
- lower compressed air usage;
- no extra booster piping and fittings;
- smaller dust collector;
- reduced installation labor;
- fewer parts to install;
- minimal maintenance;
- a less complicated system.
3. Lower transport velocities – resulting in:
- considerable less pipeline wear;
- less wasted product;
- lower product cost;
- fewer costly repairs;
- fewer leaks and less waste of compressed air.
4. Lower Sand degradation – resulting in:
- improved sand quality;
- less dust generation;
- savings in resin consumption;
- more efficient operation;
- improved casting quality;
- improved house keeping.
- Blow Tank
- Discharge Housing
- Inlet Housing
- Level Probe
- Compressed Air Inlet
- Sight Glass
- Air Control Flange
- Vent Air
In contrast, the KLEIN PLUG FLO® system does not require
fluidization or boosters to move the material through a conveying
pipe line, but rather, uses the natural properties of the material
to achieve their transport. Compressed air actually pushes the slugs
of material formed at the outlet of the blow tank through the entire
pipe line at lower velocities - typically 100 to 400 feet per minute
- much like the canisters at a bank drive-in station are delivered.
After filling the blow tank by gravity from a hopper, bin, or other
bulk material source, the material inlet valve is closed and the
tank is pressurized. Once the necessary transport pressure - which
can be as low as 15-20 psi, depending on system layout - has built
up in the blow tank the material is extruded into the conveying line
in the form of slugs. The material continues to move in the form of
slugs, separated by pockets of compressed air, until discharged into
the receiver at the other end of the line. During this process the
material is not fluidized by air, resulting in lower air
consumption, lower transport velocities and therefore less wear and
abrasion. When the blow tank is empty it is depressurized and
refilled with material for another cycle.