Bulk material flow problems in industrial settings can be an immense burden. Have you ever struggled to dispense ketchup out of a glass bottle when holding it upside down, or observed how some dump trucks continue to remain full even after their beds are fully raised?

These are classic examples of material flow problems; industrial vibrators and air blasters have long been instrumental in improving material handling – we will explore here how vibration technology and sudden blasts of air blasters solve material flow problems efficiently.

What Is Bulk Material Handling (Bulk Solid/Bulk Material)?

Bulk Solids refer to any non-fluid particulate material that is produced and distributed in large quantities without packaging.

Common types of bulk solids include
• Stored in hoppers, silos, or bins
• Shipped in railcars, self-unloading ships, bags, or trucks

Typical examples of Bulk Solids:

Kaolin Clay – Used in ceramics, papermaking and rubber tire manufacturing.

Bauxite – An important raw material for aluminum production which can also be found in bricks and oil refining processes.

Steel Production Materials – such as iron ore, manganese scrap iron magnetite dolomite ferrosilicon transported via railcars are essential in steel production processes.

Cement – Cement plays an essential part in construction.

Sand or Gravel – Used in construction and landscaping applications.

Sulfur, Lime, Wood Chips and Sawdust –Utilized for various industrial processes.

Coal, Coke and Taconite – Vital components to energy production and steel manufacturing processes.

Storage of Bulk Solids & the Need to Solve Material Flow Problems

Issues Bulk materials are stored in bins, hoppers, silos and other containers designed to empty using gravity; their interior walls may even be inclined so as to allow the material to move through their discharge opening smoothly and effortlessly.
But oftentimes gravity alone is not sufficient to ensure smooth material flow resulting in blockages and buildup that need addressing in order to ensure smooth materials distribution and discharge opening operation.

Why Do Bulk Solids Have Flow Issues?

Bulk solid materials may experience flow restrictions due to various factors, including:
Hopper Design – If not designed appropriately, material may not flow freely.
Moisture Content – Excess moisture may cause material to stick together. Compaction – Pressure from weight can compress material, restricting flow. Friction- Between Material Particles and Hopper Walls
Improper Loading- Introducing new material onto compacted materials may lead to clogging.
Density Changes- Material properties can change due to temperature or moisture variations.

Common Material Flow Problems

These are just some of the issues commonly faced when handling materials:

Bridging is when material forms an arch, blocking its outlet.
Arching occurs within bulk mass material.
Ratholing occurs when only central material flows, leaving residue along walls. Clinging refers to any adhesive material adhering to storage walls.

Solving Bulk Flow Problems- How Industrial Vibrators Work

Industrial vibrators are one of the most efficient tools available for managing material flow problems, helping restore it by reducing friction and compacting issues within storage vessels such as bins, hoppers or silos.

How Can Industrial Vibrators Solve Material Flow Problems?

• A properly chosen and installed vibrator allows material to move away from hopper walls, decreasing friction.
• As gravity pulls the material downward, smooth flow resumes. Vibrators mounted properly will not cause structural damage and instead facilitate efficient material discharge.

Industrial vibrators can be divided into two broad

categories based on the vibratory force they generate. Each variety offers advantages for different material flow challenges due to different frequency and force requirements.

General Guidelines for Bulk Material Flow: Speed and Force

Considerations In order to efficiently handle bulk material flow problems, it’s vital to match vibration frequency and amplitude with the type of material being handled. Here is a general overview:

✔Amplitude-Sensitive Materials – Large, heavy materials such as coal, rock, and gravel respond well to slower waves of greater amplitude.
✔ Frequency-Sensitive Materials – Fine particulates like salt, cement, and flour need faster vibration waves to keep flowing.
✔ Light but Airy Materials – Materials like wood chips need lower-frequency, higher-force vibrations to initiate flow.
✔ Heavy but Fine Materials – Materials like solar salt require high force to move the mass and high frequency to excite fine particles. Turbine and roller vibrators are ideal for these applications.

Air Blasters as an Effective Tool in Solving Material Flow Problems

In addition to vibrators, air blasters can also play an invaluable role in maintaining continuous material flow. By blasting compressed air at once into storage vessels, they dislodge any stuck materials and guarantee continuous movement – essential tools in industries like sponge iron, cement, steel, power plants, coal mines and sugar mills where blockages could otherwise cause costly issues.

Conclusion:

Rely on Ubon India for Reliable Bulk Flow Solutions Addressing material flow problems is integral to maintaining efficient industrial operations. From industrial vibrators and air blasters, having the right equipment ensures seamless material movement, decreased downtime, and increased productivity.

At Ubon India, we specialize in high-quality industrial solutions designed to overcome bulk material flow challenges across industries. Our air blasters and vibrators are constructed for durability and performance – the go-to choice in cement plants, steel mills, mining operations and beyond.

Read up on how the right equipment can boost industrial efficiency for more insights and expert solutions! Stay current by following us on social media or reading up on the latest blogs from us!

solutions! Stay current by following us on social media or reading up on the latest blogs from us!