Rotary lobe blower systems are available with a variety of optional components and accessories to suit different process requirements. These enhancements help improve system efficiency, safety, and reliability under various operating conditions. These include a pressure safety relief valve, vacuum safety relief valve, inlet filter, sound or acoustic enclosure, inlet air cooler, automatic blower control system, and more.
Pressure Safety Relief Valve
There are several reasons a blower system may experience excess pressure, such as pipeline blockages, excessive material feed in pneumatic conveying systems, improper valve settings, or unusually high backpressure in the line. These conditions can put significant mechanical stress on the blower, potentially leading to equipment damage or system failure. To prevent such risks, a pressure safety relief valve is installed as a critical protective component. It automatically opens when the system pressure exceeds a predefined limit, safely releasing excess air or gas to relieve the pressure buildup. This not only protects the blower and related equipment but also helps maintain safe and stable system operation during abnormal conditions.
Vacuum Safety Relief Valve
Using a vacuum safety relief valve serves a similar function as a pressure relief valve, helping to ensure the blower operates within its designated pressure range. In certain applications, especially those involving suction or negative pressure, the system may experience excessive vacuum due to blockages, improper flow control, or sudden shutdowns. Such under-pressurization can place undue stress on the blower and connected components, potentially causing mechanical damage or performance issues. A vacuum safety relief valve prevents this risk by automatically opening when the vacuum level goes beyond the acceptable threshold, allowing external air to enter the system. This helps restore the internal pressure to a safe operating range, ensuring continued reliability and protection of the equipment.
Silencer
Noise reduction is a critical consideration in the design and operation of rotary lobe blower systems. The two lobes of positive displacement blowers create continuous pressure fluctuations with each rotation. These fluctuations generate significant noise levels. To overcome this challenge, blower inlet (suction) silencers and blower outlet (discharge) silencers are installed to dampen these pressure pulses. These silencers help smooth the airflow, effectively reducing noise emissions and improving the overall working environment around the blower system.
Inlet Filter
Protecting the blower from contaminants is essential for maintaining its efficiency and longevity. Dust buildup and small particles can cause significant damage to the blower impellers, leading to reduced performance and increased maintenance costs. Inlet filters for roots blowers serve as a barrier, preventing these harmful particles from entering the system. Depending on the environment and specific process conditions, various types of blower inlet filters are selected to provide optimal protection and ensure a long service life.
Sound Enclosure / Acoustic Enclosure
Controlling noise pollution is an important aspect of operating blower systems, especially in environments where noise levels must be minimized for safety or comfort. Sound enclosures, also known as acoustic enclosues, are used to minimize the noise generated by blower systems.. These acoustic enclosures are designed to contain and absorb sound, effectively eliminating mechanical noise generated by the blower, motor, mechanical coupling, and other related components. By using these, the overall noise impact on the surrounding environment is significantly decreased, providing a quieter and safer workspace.
• Easy Maintenance and Access: Provides quick access to internal parts.
• Efficient Air Circulation and Cooling: Ensures proper airflow to prevent overheating.
• Optional Fan for Additional Cooling: Adds extra ventilation when needed.
• Optional Built-in Control Panel: Allows easy system control and monitoring.
• Robust Construction: Durable for outdoor and harsh conditions.
Inlet Air Cooler
Controlling air temperature is essential in many pneumatic conveying systems to maintain the quality of sensitive materials. Exposure to high air temperatures during the handling of food products like sugar or plastic pellets can change their physical structure or chemical composition, resulting in lower product quality. To avoid this risk, inlet air cooling systems are used to reduce the temperature of air before it reaches the blower. These cooling units help maintain the air temperature within a safe range, ensuring that the conveyed materials keep their original properties throughout the process.
Automatic Blower Control System
An automatic blower control system serves to optimize blower performance and ensure efficient operation. This PLC-based automation system continuously monitors process parameters and adjusts the blower’s flow rate, pressure, and temperature to match the process requirements. By responding dynamically to changing conditions, it helps maintain stable system performance, improves energy efficiency, and protects equipment from potential damage.
General Features
• Airflow Management: Controls and regulates the air supplied by blower units.
• Continuous Monitoring: Uses sensors to constantly monitor airflow, temperature, and pressure in the pipelines.
• Dynamic Adjustment: Allows real-time adjustment of airflow, pressure, and temperature to meet process demands.
• Flexible Control Modes: Can maintain constant airflow, pressure, or temperature based on process requirements.
• Safety Response: Automatically switches to a safe operating mode and triggers alarms if process limits are exceeded.
• Precision Control: Use PID control for accurate and stable airflow regulation.
• Demand-Based Operation: Continuously adapts airflow to match changing process needs.
• Energy Efficiency: Achieves a 20-40% reduction in energy consumption depending on process conditions.
Additional Optional Components and Accessories of Roots Blowers
• Pressure Gauge: Measures the discharge pressure of the blower to help monitor system performance.
• Vacuum Gauge: Indicates the suction pressure to ensure the blower is operating within safe limits.
• Non-return Valve / Check Valve: Prevents backflow of air or gas, protecting the blower from reverse pressure.
• V-Belt: Transfers power from the motor to the blower efficiently and is easy to replace during maintenance.
• Steel Construction Chassis: Provides a durable and stable mounting base for the entire blower assembly, suitable for heavy-duty applications.
These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
Installed below silos or hoppers, these valves are used for maintenance operations of equipment such as rotary valves, screw feeders, etc., that are positioned below the butterfly valve.
These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
In this design, the butterfly valve is sandwiched between two flanges. Rubber sealing at both faces of the valve provides a tight seal between the flanges and the wafer butterfly valve.
One side of the valve has a bolted flange connection, while the other side features a built-in short pipe designed for fixing a flexible sleeve.
These valves have bolted flange connections on both sides, making them suitable for installation on silos, hoppers, screw feeders, and similar applications.
Bulk tanker trucks or open trucks can be filled with powdered materials delivered within FIBC bags. These systems generally consist of bulk bag discharging station, mechanical or pneumatic conveyor and loading bellow. Big bag discharge station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.
Big bag discharge systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. The loading hopper of the weighing system should remain full during dosing and batching. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be employed to prevent dust emissions during hopper loading, especially for materials with high dust content.
Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks, etc. Bulk materials delivered in big bags must be transferred to packaging machines without interruption. The loading hopper of the packaging system should remain full during the filling and packaging process. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emissions during hopper loading, especially for materials with high dust content.
Mixer automation systems are used to mix dry bulk solids according to specific recipes. Raw materials delivered in FIBC bags can be transferred to mixing units through a combination of conveying equipment and bulk bag discharge systems. Depending on the type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag discharge stations can be manufactured with built-in dosing systems. The amount of raw material to be loaded into the mixer is automatically controlled with the help of a weighing and dosing system. Dust collectors can be used to prevent dust emissions during the mixer filling process.
Bulk material stored in big bags can be automatically filled into small bags. Big bag discharge systems come with optional built-in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper, providing a practical and cost-effective solution. Both big bag discharging and bag filling operations can be handled by a single, compact system. For higher bag filling needs, bag filling machines are installed near the bulk bag discharge stations. Pneumatic conveying systems or mechanical conveyors can be used to transfer bulk material from the FIBC bag discharge station to the bag or sack filling system.
Mechanical conveyors can be used for silo loading from big bag discharge stations. Screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to big bag discharge stations to fill silos. The selection of conveying equipment directly depends on the conveying distance, height, transferred material, and capacity. Bucket elevators are preferred for high silos, while screw feeders are preferred for shorter silos and short distances. The big bag discharge system can be installed on top of the silo for faster filling. In this case, rotary valves or butterfly valves are better choices as they provide simple flow control. Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some dust along with it. Vacuum fans and jet filters in dust collectors prevent dust emissions into the environment. The collected dust is sent back to the silo, thus preventing product loss.
Pneumatic conveying systems installed after bulk bag discharge units transfer bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, bulk bag discharge stations can be installed close to the warehouses, and pneumatic conveying systems are used to fill silos from long distances. This design reduces the need for forklifts and cranes for bulk material transfer on the production site and increases overall efficiency.
Pneumatic conveying systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Pneumatic conveying systems installed after bag dump units transfer bulk material through pipelines to fill silos. This configuration is ideal for applications requiring high transfer rates and long conveying distances. In production lines where raw materials are stored in warehouses far from storage silos, bag dump stations can be installed close to warehouses, allowing pneumatic conveying systems to transport materials over long distances. This design reduces the excessive use of forklifts and cranes for bulk material transfer within the production site, improving overall efficiency.
Pneumatic transfer systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on factors such as the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Mechanical conveyors can be used for silo loading from bag dump stations. In this configuration, screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to bag dump stations to fill silos. The selection of conveying equipment depends on factors such as conveying distance, height, material properties, and capacity. Bucket elevators are preferred for high silos, while screw feeders are ideal for shorter silos and short distances. Bag dump systems can be installed on top of the silo for faster filling. In such cases, rotary valves or butterfly valves are better choices as they provide simple flow control.
Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air inside the silo escapes to the atmosphere, carrying dust particles with it. Dust collectors equipped with a vacuum fan and jet filter capture airborne dust. The collected dust is returned to the silo, preventing product loss and ensuring a cleaner environment.
The inlet skirt is an optional feature designed to extend the lifespan of the flexible connector sleeve. Its upper portion is attached to the outlet port of the upstream equipment and extends down into the bin activator’s inlet port. The primary function of the inlet skirt is to serve as a protective shield, safeguarding the flexible connector seal from wear and damage.
A vibratory motor is externally mounted to the bin activator. When powered, the motor generates vibrations that facilitate a steady flow of dry bulk materials within the system. Depending on the application requirements, one or two vibratory motors can be installed externally.
To accommodate a bin activator, the cone of a silo must be shorter than usual, resulting in a wider outlet. A flange supplied with the bin activator is separately welded to the silo’s outlet, slightly above the opening, at the production site. Once installed, the vibrating bin discharger is securely bolted to the flange, ensuring a stable and reliable connection.
Special spring suspension links and an engineered polymer seal work together to create a flexible connection between a vibrating bin discharger and the equipment positioned above it.
The proper design and installation of the polyurethane seal prevent it from slipping off and ensure a secure seal, eliminating the risk of dry bulk material leakage. Additionally, the seal offers high stress resistance and long-term durability, withstanding stresses caused by motor vibrations, pressure conditions, and other operational factors.
Externally installed spring suspensions provide full resilience to the vibrations of the cone head. They ensure that the generated vibrations affect only the cone itself rather than the upstream equipment structure.
An internally tapered, conical-shaped baffle plate is positioned at the center of the bin activator’s diameter. The baffle is rigidly attached to the equipment body using structural steel components. It facilitates bulk material flow from upstream equipment by directly inducing vibrations into the material.
A secondary deflector plate reduces the weight of the bulk material in the lower portion of the bin activator by acting as a wedge beneath the material, directing it around the areas adjacent to the cone’s surface.
Polimak baffle plates are available in various configurations, including convex and cone plates, and in different angles (15°, 30°, 45°, or even 60°) depending on the flow characteristics of the handled bulk material and the specific application requirements.
