In July, 2010, Deca Vibrator Industries, Inc. responded to a regional cement manufacturer with a
problem with build-up and blockage of material in a feed hopper with 3 discharge bins feeding into an
auger conveyor delivering the material (synthetic gypsum) to the production process
The Problem:
Material: Synthetic Gypsum
The synthetic gypsum created as a byproduct of coal consumption at a local power plant combined with several
other materials retained a moisture content of about 18%. The material is located in a feed hopper and delivered
to three discharge bins (pictured below) by front end loaders. Because of the nature of gypsum material
combined with moisture content, once material was loaded into the three discharge bins and the auger feeder
was started, the material would adhere to the side walls of the discharge bins and begin to build-up. The buildup
would continue until a rat hole situation would occur – restricting the flow of material to the auger. To deal
with the build-up, personnel were using an air lance to break up build-up on walls, trying to facilitate the flow.
Feed Hopper with Three discharge Bins Front View Discharge Bins from Backside of Loading Area
Front View of One Discharge Bin, Personnel with Air Lance at Work
–
Relief from extensive labor involved in air lance usage and the interruption of material flow to the
production process were the driving force to find a solution that worked.
The Solution:
Deca Air-Slide Flow Aid System
AS65CS Air-Slide
Relief from extensive labor involved in air lance usage and the interruption of material flow to the
production process were the driving force to find a solution that worked.
The Solution:
Deca Air-Slide Flow Aid System
AS65CS Air-Slide
Immediately, Deca Air-Slide Flow Aid System was proposed to the engineering staff. Deca’s needs analysis
team was then given specification drawings of the feed hopper & the discharge bins and went to work on the
specifications of the solution. Recommendations were then presented to the facility staff and management. A
decision was made to install a beta test on one of the three discharge bins
Side View of (2) AS65CS Air-Slides
End View of (1) AS65CS Air-Slide
After the installation of the recommended number of Deca Air-Slides and the Air-Slides positioned to
specifications, the test was commissioned. The sequential controller with timer was set to fire the Air-Slides
for two complete cycles with a predetermined time delay between each Air-Slide firing. The test was initiated.
The feed hopper loaded the beta bin to its capacity and the auger was started. Within 20 minutes the result was
quite evident. The recommended solution by Deca Vibrator Industries, Inc. did not allow any build-up on walls
to occur. Soon all levels of management were onsite – impressed with the results. The Deca Air-Slide Flow
Aid System provided a low maintenance, labor free solution to the material flow problems that had been
occurring. With the correct need analysis, recommended installation features and Deca Vibrator Industries, Inc.
expertise another solution to difficult material flow dilemma was put into operation.
Deca Vibrator Industries, Inc. was given the order to supply two more Deca Air-Slide Flow Aid Systems for
the remaining of the two discharge bins on the feed hopper. They were also engaged to supply a needs analysis
for another application within the same plant.
Bin without
Bin without Air-Slides
Bin using Air-Slides
The Deca Air-Slide Flow Aid System, customized to the customer’s application, proper installation and
setting up the Sequential timing of the firing of the Air-Slides is key to thethe success of the
Flow Aid System.
- Company name:
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