Modular Bulk Material Handling Layout for Fast Batch House Deployment
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Solution Overview
Problem
Conventional glass batch houses require specialized, permanent installations that are time-consuming to construct and occupy large footprints, making them inflexible and costly for smaller scale or incremental production needs.
Innovation Solution
A modular and mobile bulk material handling system that can be pre-assembled, shipped in intermodal containers, and quickly erected, utilizing pneumatically sealed conveyance and storage systems to reduce footprint and enable rapid deployment and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional glass batch houses are constructed, then reliable bulk material handling and storage is achieved, but construction time becomes excessively long (one to two years) and footprint becomes too large (about 5,800 square feet)
Solution Approach 1:
The bulk material handling system is divided into separate functional modules including receiving modules, storage modules, and dispensing modules that can be independently constructed, tested, and assembled. This modular segmentation enables parallel construction of different modules, significantly reducing overall construction time while maintaining system reliability through standardized interfaces and proven module designs.
Solution Approach 2:
Modular components are pre-assembled and pre-tested at the equipment fabricator's facility before being shipped to the installation site. This preliminary action allows for quality control and system integration to be performed in advance, reducing on-site construction time and ensuring reliable operation from the moment of installation without requiring lengthy commissioning periods.
2Reliability
If conventional glass batch houses are constructed, then reliable bulk material handling and storage is achieved, but the large footprint (about 5,800 square feet) occupies excessive factory space
Solution Approach 1:
The system transitions from a conventional horizontal spread layout to a vertical stacked configuration where receiving modules, storage modules, and dispensing modules are arranged in multiple levels. This dimensional change allows the same functional capacity to be achieved in a much smaller footprint by utilizing vertical space, reducing the ground area occupation while maintaining reliable bulk material handling through gravity-assisted material flow between levels.
Solution Approach 2:
Components and subsystems are nested within each other to maximize space utilization. For example, conveyors are routed through existing structural elements, utilities are integrated within module walls, and equipment is positioned to minimize clearance requirements. This nesting approach enables reliable bulk material handling functionality to be packed into a compact footprint without compromising operational reliability.
3Quantity of substance
If conventional glass batch houses are constructed, then bulk material storage capacity is achieved, but the system becomes difficult to relocate and lacks flexibility for different production scales
Solution Approach 1:
The storage system is segmented into multiple independent silos and storage modules, each capable of operating autonomously or in combination with others. This segmentation allows the storage capacity to be scaled by adding or removing individual modules rather than relocating an entire fixed installation, providing flexibility for different production scales while maintaining adequate bulk material storage capacity through modular expansion.
Solution Approach 2:
The system incorporates movable components including relocatable modules with standardized mounting systems, adjustable conveyors, and flexible piping connections that can be reconfigured for different locations and production requirements. This dynamic design enables the bulk material handling system to be relocated and adapted to various production scales without requiring complete reconstruction, while maintaining storage capacity through modular reconfiguration.
4Loss of time
If modular bulk material handling systems are used, then construction time is reduced and footprint is minimized, but system complexity increases due to modular assembly requirements
Solution Approach 1:
Standardized interfaces and universal connection systems are implemented across all modular components, allowing the same connection methods, fastening systems, and alignment procedures to be used throughout the assembly process. This universality reduces assembly complexity by eliminating the need for component-specific procedures, enabling rapid installation while maintaining the construction time benefits of modular design through consistent, repeatable assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system supports efficient production with a significantly reduced footprint and volumetric envelope, allowing for rapid construction and easy relocation, and is adaptable to various production scales without the need for permanent, large-scale installations.
Implementation Method 1
receiving bulk material and pneumatically conveying the bulk material via at least one of pressurized dilute phase, pressurized dense phase, hybrid dilute/dense phase, or vacuum draw conveyance
Implementation Method 2
storing the bulk material in the bulk material containers, dispensing the bulk material from the bulk material containers
Data Source
AI summary
A bulk material handling method includes: a) receiving and pneumatically conveying bulk material via pressurized dilute phase, dense phase, and/or hybrid dilute/dense phase, and/or vacuum drawn conveyance into bulk material containers; b) storing the bulk material in the containers; c) dispensing the bulk material into a bulk material transporter; d) transporting the transporter to a bulk material transmitting vessel; and e) discharging the bulk material into the transmitting vessel, including releasing the bulk material from the transporter into the transmitting vessel, and pneumatically transmitting the bulk material to downstream bulk material processing equipment. A method of constructing a bulk material handling system includes pre-assembling modules of the bulk material handling system at an equipment fabricator, shipping the modules of the pre-assembled system from the fabricator to a product manufacturer using intermodal freight containers, and erecting the pre-assembled system from the modules at the product manufacturer.