Modular Glass Batch Handling With Sealed Pneumatic Conveying
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Solution Overview
Problem
Conventional glass batch houses are large, permanent installations that require significant construction time, occupy a large footprint, and create a dusty environment, making them unsuitable for flexible or smaller-scale glass production.
Innovation Solution
A modular and mobile glass bulk material handling system that includes prefabricated equipment configurations, eliminating the need for a basement and pit, and incorporates pneumatically sealed conveyance to minimize dust exposure, allowing for rapid expansion and reduced capital costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional glass batch house with permanent architectural installation is used, then reliable glass batch handling is achieved, but the system occupies a large footprint and requires significant construction time
Solution Approach 1:
The batch house system is divided into separate functional modules: above-ground silos for storage, modular receiving equipment for unloading, and enclosed conveyor systems for material transport. This segmentation allows each component to be optimized independently and reduces the overall footprint compared to traditional integrated designs.
Solution Approach 2:
The system transitions from ground-level pit-based receiving to elevated receiving platforms, utilizing vertical space more effectively. Silos are positioned above ground level, and materials are conveyed vertically rather than horizontally through ground-level pits, reducing the horizontal footprint.
2Reliability
If a conventional glass batch house with permanent architectural installation is used, then reliable glass batch handling is achieved, but construction time increases to one to two years
Solution Approach 1:
The system is designed as modular components that can be manufactured off-site and assembled quickly. Silos, receiving equipment, and conveyor sections can be prepared independently and installed in a standardized sequence, dramatically reducing construction time compared to custom-built permanent installations.
Solution Approach 2:
Modular components are pre-assembled and prepared in advance before final installation. The system allows for preliminary configuration of silos, conveyors, and receiving equipment, enabling rapid deployment once the site is ready.
3Productivity
If conventional open conveyors and handling equipment are used, then glass batch materials can be handled, but dust is generated creating a dirty environment
Solution Approach 1:
Enclosed conveyor systems with sealed housings prevent dust escape during material transport. The conveyors are completely enclosed with access points sealed during operation, creating a dust-containing environment that protects the surrounding area while maintaining handling efficiency.
Solution Approach 2:
The enclosed conveyor systems create a controlled environment that isolates dust-generating operations from the external environment. Negative pressure or sealed compartments prevent dust from escaping into the workspace, effectively creating a dust-free operational zone.
4Reliability
If conventional permanent architectural installation is used, then the system provides stable operation, but it cannot be relocated from one location to another
Solution Approach 1:
The system consists of discrete modular units (silos, receiving equipment, conveyor sections) that can be independently moved and reconfigured. This modularity enables relocation to different sites while maintaining operational integrity, unlike monolithic permanent installations.
Solution Approach 2:
The system transitions from a static permanent installation to a dynamic, relocatable configuration. Modular components can be assembled, disassembled, and repositioned as needed, providing operational flexibility and adaptability to changing production requirements or site conditions.
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 enables efficient, dust-free handling of glass feedstock with a smaller footprint, facilitating rapid capacity expansion and lower capital costs for smaller-scale or incremental production, while maintaining high-quality output.
Implementation Method 1
A new glass bulk material handling system includes a pneumatic bulk material conveying system with sealed conveyors for receiving, storing, and dispensing glass batch bulk materials
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
According to one aspect of the disclosure, a bulk material handling method includes receiving bulk material on a first level of a system at receiving stations equipped with dust control filtration equipment, pneumatically conveying the bulk material up to a third level into bulk material storage hoppers, storing the bulk material, dispensing the stored bulk material to a bulk material transporter on the first level, including dosing the stored bulk material to an interior of a bulk material dosing hopper to create a bulk material dose, docking the dosing hopper with the transporter via a docking apparatus, and releasing the dose into the interior of the transporter, through a reduced pressure region in an internal volume of the docking apparatus. Other disclosed aspects include a related system, subsystems, and apparatuses.