Production reliability and the working environment in cooperation
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BRUNITEC® Local filter
Local filters for better overall economy – ®
BRUNITEC -Local filters have been produced to be able to eliminate in a simple and economical way overpressure as well as the problems of dust and spillage that often occur when loading and reloading conveyor belts. They can also be used with advantage for the ventilation of silos, cyclones, chain conveyors, screws etc. where overpressure and dust occur.
In many cases this system can replace expensive and complicated central ventilation units where extensive ducting is required that is connected to each suction point The filters are designed as a standard system, are simple to install on existing conveyor belts and are completely adapted to BRUNITEC®-Transfer Point Enclosure. Low power consumption and simple maintenance result in low running costs. Furthermore reliability increases as several independent filters are used compared to a central filter system where a single fault in the central unit leads to all the suction points being put out of action.
Filter housing – The filter housing is divided into two chambers. One functions as a pressure reservoir for cleaning the filter sleeves. The other is the suction chamber. Pipes go from the pressure reservoir and come out at the holes for the filter sleeves. The membrane of the filter cleaning valves seals the rear end of the pipes. When a valve is activated, the accumulated compressed air is emptied very quickly via the pipe and out through the filter sleeve, which expands releasing the layer of dust that has accumulated.
The cleaning is in other words mechanical using compressed air. One sleeve at a time is cleaned so as not to create an overpressure in the transfer point enclosure. The fan sucks continually even during cleaning, which means that the filter sleeves expand along their whole length.
Many advantages – BRUNITEC®- Local filter is a simple and effective system that requires little rebuilding and can be adapted to the condition prevailing in each installation. They are installed lying down, for example on the transfer point enclosure where there is a low installation height. This is a major advantage when taking into account the often cramped space above the conveyor. The low height means that the filters are also easy to fit in other situations. Their low weight also eliminates the need for complicated support constructions. The large area of the opening facing the conveyor means the speed of the air flow is low, which reduces wear on the filter material as well reducing the risk for dust explosions.
The connection unit is fitted on the sides or above the filter housing depending on where the fan needs to be fitted. There is a damper in the connection unit for adjusting the amount of air. A safety valve is located on top of the filter housing where the compressed air and differential pressure meter are also fitted. The safety valve is preset and sealed at 1.2 bar. This pressure may not be exceeded under any circumstances! Measurement of the differential pressure is carried out by a connection to the dirty side of the filter via a hose and a bushing inside the tank as well as to the clean side via a bushing to the suction chamber.
Atex – BRUNITEC®-Local filters can be supplied for installation in zone 21 and 22 and on equipment with zone 20 inside.
BRUNITEC® Local filter
Filter enclosure – The filter enclosure is made of aluminium-zinc coated steel sheet, the sides are 2 mm thick and the lid 1.5 mm thick. The enclosure is also available in stainless steel for installation in aggressive environments. The enclosure is 2,400 mm long for local filter 4:2.350 with a 600 mm extension for model 4:2.950. The enclosure is bolted onto the filter housing and sealed with an end plate. The lid is fastened with an eccentric lock and sealed with a self-adhesive strip. Fan – The fan is a medium-pressure fan with a capacity of 1600m3/hr at a differential pressure of 1KPa. It is powered by a 1.5kW, 400V/50Hz motor with a nominal current of 3.8A. It can either be fitted directly onto the connection unit or separately with a hose between the connection unit and the fan.
Automatic system for filter cleaning – Operation with 4 outputs for the filter cleaning valves. Supply and operational voltage is 24 - 240V/50 - 60Hz Impulse time 0 – 0,5 seconds. Rest time 1: 0 - 180 seconds. Control of sleeve cleaning is normally interlocked with the equipment on which the filter is mounted and the sleeves are either cleaned continually using a timer or by a differential pressure sensor. The control is fitted in an IP 65 steel box and is supplied with a console for wall fitting.
Fitted on site – BRUNITEC®-Local filter is supplied unassembled. The plate enclosure and filter sleeves with baskets are supplied ready for assembling on site. The fan and connection unit are also supplied unassembled to be fitted according to the conditions at the site. The filter housing on the other hand is supplied with the filter cleaning valves fitted and has been tested for air tightness and operation before delivery. Assembly, installation and commissioning are carried out according to the instructions supplied with every filter.
Filter model
Capacity at 1 KPa
Air consumption at 30 secs. interval
Wegith incl. enclosure
Filter area
Fan motor power
4:2.350
1250 m3/h
2,2 m3/h
105 kg
3,6 m2
1,5 kW
4:2.950
1600 m3/h
2,2 m3/h
120 kg
4,5 m2
1,5 kW
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Filter sleeves and baskets – The filter sleeves can be supplied in a wide variety of qualities for different applications. They are fastened to the filter housing by sliding over a round flange and then fastening with a clamp. The sleeve basket is fitted with a stainless steel fully threaded rod in the bottom for hanging and stretching through the enclosure’s end plate. The baskets are normally made of untreated wire but galvanised or stainless steel baskets are available.
Belt cleaning system
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Clean belts - lower running cost A clean belt is one of the basic conditions for safe and smooth operation. Brunitec Engineering has long experience of belt cleaning and the system has been developed based on many years close contact with our customers. The system contains components that can either be used separately or in combination. Pre- and secondary cleaners can for example be combined for cleaning in two or more steps. We have put in a lot of effort in making the tensioners easy to use and reducing the need for constant adjustment. Products from our belt cleaning system together with our spillage handling system completely eliminate problems with carry-back spillage.
Secondary Cleaner - BRUNITEC®- Secondary
Tensioners, mounting accessories
Cleaner is normally mounted under the drive pulley so that the material cleaned off falls down the chute. The cleaner can also be placed outside the chute. In that case, a straight restrain idler is needed to keep the belt flat and tensioned. The blades work at an angle of approximately 90° to the belt surface. There are no arms or the like where material removed can accumulate and lower the efficiency of cleaning.
BRUNITEC®- Secondary Cleaners is supplied with a selfadjusting pneumatic tensioner that keeps the cleaner in constant contact with the belt irrespective of changes in tension. If compressed air is not available the screw tensioner is used. The brackets for this are the same as for the pneumatic tensioner. Mounting brackets that facilitate installation are supplied together with the tensioners
Pre-cleaner - BRUNITEC®- Pre-Cleaner is mounted direct on the drive pulley, under the point where the material leaves the belt.
Every cleaning element consists of a stainless steel holder, a loose flexible polyurethane spring and a scraper blade. The scraper blade, a thin, wear resistant tungsten carbide blade copes easily with very tough materials. The cleaning elements are bolted to a flange frame that allows every element to be individually adjusted to the shape of the belt. It is also possible to adjust the flexibility to avoid the risk for vibration against the belt.
There are two types of blades, one for the majority of abrasive materials and one that is very efficient with sticky and damp materials. The blades are mounted in stainless steel holders that slide onto the frame. There are no bolts or surfaces where material can accumulate. The pre-cleaner is supplied with a compact and simple tensioner and mounting brackets for easy installation.
Belt cleaning system Pound Idler - BRUNITEC®- Pound Idler is the best
special cleaner for belts that are very hard to clean, or for conveyors where the chute design does not allow installation of a secondary cleaner. The drum scraper is installed in the same position as a pre-cleaner. Due to its design the belts have to be in good condition and be correctly spliced.
solution for cleaning cleated or patterned belts that cannot be cleaned by scrapers. The idler is installed instead of a return-support idler. The pound segments raise and lower the belt at high amplitude and frequency that results in a “pounding” effect that cleans the belt very effectively.
In return, the performance is excellent with, for example, very abrasive materials. The thin tungsten carbide blades is mounted on stainless steel holders and bolted to the same type of frame as for the secondary cleaner. The flexible rubber elements take care of unevenness in the belt or material built-up on the drive pulley. The drum scraper is supplied with the same type of tensioner and accessories as the pre-cleaner.
The pound idler is sturdily designed to handle the forces and SKF flange bearing units are used for the shafts. The pounding segments slide onto an RHS profile and are locked by screws for easy replacement. The pound idler combined with the BRUNITEC®Spillage Conveyor for transport of carry-back spillage to the transfer chute is the best solution for spillage problems from cleated as well as standard belts.
Universal and effective systems BRUNITEC®- Belt Cleaning System can be used in all situations where carry-back spillage is a problem. It provides high efficiency, reduces the need for spare parts and reduces the total cost. The system is suitable for all common belt widths.
Brunitec Engineering AB, P.O. Box 48, SE-235 21 Vellinge, Phone +46 40 44 32 80, Fax +46 40 44 32 11 info@brunitec.se
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Drum Scraper - BRUNITEC®- Drum Scraper is a
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FIRE DAMPER A fire or dustexplosion inside or around a belt conveyor can cause severe consequences to both equipment and buildings as well as form a considerable risk for staff in the plant. The course of the fire is often very rapid due to a number of factors.The availability of flammable material is large, enclosed conveyors create a strong chimney effect which accelerates the course of the fire, spillage and dust that has been lying and dried out swirls up and easily ignites.The conveyor belt itself is normally highly inflammable and hard to extinguish. You can find a number of potential ignition sources. For example heat from bearings, hot surfaces on motors or friction heat that can ignite dust layers. Other examples are sparks or heating of foreign objects from crushing or milling, spontaneous combustion in organic material spilt around conveyors or backfire from a boiler.
BrunitecŽ Fire Damper As fires spread quickly, sprinklers are insufficient for protection of conveyors and buildings. One active measure is to the riskarea and another is to eliminate sources of ignition and efficiently survey the system in order to quickly prevent the appearance and spread of fires. Isolating risk areas is accomplished by sectioning of buildings and conveyor walkways. Belt conveyors are difficult to section off because of their design. Brunitec’s unique solution creates a seal despite the shape of the belt. The fire damper can, for example, be located between a boiler building and a fuel preparation area or store area. In combination with our monitoring and preventive protection solutions or controlled by existing monitoring systems, the BrunitecŽ fire damper offers a considerable increased level of safety and minimises the consequences of a fire or dust explosion.
powerful aircylinder. The explosive effect of the air flow from the air cannon blows the material off the belt and at the same time helping the damper to close rapidly. The gate is pressed against the belt, presses the middle part against the lower part and is fixed in the closed
Operation The damper consist of side sections, one fixed and two moving parts. The lower part acts as a counter support for the middle part and gate. The middle part is hung on springs and has enough distance to the lower part in the open position to allow the return part of the belt to pass without scraping off carry-back material. The distance between the gate and belt is sufficient for the height of the material. The gate and middle part run in guides on the side sections. An aircannon is placed at the top of the damper. The air cannon pipe orifice is inside the gate which has slots in the bottom against the belt. When the damper is activated the air cannon blasts at the same moment as the stamp is pushed down by a
position by spring-loaded air cylinders. The passage in the wall is now completely closed and secured. When closing, the fire damper does not damage the belt in any way. This is a major advantage that also allows regular testing thus confirming that the system works.
FIRE DAMPER Monitoring and control
air supply. If the operation has to be guaranteed even in the event of a pressure drop, a small accumulator vessel is installed to supply the air cylinder. The operation of the belt conveyor should be interlocked to the damper position. This is normally accomplished by output signals from the control unit in the basic package. The belt conveyor is stopped when the damper is activated or moves because of a fault.
Examples of installation
Installation The fire damper is designed to suit most types of belt conveyors. The damper is often clamped inside the conveyor frame. If for any reason it is not possible to place the damper in direct contact with a fire wall it can be supplied with fire insulation enclosure panels. The fire damper should be connected to a compressed
Brunitec Engineering AB, P.O Box 48, SE 235 21 Vellinge, phone +46 40-44 32 80, Telefax + 46 40-44 32 11 info@brunitec.se
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We offer a number of alternative solutions for monitoring and preventive protection systems integrated with the control of the fire damper. It is of course also possible to partly or completely control the damper by existing monitoring systems or manually from the control room. The choice of monitoring system should be based on a risk analysis taking into acount properties of the material being handled, risksources and the layout. The systems are divided in four packages that can be used separately or together in different ways depending on the conditions. The basic package contains one control unit and two water extinguishing zones, one in front of and one after the fire damper. The extinguishing zones increases the effective sectioning time at a fire by cooling the area around the damper and eliminating small sparks, embers or flames that can slip through the sectioning area. The control unit controls the fire damper and the solenoid valves in the extinguishing zones and handle the necessary output signals to the plant PES as well as input signals from monitoring systems. The simplest form of surveillance consists of a heatdetecting cable placed over and along the conveyor. The cable signal unit is connected to the control unit provided in the basic package for activation of the fire damper and extinguishing zones. Next package contains two flame detectors that are installed in the conveyor or conveyor walkway in front of and after the fire damper. The detectors react to and identify open flames or embers but are insensitive to static light sources and daylight. The fourth packge contains ember/flame detectors and a water extinguishing zone with nozzles. The system is fitted in the conveyor loading chute to minimise the risk of hot particles, embers or sparks entering the conveyor. Based on the information from the detectors the control unit closes the damper or just activates the extinguishing zone. The actions taken depend on the number and energy content of the particles that pass the detectors.
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FIRE DAMPER - Preventive protection and control To ensure safe operations, increase overall safety and simplify the installation of the BRUNITECÂŽ Fire Damper we offer four different solutions for control, monitoring and extinguishing. Depending on the premises and requirements these can be combined or used separately to achieve the desired level of safety. We do also supply extended preventive solutions based on the same technology to improve plant safety even further.
Basic package
Supplementary package 1B
The basic package consists of one CUE control unit and two water extinguishing zones, one placed in front of and the other after the fire damper. Each zone uses three WNS75Q water nozzles controlled by one RV20 solenoid valve per nozzle. The nozzles have snap connections and flexible water hoses for easy maintenance and testing of the installation. The CUE control unit handles output signals to the fire damper pneumatic case, water extinguishing zones and plant control and monitoring system (CMS) for process stop, interlocking, fault alarm and confirmation. The CUE also handles input signals from the fire dampers position indication. The control unit can, for example, be connected to an existing fire monitoring system, directly to existing detectors or to detectors in our supplementary packages and to existing plant CMS for signals that will activate the fire damper.
Contains four GD flame/ember detectors and one extinguishing zone with six WNS90QC waternozzles controlled by one RV20 solenoid valve per nozzle. The detectors are placed in the loading chute of the conveyor where the material has been falling freelyfor at least 300 mm before it passes the detectors. The extinguishing nozzles are installed at minimum of 500 mm underneath. If individual hot or glowing particles are spotted by any of the detectors the extinguishing zone will be activated instantly, normally for two seconds. At a frequency above programmed level, RISK RATE, the extinguishing zone in the chute is activated at the same time as the fire damper and the zones in the basic package. The process is stopped.
CUE
CUE
Supplementary package 1A Contains two FD flame detectors that are installed over the conveyor in front of and after the firedamper and sectioning wall. The detectors identify open flame and dangerous particles but are insensitive to daylight and static light sources. The two extinguishing zones are activated and the fire damper is closed at the same time as the belt stops when levels above the programmed Risk Rate are detected. This solution guarantees that fire will be detected on both sides of the fire sectioning. CUE
Supplementary package 1C The simplest form of monitoring. A heat detecting cable is installed over and along the conveyor. The cable detects increases in temperature and is connected to an S-TLD signal unit. An alarm signal to the CUE control unit closes the fire damper and activates the extinguishing zones when the temperature exceeds the set level. C CUE C C
FIRE DAMPER - Preventive protection and control Detectors
Control unit CUE
CUE
The control unit is the heart of the protection, extinguishing and control system. The unit is installed close to the process section to minimise cable lengths. The unit has an integrated processor, log, battery back-up etc. The operator’s interface is user friendly with a large LCD display and simple menu presentation. The communication with the existing plant control system is accomplished by switching alarm contacts and full data communication. The CUE processes information from monitoring systems and controls and monitors the fire damper and extinguishing zones.
min and the angle of spread 110° at 6 bars. The solenoid valves is supplied with a flexible metal hose for the water supply and cable with plug-in contacts.
Accessories The extinguishing system requires a sufficient flow of water and continiuos pressure to be effective. In supply systems with variations in flow and pressure we can offer a hydropress unit to ensure reliability. If there is risk for freezing we can supply complete heating cable systems with control units and alarm signal for the CUE. All packages contain mounting accessories such as weld rings and nipples, water filter, main valves, flexible hoses and cables for connection of solenoids and detectors to the control unit.
Nozzles and valves The full cone water jets have snap connections with cotter pin to a welding nipple. The capacity is 75 or 90 l/
Brunitec Engineering AB, Box 48, 235 21 Vellinge, telefon 040-44 32 80, Telefax 040-44 32 11 info@brunitec.se
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The detectors are of a well-proven infrared type. The ember/flame detector is specially adapted for detection in flowing materials and both counts and measures energy content of sparks, hot (black) or glowing particles. Flames are also detected. The detector has seven control zones and does not give an alarm until a particle is indicated in three zones and has passed the centre of the detector. This provides a high safety margin against disruption and makes it possible to adjust and control the measures taken to eliminate a source of ignition according to the actual risk. All the logic needed for signal processing and calculations is built into the detector. This solution guarantees the fast reactions needed. The FD flame detector reacts to glowing energy, both static and moving. All detectors are supplied with cable with plug-in contacts.
Transfer point enclosure
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Reduced dust and spillage from transfer points - lower running cost A large amount of spillage and dust from conveyor belts is caused by transfer point enclosures that are too short and too narrow. It results in dust leakage from skirtings and openings. These problems not only lead to potential fire and health risks but they also result in considerable costs for cleaning up. Brunitec Engineering has developed a standardised solution for the loading zone of the conveyor. The system guarantees enough volume for material and air, deflects the material from skirtings and provides the best skirting solutions. The enclosure system is adapted for good access and ease of service. Combined with the BRUNITECÂŽ - Local Filter this will give you problem free loading and transport in your conveying system.
Enclosure - BRUNITECÂŽ
- Transfer Point Enclosure is built from a number of standardised and prefabricated components. The enclosure sides, lids and backing plates for skirting are made of aluminium-zinc coated steel sheet. Fixing components are cast in aluminium or bronze for Eex requirements. The enclosure can be supplied in stainless steel for extremely corrosive environments or where hygiene regulations demand that the system can be
cleaned by water. As standard the enclosure sides are 2.4 m long. A backing plate designed for the skirting system is bolted to the side. Inside, there is an adjustable deflector or wear plate, as standard these are made of aluminium-zinc coated steel sheet but can be supplied in stainless steel or other wear resistant materials.
The deflector plates protect the skirtings from direct material pressure and centre the material on the belt. The lids are fastened by eccentric locks that allow easy access for cleaning, inspection and adjusting of the deflector plates.
The enclosure sections are bolted and clamped to the conveyor frame by support legs with adjustable cast fasteners. Bolting is used instead of welding for all assembly and installation. The downtime needed for installation is extremely short. The height of the enclosure is chosen from the standard measurements according to the belt width and the trough angle to achieve the correct volume. Belt speed, capacity and material characteristics determine the length of the enclosure.
Skirtings BRUNITEC® - Transfer Point Enclosure can be supplied with two types of skirting.
for dry, fine and dusty materials. The skirting consists of a brush strip, wrapped in rubber, fixed in a steel profile that forms a very close and wear resistant labyrinth seal.
The brush skirting is mounted on the backing plate by adjustable clamps. Brush skirtings can also be installed on existing enclosures by welding on a special mounting plate to which the backing plate fits. In many cases a deflector plate is also needed to avoid direct material pressure to the skirting.
made of stainless steel. The rubber strip is kept in place by the spring force and a T-bar. The clamp locks securely without any moving parts or locking. The rubber strip can be adjusted by lightly tapping it towards the belt without opening the clamps. The T-bar grips into the rubber and prevents the belt from lifting it up. Changing the rubber strip is quickly done by opening the clamps, removing the worn rubber, sliding the new strip in and locking. The clamps are mounted to the backing plate by one bolt. BRUNITEC®- Skirt Clamps can also be installed on existing enclosures by welding a special mounting plate to which the backing plate fits.
Completely enclosed conveyors The BRUNITEC®- System 2000 for totally enclosing conveyors consists of a BRUNITEC®- Transfer Point Enclosure with a BRUNITEC®- Local Filter, apron or sheet steel covers and a BRUNITEC®- Spillage Handling system. This provides a completely dust and spillage free conveying system. It meets ATEX requirements regarding risks for fire and dust explosions.
Brunitec Engineering AB, P.O. Box 48, SE-235 21 Vellinge, Phone +46 40 44 32 80, Fax + 46 40 44 32 11 info@brunitec.se
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Brush skirting - BRUNITEC®- Brush Skirting is suitable
Skirt clamp - BRUNITEC®- Skirt Clamps are completely
Spillage handling
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Automated spillage handling lower running cost All conveyor belts generate a certain amount of carry back spillage. Costs for cleaning up is often high and the risks for those who have to carry out the work are considerable. In many cases material accumulating around conveyors means extra risk for fires and also mould and other hygienic risks when handling organic materials. Spillage also reduces the working life of bearings and other components in the conveyor system. Brunitec Engineering has developed a system to handle spillage from conveyor belts continuously during operation. The system can be applied to the whole length of the conveyor or at loading and unloading points where the
volumes of spill are greatest. When mounted at the drive end, the material is normally reintroduced to the flow in the transfer chute, while at the loading zone it is lifted back to the belt by our spillage hoist. The spillage conveyor and spillage hoist are extremely compact, allowing them to be mounted on the majority of existing conveyors.
Spilllage conveyor - The BRUNITECÂŽ- Spillage
Drive station - As standard, the drive is a shaft
Conveyor is based on a modular system consisting of transport components as well as drive and tensioning stations. Each section is 1500 mm long and 295 mm high. The width is adapted to the actual belt width and conveyor frame. On very long conveyors several spillage conveyors can be placed in series. The construction is completely made of stainless steel.
mounted gearbox with a 2.2 kW motor. The speed of the conveyor is 0.14 m/s.
Chains and chain supports - The conveyor chain is specially designed to manage splinters and the like without problems. The chain links have a generous fit against the sprocket wheels thus eliminating the risk for the conveyor jamming.
The conveyor should be run intermittently at intervals that are just long enough to handle the volume of spill that is generated. This increases component life and minimises the need for maintenance.
Tensioning station- The tensioning station is available in different designs. As standard it is delivered with screw tensioners on both sides. An accessory allows the tensioning of both chains from one side, an advantage when the conveyor bridge is mounted close to a wall for example. The chains are easily extended or shortened without tools. Both the upper and lower parts slide along their whole length on sturdy oak supports. The result is minimal wear and low noise levels as the flights are not in direct contact with the bottom of the conveyor.
The automatic tensioner keeps the chains correctly tensioned using a friction clutch and a screw jack that are actuated by the chain flights. The initial tension is set by a crank on one side of the conveyor. The automatic tensioner can be supplied with a monitor and alarm to indicate when the chain needs shortening.
Spillage handling Mounting accessories - We have a number of
Spillelevator -
The BRUNITECÂŽ- Spillage Hoist is used for lifting the material from the spillage conveyor back to the belt when spillage from the loading zone is handled separately. It can also be used on very long conveyors where it is not possible to cover the whole length with one spillage conveyor or where for some reason it is not possible to unload into the transfer chute.
The hoist consists of a sturdy lower part where the material is fed in. The lower part is bolted and connected to the drive station of the spillage conveyor. The compact, vertical channels are bolted to the lower and upper parts and take up little space laterally. The upper part has chain sprockets in the corners and tensioning wheels in the middle. The material is unloaded through a chute in the centre onto the belt. The hoist is driven by a 1.5 kW shaft-mounted gear motor. The chains are of the same type as used in the spillage conveyor. The hoist is completely made of stainless steel. The upper part and vertical channels have loose covers for inspection and maintenance.
Spillage evaluation - Brunitec Engineering has methods and tools to measure volumes of spill and how they are distributed along the conveyor. With that information we can easily evaluate the length and location of spillage conveyors to give the best results for the investment made.
Brunitec Engineering AB, P.O. Box 48, SE-235 21 Vellinge, Sweden. Phone +46 40 44 32 80, Fax +46 40 44 32 11 info@brunitec.se
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standardised hanger mounts, protection and covering plates etc. that provide fast and easy mounting. Bolt assembly of all parts eliminates the need for welding.
Belt cleaning - The spillage handling system offers the best opportunities for efficient belt cleaning as a number of belt cleaning devices can be placed for example in transfer chutes without worrying about space restrictions. Material cleaned off falls into the conveyor and is transported back to the main flow. The cleaning of cleated belts is especially effective when using the BRUNITEC ÂŽ pound idler/s placed above the spillage conveyor. (see the Belt cleaning system product sheet).