BULKFLOW TECHNOLOGIES INC.

About Bulkflow Technologies

Bulkflow Technologies Inc. was formed in 1999, but the company`s patented heat exchanger technology was created almost 20 years ago in 1986. An engineer at the Cominco Fertilizer (now Agrium) plant near Calgary, Alberta, Canada was inspired to come up with a better way to cool granular fertilizer and the Bulkflow Heat Exchanger was born. The technology combines zero emissions, lower energy consumption and lower capital costs with exceptional results.

The Better Way to Heat or Cool Powder and Bulk Solids

Cominco Engineering Services Ltd. marketed the innovative heat exchanger until 1999 when a group of employees got together and bought the technology from Cominco, forming a new company called Bulkflow Technologies. From its initial application with cooling fertilizers, the concept has been expanded for heating or cooling powders and bulk solids in a wide variety of industries, including sugar, detergents, plastics and chemicals. As a result of ongoing development and testing, the Bulkflow Heat Exchanger technology has now been successfully installed in more than 200 locations worldwide. 

The backbone of the company is an experienced team of people who have been involved in the development and application of the technology from its inception. Bulkflow has a full-time staff of 12 people in North America and four based in Europe, supported by a large network of consultants, service providers and suppliers.

Engineering Standards

Engineering is the strength of the company. The first step is to fully understand our customer`s needs. This covers many topics including process and operating requirements, upstream and downstream conditions, physical location, and potential operating hazards. A clear definition of each of these topics is developed with the customer and this forms the basis for the design of the Bulkflow Heat Exchanger. At all times we strive for close communication with our customers.

Bulkflow`s project engineers are based in Calgary and dedicated to the successful translation of our customer needs into a fully functioning piece of pressure equipment. Rigorous design; compliance with international codes and standards; close partnership with selected fabricators; detailed customer documentation and operating manuals; on-site commissioning and post commissioning activities are all necessary steps to ensure a successful project.

Quality Control Requirements

Bulkflow Technologies is committed to meeting the most relevant quality control guidelines, wherever it operates around the world. The company adheres to the American Society of Mechanical Engineering`s (ASME`s) codes for pressure vessels, a universally recognized guideline for manufacturing heat exchangers and other equipment. The company also meets the requirements of the Pressure Equipment Directive (PED), an alternate set of guidelines used primarily in Europe. Where ATEX (Atmosphère Explosive) approvals are needed, the company is able to meet those requirements, as well.

With each new piece of pressure equipment, Bulkflow`s engineers follow a customized Inspection and Test Plan (ITP). The plan calls for testing and inspection against more than 35 different criteria in several categories. Company engineers assure compliance at every step in the process, from early in the design phase through to installation and commissioning. Bulkflow also monitors each new installation to ensure ongoing high quality performance.

Research and Development Creates Opportunity

Bulkflow Technologies owes its success to the courage and vision of its founding employees. These same qualities continue to guide the company as it explores new opportunities for further growth within its area of expertise. Bulkflow`s engineers are currently researching pressure equipment designs to handle very high temperature products (in the range of 1000º Celsius). There is also interest in capturing the enormous amount of energy that is wasted when handling high temperature products. The company is looking at ways of recovering energy for cost savings and improved environmental performance. As energy prices increase worldwide, the motivation for improved energy efficiency has never been more evident.

Bulkflow is also exploring the use of indirect heat in the drying process. This promises to dramatically improve the energy efficiency compared to conventional dryers where a hot air stream provides the energy required to heat the product and evaporate the water. Conventional air dryers often have energy efficiencies of less than 40 per cent with the highest energy losses to the stack. In comparison, the Bulkflow dryer will add heat to the process indirectly through heat transfer plates using hot water or steam as the heat transfer fluid that can easily be re-circulated to minimize losses. Air is still required to remove the moisture but quantities are much lower. The result will be a high efficiency dryer.

Bulkflow Heat Exchanger Technology

Bulkflow Heat Exchanger: How It Works

The Bulkflow Heat Exchanger heats or cools powder and bulk solids by combining a welded plate heat exchanger with mass flow design.

The equipment includes a vertical assembly of welded stainless steel heat exchanger plates called the ``plate bank,`` and a mass flow discharge feeder mounted below the plate bank. Free-flowing bulk solids pass slowly through the vertical channels between the heat exchanger plates. Heat transfer fluid flows inside the welded stainless steel plates to heat or cool the material as it passes through. A control system maintains product level in the inlet hopper for even distribution during operation.

Mass Flow of Powder and Bulk Solids

The product moves slowly through the equipment to achieve uniform heating or cooling. The heat exchanger plates are spaced to ensure reliable flow. With our mass flow design, all of the material is in motion with uniform velocity over the full cross-section of the heat exchanger. A specially designed discharge feeder is mounted below the plate bank to control the discharge rate of the product and to achieve mass flow through the pressure equipment. This results in a ``first-in-first-out`` sequence, an important element in the design of the Bulkflow Heat Exchanger.

Heating or Cooling: Powder and Bulk Solids

For cooling, water or glycol heat transfer fluid is circulated through the heat exchanger plates. For heating, steam is commonly used, but hot water or thermal oil can also be used effectively as a heat transfer fluid. For maximum efficiency, the heat transfer fluid flows counter-current to the product flow. The vertical configuration of heat exchanger plates provides a large heat transfer surface in a compact unit. Unlike rotary drum or fluid bed processors where air is in contact with the product, this indirect method of heat transfer maintains product quality while eliminating the need for costly air handling equipment.

Multiple plate banks can be mounted in a single piece of equipment. This configuration operates with a higher thermal efficiency by offsetting the heat exchanger plates in each bank.

In warm climates with high relative humidity, low volume dry air is injected to prevent condensation. This reduces the dew point of the entrained air inside the heat exchanger.

Mass Flow Discharge Feeder

The Bulkflow Heat Exchanger is engineered with a mass flow discharge feeder that regulates the product feed rate through the equipment. The discharge feeder is mounted directly below the plate bank and material is fed uniformly over the entire cross section of the heat exchanger.

There are a number of alternative discharge feeders that can be selected, depending on the flow characteristics of the material: the vibrating feeder, mass flow hopper and gate feeder.

Bulkflow Heat Exchanger Technology: Plate Bank, Control System

Bulkflow Heat Exchanger Plates

The heat exchanger plates are fully welded, require no gaskets and are available in stainless steel and other corrosion-resistant alloys to suit the process conditions. To make the plates, two panels are laser or resistance welded together in a preset pattern of spot welds. Perimeter and pass seam welds are completed followed by installation of the welded inlet and outlet tube connections. Weld discoloration is removed by pickling.

The welded plates are hydraulically inflated under controlled conditions to provide uniform corrugations, or dimples. These dimples create turbulent flow inside the plate resulting in efficient heat transfer. The heat exchanger plates have a low profile with smooth and uniform heat transfer surfaces exceptionally resistant to fouling.

Bulkflow Heat Exchanger: Plate Bank

The finished heat exchanger plates are installed in a stiffened casing with access doors to allow easy cleaning and inspection. The connections to the pipe manifolds are made on the exterior of the casing with flexible stainless steel hoses. The completed assembly is then hydrotested before shipping.

Each Bulkflow Heat Exchanger is designed to suit the customer`s specific application. The spacing between the plates is determined by the particle size and flow characteristics of the product. The number and size of the heat exchanger plates is calculated using a sophisticated heat transfer model based on the properties obtained from laboratory and pilot testing of the powder or bulk solids to be used.

Bulkflow Heat Exchanger: Control System

The Bulkflow Heat Exchanger employs a simple, yet effective level control system. The inlet hopper distributes incoming product evenly into the heat exchanger plate bank, forming a conical pile. The bulk solids then pass slowly through the plate bank with sufficient residence time to obtain the specified product temperature. The discharge feeder regulates the product flow.

For continuous operation, the control system varies the rate of the discharge feeder to maintain a preset level in the inlet hopper. For batches, the Bulkflow Heat Exchanger can also operate between high and low level switches maintaining the product level above the heat exchanger plates.

Product temperature is typically measured at the inlet and outlet of the heat exchanger. Recirculating or modulating the temperature of the heat transfer fluid controls product temperature.

Lab Testing for Bulk Solids, Mass Flow Testing and Design, On-Site Pilot Testing

Lab Testing for Bulk Solids

Bulkflow Technologies has fully equipped lab facilities to evaluate bulk solids. Product samples are tested with the following objectives:

• To evaluate the heat transfer properties and flow characteristics of the bulk solid;
• To determine the optimum plate spacing for the heat exchanger plates; and
• To assess the most effective type of discharge feeder.

Bulkflow determines the rate of heat dissipation for a layer of bulk solid material by using thermal conductivity testing. The measured value is used to determine the required heat transfer area for the Bulkflow Heat Exchanger.

The material sample is tested to determine particle size distribution, bulk density, moisture content and angle of repose. Mass Flow testing is performed in a clear test unit fitted with heat exchanger plates that are spaced at different intervals.

Test samples should be representative of the range of bulk solids to be handled by the equipment. Material Safety Data Sheets must be included with the sample, in accordance with government regulations.

Mass Flow Testing and Design

Solids Handling Technologies Inc. provides mass flow testing and consulting services to Bulkflow Technologies. Joe Marinelli is a bulk materials handling expert active in testing bulk solids and consulting on the design of bulk materials handling systems since 1972. Previously a consultant with Jenike & Johanson, he has years of practical experience testing bulk solids as well as designing feeders and hoppers for reliable flow.

Material flow property tests are done with a Jenike Shear Tester to determine wall slopes for mass flow and opening sizes to prevent bridging. The material flow properties determine the recommended feeder design.

On-Site Pilot Testing

Bulkflow Technologies has pilot testing equipment to demonstrate the operation of the Bulkflow Heat Exchanger at the customer`s plant under normal process conditions. The on-site pilot test is used to evaluate:

• thermal performance;
• product flow characteristics and heat exchanger plate spacing; and
• The operation of the discharge feeder.

The plate bank is comprised of three stainless steel heat exchanger plates with adjustable plate spacing. Material flow is observed through clear Plexiglas side panels. A variable speed discharge feeder regulates product flow through the unit. The pressure equipment collects heat transfer data during operation.

Bulkflow Technologies would be pleased to provide you with a test proposal to suit your specific application

Applications of Bulkflow Heat Exchanger Technology

The Bulkflow Plate Heat Exchanger Technology with large Heat Transfer area for Product Heating and Cooling of Bulk Solids, Powder and Granules has applications in the following areas:

Chemicals

The Bulkflow Heat Exchanger has been used effectively for heating and cooling a wide variety of chemicals. Some of these products include:

Ammonium Sulphate, Boric Acid, Calcium Chloride, Hexamine, Potassium Chloride, Potassium Nitrate, Potassium Sulphate, Soda Ash, Sodium Acetate, Sodium Bicarbonate, Sodium Bisulfate, Sodium Carbonate, Sodium Percarbonate, Sodium Formate, Sodium Hydroxide, Sodium Sulfate, Sodium Tripolyphosphate, Superabsorbent, Tetrapotassium Phosphate, Tri-Calcium Phosphate

The Bulkflow Heat Exchanger maintains or improves product quality and can replace high maintenance pressure equipment.

Fertilizers

After drying and screening, most fertilizer products need additional cooling to avoid potential caking in storage. With more than 75 pressure equipment installations worldwide, the Bulkflow Heat Exchanger is a proven, cost effective solution for cooling fertilizer products of all types including:

Ammonium Nitrate, Ammonium Sulphate, Coated Fertilizers, LDAN, NPK Fertilizer, MAP, DAP, Scotts® Turf Builder®, Triple-Super Phosphate, Urea Granules, Urea Prills

Our heat exchanger technology requires no costly air handling or dust collection equipment. The modular construction also allows for future plant expansion.

Polymers

The Bulkflow Heat Exchanger uses plate heat exchanger technology for efficient, indirect heating or cooling of polymers and resins. These polymers include:

ABS, EPR Resin, EPDM, EVOH, Nylon, PET, Polyactic Acid Pellets, Polyethylene, Polypropylene, PVC, Superabsorbent Polymer, TPU Pellets

Cooling of polymers prevents lumping in the packaging process and can be done continuously to increase production rates. Our technology can also be used for degassing or conditioning of pellets. The Bulkflow Heat Exchanger preheats resin to increase extrusion capacity.

Detergents

The Bulkflow Heat Exchanger has been used effectively for cooling detergent powders and related detergent products including:

Detergent Powder, Sodium Percarbonate, Sodium Tripolyphosphate, Trisodium Phosphate, Tetrapotassium Phosphate

Our technology can replace expensive nitrogen cooling methods and prevent the caking of product, thereby improving product quality.

Catalysts

Catalysts are typically processed at high temperatures and must then be cooled before handling and packaging. Catalyst coolers have been supplied to producers worldwide for various sizes and types of catalyst products, including:

Activated Alumina, Alumina Catalyst, FCC Catalyst, Molecular Sieve Beads, Zeolites

The Bulkflow Heat Exchanger has a large heat transfer area to cool high temperature products.

Minerals

Minerals are typically processed at high temperatures and must be cooled before packaging. Some products must be preheated to improve the process. Bulkflow`s technology has been applied to a number of minerals and other products including:

Activated Carbon, Alumina, Carbon, Catalyst, Clay, Coal, Copper Powder, Ceramic, Foundry Sand, Glass, Graphite, Iron Carbide, Iron Powder, Limestone, Nickel Powder, Resin-Coated Sand, Silica, Talc Pellets, Welding Flux, Zircon

The Bulkflow Heat Exchanger has a large heat transfer area to cool high temperature products.

Oilseeds, Grains and Food Products

The Bulkflow Heat Exchanger has been used effectively for heating and cooling various types of oilseeds, grains and other food products, including:

Animal Feed, Bird Seed, Canola, Corn Germ, Distillers Dry Grain Solids, Isomalt Crystals, Lysine, Methionine, Popcorn, Rape Seed, Rice, Salt, Soybean, Sugar

Our technology has a large heat transfer area to cool high temperature products. The product discharge is within 5°C of heat transfer medium temperature.

Sugar

After sugar crystals are dried, cooling is required to prevent caking and maintain product quality in storage. Bulkflow Technologies has supplied 10 coolers to the sugar industry since 1999 for cooling beet sugar, cane sugar and starch derivatives. The sugar products handled by Bulkflow include:

Beet Sugar, Cane Sugar, Isomalt Crystals, Starch Derivatives

The Bulkflow Sugar Cooler is recognized as a proven, cost effective solution for cooling sugar crystals.

Biosolids

Biosolid pellets are formed by drying sewage sludge to make an organic fertilizer. The pellets must be cooled before they are conveyed to storage bins to prevent smoldering and combustion.

The Bulkflow Heat Exchanger has been used to cool dried biosolids since 1992, with more than 40 units supplied worldwide. Unlike air coolers, this indirect method of cooling does not require additional dust and odor removal. The slow movement of the pellets through the equipment prevents product breakage and the generation of fines that can occur when using jacketed screw conveyors. There are few moving parts, resulting in low maintenance and operating costs.

Advantages of Bulkflow Heat Exchanger Pressure Equipment

Advantages of Bulkflow Heat Exchanger Pressure Equipment

The Bulkflow Heat Exchanger has been used effectively to heat or cool a wide variety of powders and bulk solids. The Bulkflow Heat Exchanger has a number of advantages over competing technologies:

No Emissions
The Bulkflow Heat Exchanger operates without cooling air and there is no need for costly air handling and dust collection equipment such as baghouses and scrubbers. Our pressure equipment is completely sealed and produces no emissions.

Cost Effective
The cost of installing, operating and maintaining the Bulkflow Heat Exchanger is low. Our level of energy consumption is lower than our competitors.

Compact Design
The design of the Bulkflow Heat Exchanger is compact allowing it to be installed in a small floor space. The Bulkflow Heat Exchanger allows full and easy access for inspection and cleaning.

Improved Process
Bulkflow Heat Exchanger can provide additional heating or cooling to increase plant capacity. Multiple plate banks in a series provide improved thermal efficiency.