The Vortex Dust Control Skirt is intended for open loading applications. It is constructed from heavy, durable neoprene rubber. Rather than flaring the skirt from a common piece of neoprene rubber, each flared section is a stand-alone neoprene rubber strip. Each strip of rubber is overlapped to prevent pathways for dust emissions to atmosphere. By flaring larger, the Vortex Dust Control Skirt is able to fully encompass the peak of the material pile, to better contain fugitive dusts.
Power of Comparison:
Alternative loading spouts offered by the industry are specifically constructed for use in either an open or enclosed loading application. For clients that require both open and enclosed loading from a single source, those spout designs limit their capabilities – and often require the purchase of two loading spouts. To address this issue, Vortex offers an optional detachable Dust Control Skirt. By including this option, a spout can be supplied with an outlet scavenger to accommodate enclosed loading applications; then, to properly equip for open loading applications, the Dust Control Skirt can be attached along the upper perimeter of the outlet scavenger. Because of this capability, a Vortex Loading Spout can serve dual purposes.
A dust collection system is able to collect the majority of fugitive dusts generated during the loading process. However, once loadout is complete, trace amounts of material and dusts may remain within the spout’s outer sleeve. As the spout extends and retracts, those materials and dusts can shake loose and create material spillage and/or dusting to atmosphere. To address this in enclosed loading applications, a Self-Sealing Discharge (SSD) can be installed beneath the spout’s outlet scavenger.
By design, the Self-Sealing Discharge is simply a closure cone that extends and retracts to allow or forbid materials from discharging through the outlet scavenger. Between loading cycles, the SSD is retracted to create a “lid” over the loading spout’s outlet scavenger. As the loading spout is extended toward an enclosed truck or railcar, the SSD remains closed. Once the spout’s outlet scavenger is seated into the loading hatch, the SSD extends to allow material discharge. As the spout begins to retract out of the loading hatch, the SSD immediately closes to once again seal off the outlet scavenger.
The Self-Sealing Discharge does not require power and operates automatically, without operator command.
For open loading applications, the purpose of a material level-sensing device is to automate the spout retraction process. In doing so, material level-sensing devices prevent material build-up in the spout, eliminate the need for visual monitoring throughout the loading process, and avoid vessel overfilling.
For enclosed loading applications, the purpose of a material level-sensing device is to detect product level within the vehicle. Once detected, several actions can be initiated, depending on a facility’s preferred level of automation. There are several types of material level-sensing devices. Each performs exactly the same function; they are simply alternatives to one another. However, certain loading circumstances call for certain material level-sensing technologies.
In enclosed loading applications, a Tilt Probe is mounted beneath the outlet scavenger so that it can be lowered into the loading hatch. As materials fill near the top of the vessel, the Tilt Probe will come in contact with the material pile and gradually begin to tilt. Once the probe is tilted to approximately 16°, several actions can be initiated, depending on a facility’s preferred level of automation. Options range from visual indication (via lights) to automated halt of material flow and automated spout retraction – all the way to upstream process control.
In open loading applications, a Tilt Probe is mounted at the outlet scavenger. The outlet scavenger and the Tilt Probe are typically separated by a Vortex® Dust Control Skirt. As the material pile grows beneath the Dust Control Skirt, the Tilt Probe gradually begins to tilt. When used in tandem with an Auto-Raise System, once the probe is tilted to approximately 16°, it triggers an automatic, incremental retraction of the spout as materials continue to discharge. Once the specified load is achieved, the Tilt Probe can be synchronized with the process gate (or belt conveyor) above to automatically halt material flow before the spout is fully retracted.
Both Vibratory Probes and Pneumatic Probes are primarily used when handling lightweight and/or fine dry bulk solid materials.
Similar to a tuning fork, a Vibratory Probe puts out a consistent vibration frequency throughout the loading process. When contacted by the material pile, the probe’s vibration frequency is altered.
Alternatively, with a Pneumatic Probe, a sensor head applies an air stream throughout the loading process. When the sensor head is covered by the material pile, it creates back pressure.
In either case, in enclosed loading applications, this triggers an auto-command to the process gate (or belt conveyor) above to halt material flow. This prevents vessel overfilling and triggers an automated spout retraction process.
In open loading applications, either probe is often used in tandem with an Auto-Raise System. Once the probe’s signal is altered, this triggers an automatic, incremental retraction of the spout as materials continue to discharge. Once the specified load is achieved, the probe can be synchronized with the process gate (or belt conveyor) above to automatically halt material flow before the spout is fully retracted.
Rotary Paddle Probes are primarily used in enclosed loading applications – and more specifically, in tandem with a Self-Sealing Discharge (SSD). When applied in this way, the Rotary Paddle Probe is mounted below the SSD’s closure cone and is protected by a metal housing. A Rotary Paddle Probe consists of a paddle which continually revolves throughout the loading process. As materials fill near the top of the vessel, the paddle will come in contact with the material pile, causing its revolutions to slow or cease. This triggers an auto-command to the process gate (or belt conveyor) above to halt material flow. This prevents vessel overfilling and triggers an automated spout retraction process.
The Vortex Manual Material Sampling Unit allows a small material sample to be manually extracted as materials pass through the spout’s outlet scavenger. This provides a final test of product quality at the point of loading. *Contact us to discuss automated material sampling options
Mounted along the outlet scavenger. To conclude the loadout process, vibrators can continue to be run briefly to encourage residual materials to fall away from the spout’s outer sleeve and down into the load, prior to spout retraction.
Mounted beneath the outlet scavenger. The purpose of a spin loader’s disc-shaped vane is to evenly disperse lightweight materials over a large surface area.
For enclosed loading applications, a Vortex® Loading Spout can be supplied with optional Hatch Adaptors.
Common scenarios for a Vortex Hatch Adaptor include:
• If a facility is loading trucks and/or railcars with non-standard loading hatch configurations. Vortex Hatch Adaptors are custom-designed to match the unique hatch(es).
• If a Vortex Loading Spout is sized to meet a client’s load rate capacity requirements, but that spout size is intended for filling vessels of a different size. Example: To meet a client’s load rate capacity requirements, a Vortex VES-25 Loading Spout is supplied. Standard outlet scavenger size for a VES-25 Loading Spout is 16 in | 405 mm. Typical loading hatch size for a truck is 20 in | 500 mm, while typical loading hatch size for a railcar is 30 in | 760 mm. To compensate for the sizing differences, Vortex Hatch Adaptors ensure a Vortex Loading Spout’s proper fit into larger hatch sizes.
Vortex Hatch Adaptors are available in either round or rectangular options. Rectangular Hatch Adaptors are intended to address environmental issues when loading railcars that contain elongated loading hatches, also known as “trough hatches.” Its purpose is to confine airborne particulate generated during the loading process.
How it works:
Once a loading spout is lowered atop a railcar, the rectangular Hatch Adaptor fully covers the railcar’s rectangular opening. When used in tandem with a dust collection system, the rectangular Hatch Adaptor effectively closes off the opening to foster a strong and consistent air withdrawal throughout the loading process. Along the perimeter of a rectangular Hatch Adaptor is a Vortex Dust Control Skirt. The neoprene rubber skirt prevents pathways for dust emissions to atmosphere.
Put simply, a remote control pendant is a handheld push-button device. Remote control pendants enable automation by allowing loading spout operators to guide the spout into position using programmed controls. Such commands include auto-extend, auto-raise, auto-material start, auto-material stop, full-extension and full-retraction, among others. For safety reasons, remote control pendants are attractive because they allow spout operation to be performed away from hazardous catwalks; walkways; and the tops of trucks, railcars, barges and ships.
For enclosed truck and railcar applications, Vortex Loading Spouts can be equipped with a Spout Caution System. This includes a flashing overhead light which works in tandem with an audible alarm system. The purpose for both is to inform the loading spout operator and the truck driver or railroad engineer that the spout is not fully retracted. This reduces the risk of damaging the spout, truck or railcar, as a result of premature pull away.
How it Works: When the loading process is complete, the process gate above is closed or the belt conveyor becomes idle. Once material flow is halted, a relay switch sends an electrical transmission to the Spout Caution System to initiate the flashing overhead light and the audible alarm system. The beacon and horn systems run throughout the spout retraction process, which typically lasts 5 – 10 seconds.