A hopper is a large, inverted pyramidal or conical container used in industrial processes to hold particulate matter or flowable material of any sort (e.g. dust, gravel, nuts, or seeds) and dispense these from the bottom when needed. In some specialized applications even small metal or plastic assembly components can be loaded and dispensed by small hopper systems. In the case of dust collection hoppers the dust can be collected from expelled air. Hoppers for dust collection are often installed in groups to allow for a greater collection quantity. Hoppers are used in many industries to hold material until it is needed, such as flour, sugar or nuts for food manufacturing, food pellets for livestock, crushed ores for refining, etc. Dust hoppers are employed in industrial processes that use air pollution control devices such as dust collectors, electrostatic precipitators, and baghouses/fabric filters. Most hoppers are made of steel.
Materials can be added either manually or automatically to the top of a hopper. For dust collection, it enters the hopper from a collection device. For example, baghouses are shaken or blown with compressed air to release caked-on dust from the bag. Precipitators use a rapping system to release the dirt. The crumbling dust falls into the hopper. Once the material in the hopper reaches capacity, it is released through an opening in the bottom with a diameter of about 8–12 inches (20–30 cm). Hoppers are rectangular or circular in cross section but have sides that slope at about a 60° angle. Slanted sides make it easier for the contained material to flow out. Conveyors are sometimes used to carry away the particulate matter. [1]
Hopper walls are often insulated to protect the outside environment and personnel from the contents. Often, the bottom 1/4 – 1/3 of the container is heated to eliminate the possibility of condensation inside the hopper. [2]
The greatest difficulty associated with the removal of very fine material, like flour or dust, from a hopper is the compaction of the material. Moisture content, particle shape and size, and vibration are all factors that contribute to compaction. Typically, with such fine materials, vibrators are installed on the outer walls of a hopper to shake and release the material, however other kinds of discharging aids can be considered if necessary. [3]
Filtration is a physical separation process that separates solid matter and fluid from a mixture using a filter medium that has a complex structure through which only the fluid can pass. Solid particles that cannot pass through the filter medium are described as oversize and the fluid that passes through is called the filtrate. Oversize particles may form a filter cake on top of the filter and may also block the filter lattice, preventing the fluid phase from crossing the filter, known as blinding. The size of the largest particles that can successfully pass through a filter is called the effective pore size of that filter. The separation of solid and fluid is imperfect; solids will be contaminated with some fluid and filtrate will contain fine particles. Filtration occurs both in nature and in engineered systems; there are biological, geological, and industrial forms.
Static electricity is an imbalance of electric charges within or on the surface of a material. The charge remains until it can move away by an electric current or electrical discharge. The word "static" is used to differentiate it from current electricity, where an electric charge flows through an electrical conductor.
Hopper or hoppers may refer to:
Cyclonic separation is a method of removing particulates from an air, gas or liquid stream, without the use of filters, through vortex separation. When removing particulate matter from liquid, a hydrocyclone is used; while from gas, a gas cyclone is used. Rotational effects and gravity are used to separate mixtures of solids and fluids. The method can also be used to separate fine droplets of liquid from a gaseous stream.
Flue-gas desulfurization (FGD) is a set of technologies used to remove sulfur dioxide from exhaust flue gases of fossil-fuel power plants, and from the emissions of other sulfur oxide emitting processes such as waste incineration, petroleum refineries, cement and lime kilns.
Sawdust is a by-product or waste product of woodworking operations such as sawing, sanding, milling and routing. It is composed of very small chips of wood. These operations can be performed by woodworking machinery, portable power tools or by use of hand tools. In some manufacturing industries it can be a significant fire hazard and source of occupational dust exposure.
An electrostatic precipitator (ESP) is a filterless device that removes fine particles, such as dust and smoke, from a flowing gas using the force of an induced electrostatic charge minimally impeding the flow of gases through the unit.
Scrubber systems are a diverse group of air pollution control devices that can be used to remove some particulates and/or gases from industrial exhaust streams. An early application of a carbon dioxide scrubber was in the submarine the Ictíneo I, in 1859; a role for which they continue to be used today. Traditionally, the term "scrubber" has referred to pollution control devices that use liquid to wash unwanted pollutants from a gas stream. Recently, the term has also been used to describe systems that inject a dry reagent or slurry into a dirty exhaust stream to "wash out" acid gases. Scrubbers are one of the primary devices that control gaseous emissions, especially acid gases. Scrubbers can also be used for heat recovery from hot gases by flue-gas condensation. They are also used for the high flows in solar, PV, or LED processes.
A silo is a structure for storing bulk materials.
A dust collector is a system used to enhance the quality of air released from industrial and commercial processes by collecting dust and other impurities from air or gas. Designed to handle high-volume dust loads, a dust collector system consists of a blower, dust filter, a filter-cleaning system, and a dust receptacle or dust removal system. It is distinguished from air purifiers, which use disposable filters to remove dust.
Acoustic cleaning is a maintenance method used in material-handling and storage systems that handle bulk granular or particulate materials, such as grain elevators, to remove the buildup of material on surfaces. An acoustic cleaning apparatus, usually built into the material-handling equipment, works by generating powerful sound waves which shake particulates loose from surfaces, reducing the need for manual cleaning.
A flue-gas stack, also known as a smoke stack, chimney stack or simply as a stack, is a type of chimney, a vertical pipe, channel or similar structure through, which combustion product gases called flue gases are exhausted to the outside air. Flue gases are produced when coal, oil, natural gas, wood or any other fuel is combusted in an industrial furnace, a power plant's steam-generating boiler, or other large combustion device. Flue gas is usually composed of carbon dioxide (CO2) and water vapor, as well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a small percentage of pollutants such as particulate matter, carbon monoxide, nitrogen oxides and sulfur oxides. The flue gas stacks are often quite tall, up to 420 metres (1,380 ft), to increase the stack effect and dispersion of pollutants.
A venturi scrubber is designed to effectively use the energy from a high-velocity inlet gas stream to atomize the liquid being used to scrub the gas stream. This type of technology is a part of the group of air pollution controls collectively referred to as wet scrubbers.
The term wet scrubber describes a variety of devices that remove pollutants from a furnace flue gas or from other gas streams. In a wet scrubber, the polluted gas stream is brought into contact with the scrubbing liquid, by spraying it with the liquid, by forcing it through a pool of liquid, or by some other contact method, so as to remove the pollutants.
Rotary feeders, also known as rotary airlocks or rotary valves, are commonly used in industrial and agricultural applications as a component in a bulk or specialty material handling system. Rotary feeders are primarily used for discharge of bulk solid material from hoppers/bins, receivers, and cyclones into a pressure or vacuum-driven pneumatic conveying system. Components of a rotary feeder include a rotor shaft, housing, head plates, and packing seals and bearings. Rotors have large vanes cast or welded on and are typically driven by small internal combustion engines or electric motors.
A dust explosion is the rapid combustion of fine particles suspended in the air within an enclosed location. Dust explosions can occur where any dispersed powdered combustible material is present in high-enough concentrations in the atmosphere or other oxidizing gaseous medium, such as pure oxygen. In cases when fuel plays the role of a combustible material, the explosion is known as a fuel-air explosion.
Industrial fans and blowers are machines whose primary function is to provide and accommodate a large flow of air or gas to various parts of a building or other structures. This is achieved by rotating a number of blades, connected to a hub and shaft, and driven by a motor or turbine. The flow rates of these mechanical fans range from approximately 200 cubic feet (5.7 m3) to 2,000,000 cubic feet (57,000 m3) per minute. A blower is another name for a fan that operates where the resistance to the flow is primarily on the downstream side of the fan.
A baghouse, also known as a baghouse filter, bag filter, or fabric filter is an air pollution control device and dust collector that removes particulates or gas released from commercial processes out of the air. Power plants, steel mills, pharmaceutical producers, food manufacturers, chemical producers and other industrial companies often use baghouses to control emission of air pollutants. Baghouses came into widespread use in the late 1970s after the invention of high-temperature fabrics capable of withstanding temperatures over 350 °F (177 °C).
Rappers are used to transmit strong shearing forces to collecting plates in order to release deposited dust particles. Rapping is the process by which electrodes and particles are broken apart by vibrations from the rappers. Often used in electrostatic precipitators, rappers relapse the caked on dust layer which then descends into a hopper. Number, size, and frequency of the rappers vary from system to system based upon the specific characteristics of the dust being collected.
Fugitive dust is an environmental air quality term for very small particles suspended in the air, primarily mineral dust that is sourced from the soil of Earth's pedosphere. A significant volume of fugitive dust that is visible from a distance is known as a dust cloud, and a large dust cloud driven by a gust front is known as a dust storm.