3 replies to this topic

[Dumpmeadrenaline]

Hi Fellow Engineers, 

I have been tasked with a project to minimize raw material loss during handling and processing at our float glass manufacturing facility. My current focus is on minimizing sand loss. Through multiple inspections of the unit I identified the following potential sources of sand loss: unloading of sand from the bucket loader, leaks from compressed air systems used for dust extraction and control , spillage at loading points where sand is conveyed between troughed belt conveyors through chutes or from chutes onto vibration screens or hoppers, losses from vibration screens, and fine and coarse sand particles collected in waste bins from vibration screens.

 

 Quantifying intangible losses posses a challenge any ideas on how one can one estimate losses from activities such as unloading,conveyance, and dust control. 

However, Coarse and Fine particles collected from vibration screens can be quantified as they are collected in Disposal bins. Unfortunately, the company that manufactured and installed the dust control system 25 years ago is no longer in service so they cannot assist in assessing these losses.

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•  3.jpg   61.66KB   1 downloads

Edited by Dumpmeadrenaline, 23 June 2023 - 03:04 AM.

[Pilesar]

I would try to quantify by measurement and place open-top containers in strategic locations to see how much is collected over time -- similar to using rain gauges. This project may be somewhat interesting, but it would be difficult for me to document the experience for my next job 'I engineered a way to keep from spilling sand.'

[breizh]

Hi,

I would suggest you check on a yearly basis the tonnage of sand entering the facility vs the usage in the process, I guess your accounting department is monitoring the ratio sand/finished product. This is the way to get a macroscopic balance and calculate the losses.

If this is significant you may propose to invest in metering devices to follow the usage.

On a mechanical point of view, it should not be too difficult to fix some visual losses (chutes, screens, etc)

My view

Breizh 

[Dumpmeadrenaline]

I would try to quantify by measurement and place open-top containers in strategic locations to see how much is collected over time -- similar to using rain gauges. This project may be somewhat interesting, but it would be difficult for me to document the experience for my next job 'I engineered a way to keep from spilling sand.'

This is an interesting approach to estimate the sand lost. However I see a few issues with this method: The troughed belt conveyor is outdoors and is inclined upwards to a chute located on the third floor i think it may be difficult to collect the spilled sand as it can be carried away by wind leading to underestimation of spilled sand. 

Hi,

I would suggest you check on a yearly basis the tonnage of sand entering the facility vs the usage in the process, I guess your accounting department is monitoring the ratio sand/finished product. This is the way to get a macroscopic balance and calculate the losses.

If this is significant you may propose to invest in metering devices to follow the usage.

On a mechanical point of view, it should not be too difficult to fix some visual losses (chutes, screens, etc)

My view

Breizh 

Input=Consumption+ Conveyance losses+ Screening losses+ Dust leakage.

I have records of the sand procured  from weigh tickets of the sand supplied. Sand may not be immediately used for production of float glass and is instead stored in the warehouse. The weigh of sand consumed is tracked knowing the sand used per batch and the number of batches made from the load cells on scales under the Sand-silo. The consumption of sand in making float glass amounts to around (250 Ton/day) thats why a daily monitor is made because losses are indeed significant. Screening losses can be estimated by measuring the weight of waste bins containing the fine and coarse particles. The loader unloads an unknown amount of sand onto the hopper and the belt conveyors operate  (input is not known) based on the signal from the high level indicator inside the silos (the paddle stops rotating). 

Edited by Dumpmeadrenaline, 23 June 2023 - 02:32 PM.