Handling non-free-flowing bulk materials presents unique challenges that require specialized equipment to maintain efficiency, prevent blockages, and reduce wear and tear. Materials such as wet powders, sticky substances, and highly cohesive particles often resist gravity-fed movement, making it essential to select the appropriate bulk material handling system.
WTW Americas specializes in engineering, designing, and manufacturing equipment specifically tailored to handle sticky, wet, hot (up to 750°C), abrasive, and non-free-flowing bulk materials. Their heavy-duty, German-engineered equipment is rigorously lab-tested to ensure mass flow without issues like rat-holing or bridging.
Understanding Non-Free-Flowing Materials
Unlike free-flowing materials that move easily through standard chutes, conveyors, and hoppers, non-free-flowing materials tend to clump, bridge, or arch, leading to operational inefficiencies. Common examples include:
- Moist powders such as cement, gypsum, and clay.
- Sticky substances like certain food products.
- Fibrous materials such as wood chips and biomass.
- Highly abrasive materials like ores, minerals, and sintered metals.
Selecting the right combination of flow aids, material-specific conveyors, and wear-resistant components can significantly improve handling efficiency and reduce operational challenges.
Key Bulk Material Handling Equipment for Non-Free-Flowing Materials
1. Truck Discharge Machines (TDM)
Efficient unloading of bulk materials from transport vehicles is crucial to maintaining workflow. WTW Americas’ Truck Discharge Machine (TDM) is engineered to expedite the unloading process of materials into processing facilities with minimal civil work and without the need for costly excavation. It can handle materials delivered by trucks, front-end loaders, barges, and railcars, with discharge rates adjustable from 0 to 1,200 t/h.
2. Silo Discharge Machines (SDM)
Storing non-free-flowing materials in silos can lead to challenges like bridging and ratholing. The Silo Discharge Machine (SDM) from WTW Americas features a rotating discharge arm that uniformly extracts materials such as wet sands, clays, and mineral inputs directly from silos, ensuring consistent flow and preventing solidification over time.
3. Bunker Discharge Machines (BDM)
For reclaiming materials from stockpiles, domes, or hoppers, WTW Americas offers the Bunker Discharge Machine (BDM). It is particularly effective in managing tough-to-handle inputs like phosphate rock and wet potash, operating on rails to ensure uniform material extraction and transport to downstream processes. With reclaim rates ranging from 10 to 2,500 t/h, the BDM is ideal for scaling production in large manufacturing plants.
4. TKF Chain Conveyors
Transporting non-free-flowing materials requires conveyors that can handle stickiness, abrasiveness, and varying temperatures. The TKF Chain Conveyors from WTW Americas are designed to transport materials with high precision and minimal loss. They can operate horizontally, vertically, or on an incline, handling loads from 0 to 1,000 t/h. Manufactured using high-quality alloy steels and subjected to rigorous testing, these conveyors are built to withstand extreme conditions, ensuring long-lasting performance.
Key Considerations When Selecting Bulk Material Handling Equipment
When choosing bulk material handling equipment for non-free-flowing materials, several factors should be evaluated:
- Material Properties – Consider particle size, moisture content, and stickiness.
- Flow Challenges – Identify risks of bridging, arching, or compaction.
- Durability Needs – Select abrasion-resistant components for handling rough or highly corrosive substances.
- Operational Efficiency – Choose automation-ready designs that reduce maintenance and optimize energy consumption.
How WTW Americas Supports Bulk Material Handling Operations
At WTW Americas, understanding that every material presents unique handling challenges is paramount. Their engineered solutions help industries optimize material flow, minimize equipment wear, and reduce unplanned downtime. Whether designing new systems or retrofitting existing equipment, they provide:
- Custom conveyor and hopper designs for challenging materials.
- Wear-resistant components to extend equipment lifespan.
- Automated material handling systems for improved efficiency.
- Expert consultation to ensure the right solution for your application.
Selecting the right bulk material handling equipment for non-free-flowing materials is crucial for maintaining smooth operations and reducing costly downtime. By incorporating specialized discharge machines, chain conveyors, and abrasion-resistant components, industries can significantly improve material movement efficiency.
To learn more about how WTW Americas can support your bulk material handling needs, contact the team for customized solutions.