Expansion plants / peripheral plant engineering
BUBLON systems are always designed with particular regard to the specific requirements of the customer. These vary with respect to production capacity, the target product, material supply, and integration into existing production facilities, etc. The minimum scope of supply usually includes all the plant components that are crucial for ensuring product quality, such as material dosing and supply, the actual expansion process, including the regulation of temperature and pressure conditions in the expansion furnace, conveying the product right up to transfer into silos, as well as further processing or packaging. In order to avoid process interfaces, Bublon also supplies raw material and product silos as well as bulk bag discharging and filling stations.
Bublon GmbH offers customised turn-key plants from one single source. Apart from its core technology – expansion – it covers all necessary up-stream and down-stream process steps with Group-internal products.
To this end the company has full access to over 110 years of experience of its parent company in the fields of mechanical engineering and plant construction as well as the latest technological developments that are implemented jointly with our cooperation partners.
The Bublon GmbH offers with BUBLON® systems process components and entire plants, covering both BUBLON’s core technology as well as up-stream and down-stream process steps such as crushing, screening, thermal conditioning and packaging with group-internal products.
COMEC impact crushers are used to crush different types of rock. They achieve an optimal grain shape and a low proportion of fine material, even with high flow rates. Thanks to easily adjustable impact walls, screen characteristics can be adjusted very well to individual requirements of any relevant job.
Before the down-stream screening process, the material can be improved in terms of quality by way of optical sorting, if the raw material composition should make it necessary.
The comprehensive screening machine program by Binder+Co allows using the best machine for the relevant area of application. The precise and efficient screening of difficult bulk goods is performed with the top product BIVITEC. Circular, linear and resonance screening machines are used for conventional jobs.
Drying and cooling are basic process steps in the preparation of bulk goods. Apart from constant quality of the final product, high availability of the plant and its profitable operation are vitally important factors. With DRYON, Binder+Co offers a flexibly usable technology that is known for its long service life and efficient use of energy.
Expanding – the core process of the plant
The expansion furnace is the centrepiece of the BUBLON technology. This process takes place in a vertical, well insulated tall fabric chamber made from high-temperature resistant ceramic fabric. Due to the high reaction temperatures of up to 1100°C, the expansion furnace is primarily heated with electricity, or optionally with natural gas. This ensures that the process input energy is achieved by radiation – an idea modelled on natural sunlight – and transmitted into the Perlite sand with almost 100% efficiency. Another advantage of radiation-based heat transmission is that no hot waste gas must be discharged from the shaft. This avoids investment costs for waste gas cleaning and allows significantly simpler maintenance.
The structure of the expansion furnace is modular. This means that another module e.g. to increase the output or extend the process duration of the prepared perlite in the hot area can be retrofitted at a later time.
The expansion furnace contains no moving parts so wear is minimal. Only the exposure to high temperature must be taken into account. The different heat expansion rates of the materials used is taken into account by a sandwich construction of the insulation as well as by relocating supporting parts to the outer, cooler areas.
In combination with the pneumatic conveying of fully expanded materials, the operation of the expansion furnace takes place under a slight vacuum, avoiding the emission of dust and particulate matter.
If the raw material quality should lead to an excessive proportion of non-expanded material in the final product, quality improvements are possible by way of optional air-stream sorting.
Packaging and palletizing
High speed, compact construction and various areas of application characterise the packaging technology by Statec-Binder, another Group company of the Binder+Co Group. With the simple and quick exchange of the filling clamp, PRINCIPAC ensures high availability even with varying jobs. Bag palletizing also requires speed and efficiency. Apart from the high-performance system PRINCIPAL, Statec-Binder also offers palletizing robots for smaller bag quantities.