As Published in Dry Bulk Magazine

1. How can conveyor systems meet the specific individual needs of dry bulk operators?

Vortex Aero Slide Conveyors are custom designed for each project to meet specific operational demands. For example, they excel in handling lightweight, fluidizable dry bulk materials like cement, fly ash, and gypsum. Their flexibility allows for tailored configurations, such as varying slopes and lengths, ensuring optimal flow rates and efficient material transfer that cater to the unique needs of dry bulk operators.

2. What are some recent developments in conveyor technology?

Recent advancements in conveyor technology include improved porous media materials, integration with automation systems like PLCs, and enhanced durability features. Vortex Aero Slides utilize a non-woven, polyester porous media that resists wear and tear better than traditional woven fabrics, which reduces downtime. Additionally, Vortex systems incorporate smart technology to enable unmanned 24/7 operations, further enhancing efficiency.

3. How can conveyor systems deal with particularly dusty, flaky, or powdery bulk materials?

Vortex Aerated Equipment is specifically designed for dusty and powdery materials. Aerated systems use downward gravity and low-pressure, dry air to fluidize materials, allowing them to flow seamlessly. Dust collection vents and inline compact filters ensure dust-tight operation, containing fine particles and reducing environmental hazards. This maintains safety and compliance while being cost-effective.

4. How are conveyor systems adapting to new technologies like AI and the Internet of Things (IoT)?

Conveyor systems, including Vortex Aero Slides, are beginning to incorporate AI-driven monitoring and IoT-connected devices to provide real-time feedback. Systems like the Vortex VALS System integrate smart sensors, cameras, and PLCs to monitor operational flow, detect anomalies, and automate adjustments. These advancements not only improve material flow precision but also allow for predictive maintenance, reducing unplanned downtime.

5. Can you provide a case study of a recent conveyor project at a port, terminal, or mine, listing any challenges that arose and how you faced them?

Spring Hill Cement Terminal Project

• Scenario: Vortex installed Aero Slide systems at a cement terminal with four silos, each holding 2,500 short tons, to transfer cement at 500 TPH.
• Challenges:
• Material compaction led to "ratholing" in the silos.
• Dust and maintenance were concerns.
• Solutions:
• Installed Aero-Troughs and Bin Bottoms to fluidize materials effectively, eliminating ratholing.
• Implemented inline compact filters to manage dust and return it to the vessel.
• Integrated a Positive Displacement Blower for consistent airflow.
• Outcome:
• The system operates 24/7 with automated control, loading multiple trucks daily without interruptions.

6. What can be done to address noise reduction in dry bulk conveyor systems?

Vortex Aero Slide Conveyors are designed with low-pressure blowers, which are quieter compared to high-pressure alternatives. The placement of centrifugal blowers away from the conveyor system further reduces noise levels. Additionally, the absence of moving parts in the systems significantly minimizes operational noise, making them ideal for environments where noise control is critical.

7. How do you adapt your services for abrasive or corrosive bulk materials?

For abrasive or corrosive materials, Vortex uses durable construction materials such as stainless steel and needled polyester porous media. Options like stainless steel media grates and protective coatings enhance resistance to wear and chemical damage. Custom modifications, including cleanout ports and reinforced structures, ensure that the equipment lasts longer in harsh conditions.

8. What monitoring and automation options are included in your conveyor systems, and how do these features improve operational safety?

Vortex Aero Slides can be equipped with advanced PLC-based automation systems, such as the VALS System. This system incorporates cameras, safety switches, and real-time monitoring to ensure seamless, automated operations without the need for human intervention. Additionally, control sensors like capacitance, vibratory, or rotating paddle probes can be integrated into the system to monitor material flow and overall system performance, providing enhanced oversight and efficiency.

To further improve safety and efficiency, Vortex systems include retractable self-sealing spouts and shut-off valves, which help prevent spills and ensure safe handling of materials. For processes requiring added protection, lump traps can be installed inline with the Aero Slide. These devices effectively catch lumps that could disrupt the flow or cause issues further downstream, ensuring smooth operations and protecting the end user of the material.

9. What is your approach to sustainability—both in terms of the environment and the longevity of your conveyor systems?

Environmental sustainability at Vortex is achieved by designing conveyors that are dust-tight to the atmosphere, reducing environmental impact. Additionally, conveyors are energy-efficient, requiring only a single power source (e.g., centrifugal blowers). For product longevity, the systems feature durable materials, easy maintenance access, and design elements that minimize wear, ensuring a life cycle that outlasts traditional conveyor systems.

By addressing these areas, Vortex Aero Slides continue to lead innovation in the bulk materials handling sector while maintaining operational efficiency and safety.

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Article Contributors:
Kyle Langley (Author) started with Vortex as a Sales Application Specialist before transitioning to Marketing. Adam Schrage who has an esteemed engineering background in Loading Systems also contributed to this article and is the Technical Sales Manager for Vortex Loading Solutions.