High Temperature Injection Screw Conveyor

General Description

Climax Molybdenum, a Freeport McMoran Company, located in Fort Madison, Iowa, is one of the world’s leading producers of molybdenum and molybdenum-based products. Their processing operations require handling materials at extreme temperatures while maintaining precise control over material flow and distribution. The facility needed specialized conveying equipment capable of withstanding high-temperature environments while providing reliable performance for its critical production processes.

As a well-known industry leader, Coperion Process Solutions was selected by Climax Molybdenum to provide a rotary calciner and associated conveying equipment for a new production process. As part of the conveying equipment, the following requirements were deemed critical: The screw conveyor is to convey the material from the outlet of the loss-in-weight (LIW) metering feeder into the calciner. The screw conveyor trough should be tubular and feature a flange that would be bolted to an isolation boot or joint that would connect to the breeching of the calciner. The screw conveyor outlet can be an end discharge or bottom discharge with a cutout of the bottom of the trough at the end. Coperion Process Solutions turned to KWS as an expert in high temperature conveying solutions to design and supply the calciner feed screw conveyor.

Injection Screw Conveyor Transfers Ammonium Dimolybdate to Calciner

Design Parameters

Product Type: Ammonium Dimolybdate
Material Density: 75 Lbs. per Cubic Foot
Conveyor System Capacity: 100 Cubic Feet per Hour
Design Temperature: 400-Degrees F
Duty: Continuous

KWS Advantages

As with all KWS projects, this solution demonstrates our commitment to addressing challenging material handling problems with expertly engineered equipment. Our team’s extensive knowledge of high-temperature applications and specialized conveying requirements enabled us to develop a solution perfectly matched to Climax Molybdenum’s needs.

The success of this project further reinforces KWS Manufacturing’s position as the industry leader in custom bulk material handling solutions, particularly for demanding applications. All equipment was proudly designed and manufactured in the United States at our state-of-the-art facility, adhering to the most stringent quality standards.

Special Features

The custom injection screw conveyor was precisely engineered to handle high-temperature materials with controlled flow rates. 304 stainless steel construction has proven its value in resisting the corrosive conditions present in the facility, while the high-temperature design elements have maintained structural integrity despite the extreme thermal conditions.

The KWS design included the implementation of a Dodge SOLIDLUBE sleeve bearing. These specialized bearings feature solid graphite inserts that provide continuous self-lubrication through microscopic graphite particles that transfer to the shaft during operation. This innovative technology eliminates the need for conventional grease or oil lubrication systems that would quickly break down in high-temperature environments. The SOLIDLUBE bearings maintain optimal performance in sustained temperatures up to 400-degrees F, far exceeding the capabilities of standard bearings.

Because the tail shaft, which would typically provide rotational feedback to a sensor, is inaccessible, KWS selected the Siemens Milltronics MSP-12 motion sensing probes coupled with MFA-4p failure alarm control units to provide comprehensive monitoring capabilities for the conveying system. These sensing probes utilize a non-contacting inductive sensing technology that detects screw rotation speeds with exceptional accuracy even in the harsh, high-temperature environment. The system is configured with adjustable start-up delay timers and alarm response delays to prevent false alarms during normal operational sequences. The MFA-4p control unit interfaces directly with the facility’s automation system, triggering immediate shutdown protocols if motion falls below predetermined safe thresholds. This integrated motion monitoring system provides crucial protection against material backup and potential equipment damage, enhancing both operational safety and process reliability.