High Temperature Screw Feeder for Metering Abrasive and Corrosive Bulk Materials
General Description
BDI in Independence, Ohio partnered with KWS to supply a replacement screw feeder for Zircoa, a leading manufacturer of advanced zirconia-based materials. The application required metering a proprietary bulk material containing trace amounts of hydrochloric acid into a furnace operating at temperatures exceeding 1,200-degrees F. The existing screw feeder experienced material leakage due to an inadequate seal design and was not optimized for the corrosive and high temperature environment. Zircoa required a robust, reliable solution that would eliminate leakage, improve safety, and ensure consistent metering into the furnace under continuous operating conditions.
Redesigned Tail End Assembly Eliminates Bulk Material Leakage
Design Parameters
- Product Type: Proprietary Zirconia-Based Material with Trace Hydrochloric Acid
- Material Density: 75 Lbs. per Cubic Foot
- System Capacity: 1,500 Lbs. per Hour
- Duty: 24 Hours per Day, 7 Days per Week
KWS Advantages
KWS collaborated closely with the engineering teams at Zircoa and BDI to evaluate the shortcomings of the original feeder and develop a superior design. Our engineering team reviewed the corrosive properties of the material and the extreme thermal conditions associated with the furnace interface. By upgrading critical components and redesigning the sealing arrangement, KWS delivered a screw feeder capable of withstanding both chemical attack and elevated temperatures. Detailed engineering drawings and design reviews ensured seamless integration with existing upstream and downstream equipment, resulting in a smooth installation and immediate performance improvements.
KWS Special Features
The screw feeder was constructed using materials selected specifically for resistance to corrosion from trace hydrochloric acid while maintaining structural integrity at elevated temperatures. Special consideration was given to thermal expansion to prevent binding and premature wear under continuous high temperature operation.
A primary improvement over the original unit was the redesigned tail end seal assembly. The previous seal allowed material leakage during operation, creating housekeeping and maintenance concerns. KWS engineered a heavy-duty split gland seal incorporating high temperature Fiberfrax packing. The split gland design allows for ease of maintenance while providing uniform compression of the packing material. Fiberfrax packing was selected for its ability to withstand both the corrosive characteristics of the proprietary bulk material and the elevated temperatures generated by the adjacent furnace.
The screw feeder was also designed to meter the bulk material consistently into the 1,200-degree F furnace, ensuring stable process control and protecting downstream equipment. Reinforced construction and precision alignment minimized deflection and maintained sealing integrity over time. The result is a robust, leak free screw feeder engineered for one of the most demanding bulk material handling environments.
Customer Testimonial
“KWS worked closely with our team to redesign this feeder and address long standing leakage issues. The new unit is performing exactly as intended in a very challenging environment.”
Project Engineer, Zircoa
Screw Feeder Meters Bulk Materials Consistently at 1,200-Degrees F
