Matrix Engineering was asked to help solve material storage problems due to the hygroscopic nature of Carbopol. Matrix provided the mechanical engineering necessary for designing a new bin vent and DRY nitrogen purge arrangement that vented the hopper only when necessary and cleaned the filter bags only when dirty. Matrix also provided a bin discharging aeration system for eliminating and/or preventing bridging problems. In addition, Matrix provided the control sequence and electrical engineering necessary for operation of the bin vent and aeration discharge system in a Class I Div 2 Group D and G environment.

Matrix Engineering performed the mechanical and electrical design for the relocation for an existing steam spray dryer head tank. Space was so limited, we had to mount it tank on the ceiling...

Matrix Engineering performed the mechanical, electrical and control system design for a central vacuum system for primary handling of coal dust. The system has over 50 hose pick-up points in 2 different zones with over 250 ft convey distance required. We designed a 2” hose system at 14” Hg for maximum performance.

Matrix provided the mechanical design for custom design of a sanitary u-bend at the bottom of an existing spray dryer. The u-bend had to be dis-assembled and cleaned frequently for product changeovers. Our sanitary design allowed for quick and easy cleaning by rolling back half the u-bend on a track and rotating the other half on a pivot bearing. Not only did the tool-less design provide ease dis-assembly and assembly, but it also provided a superior o-ring seal over the previous arrangement. This is extremely beneficial for a vacuum system handling a glue-like powder that is seeking moisture. Our design substantially reduced product build-up between cleanings and allowed viewing of operation and status with a properly positioned viewport and light.

Matrix provided the structural, mechanical and electrical engineering required for the production of a new leavening powder in an existing process. Major modifications were required to an existing air blending and conveying system and a new separate dust collection system was required to avoid cross contamination between the different products. The dust collection systems for these products was very sophisticated. Simultaneous operation was required for on both collectors for the packaging of one product while another was being produced. This simultaneous operation had to be accomplished with cross contamination adding a high element of complexity to the control system. Matrix provided the engineering for a new control system for the blending, conveying, packaging & dust control system. Matrix also provided total commissioning/start-up support for this system. There were also considerable spatial constraints for introducing this new product to a well established process area. However, we were able to squeeze our new production surge hopper between existing storage and packaging bin to utilize existing blending and dense phase systems.

Matrix provided the structural, mechanical and electrical engineering required for a 3500 cfm fugitive dust collector in a Class I Div 1 environment. The dust collector provided central dust collection for several packaging systems as well as a specially designed hood for an adjacent air pallet unloading station.

Matrix provided the civil, structural and mechanical engineering necessary for designing a lime drying and pulverizing facility with a through-put of 75 tons per hour. The design required a re-furbished rotary kiln dryer fed by a weigh belt and large capacity screw conveyors with a bucket elevator feeding a 65 ft tall milling and screening structure. The mill was a 200 hp hammermill and vibratory screens and an air separator segregated the lime into two different products with an overs recycle back to the mill. A gas solids injector (GSI) screw pump (or "fuller" type pump) pneumatic conveyor was sized to deliver 60 tons per hours to two different storage silos. Matrix also provided all of the engineering necessary to properly vent and collect dust off all of the process equipment. A 7500 cfm dust collector was used along with a carefully designed network of collection ductwork to prevent duct clogging. We re-used an existing 18,000 cfm dust collector for the rotary kiln dryer. This provided a challenge since the collector was over 90 ft away from the dryer. A 30" dia grasshopper duct was designed originating from the dryer discharge up to the top of the 65 ft mill structure and back down to the dust collector in the existing process area. The duct angles were kept in excess of 50 deg. to prevent product fall-out and line clogging.

Matrix Engineering provided the structural and mechanical design for dust collection on an existing truck loading system for Texas Lime in Cleburne Texas. The truck loading facility consisted of (2) retractable loading spouts which required adequate collection to prevent dusting when filling trucks. Two 1000 cfm dust collectors where installed on newly designed platforms with fans above the existing product silos for independent operation of each truck loadout from the ground.