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Whirl Air Flow

Whirl Air Flow, the “Grand Daddy” of Dense Phase Conveying is a recognized leader in the supply of all types of pneumatic conveying systems. System integration, conservative design and their unique Air Assist technology make Whirl Air Flow an excellent value.

Offering all types of pneumatic conveying systems allows WAF to specify the correct system for you. Offerings include:

  • Turnkey Systems
  • Dense Phase Conveying
  • Dilute Phase Conveying
  • Transporters/ Blenders
  • Silos
  • Dust Collectors
  • Control Systems

Design, Fabrication, Testing, Commissioning

  • In-House Specialty Fabrication - Whirl-Air is one of the few bulk material handling companies actually building the physical equipment in an ASME Certified fabrication facility. When fabrication is complete, Whirl-Air provides complete assembly. In addition, we provide custom machining and heat stress relieving.
  • Custom Fabrication - With a full in-house fabrication facility, Whirl-Air can sub-assemble prior to shipping, saving considerable installation cost. Advance sub-assembly also reduces start-up time, as equipment is thoroughly checked out prior to installation.
  • Testing Facility - Whirl-Air boasts a fully functional test lab facility, featuring dense and dilute conveying as well as air blending. With over 55 years experience in the industry, Whirl-Air has tested a vast range of products and materials. This Whirl-Air experience is invaluable, allowing us to determine how products of varying consistencies will behave, when used in various conveying methods.
  • Field Support - Whirl-Air field technicians can oversee your project through installation, start-up and run-in. As your needs change, Whirl-Air field personnel can assess the applicability of your system to new products, rates and configurations, recommending appropriate courses of action.
Kaolin Clay System

Complete Kaolin Clay System

Aeration System

Aeration System to Promote Kaolin Flow

Kaolin Batch Transporter

Kaolin Batch Transporter

Weighs each batch and conveys to mixer

WAF Blender

Blending Transporters

Low velocity, High pressure system. Pressure or Vacuum. This design is typically used to minimize wear or to minimize product degradation. 

In operation an inlet and vent valve open to fill the transporter. When a high level indicator is reached, the inlet and vent valve are closed. The transporter is pressurized, from 15-80 psig. When the downstream line pressure is overcome material begins flowing down the conveying line at a low velocity. 

Air Boosters are used to separate the product flow, creating “slugs” of product, and aid in conveyance to the destination. WAF’s booster injects air directionally forward and circumferential to provide the best dispersion possible. Our system requires only one product conveying pipe and one source air pipe to provide dependable conveyance.

Conveyance is completed once the pressure in the transporter reaches approximately 5 psig, as this indicates that the transporter and the conveying line are empty. The inlet and vent valve are then opened and the sequence is repeated.

Options:

  • Batching Transporters. Often the transporter will be weighed and used as a weigh hopper. The transporter will be filled to the appropriate weight and then conveyed with a very high degree of accuracy.
  • Blending Transporters. With the addition of Whirl Air Flow’s Aeration Cone this same material, volumetric or weighed amount, added can be blended, within the transporter, before being conveyed.
  • Continuous Systems. When continuous dense phase conveying is required two transporters are used in an alternating fashion. While one conveys the second unit fills. This provides the benefits of low velocity conveying with a continuous feed stream.

In operation, either one or two railcars are unloaded to a common receiver/transporter. When the vessel is full, the system will pressurize and convey the material to the selected silos. During the pressure delivery side of the system the vacuum system continues to unload the railcar. Systems of this design generally unload at a rate of 45,000 to 55,000 pounds per hours.

The System requires no pits and provides high unloading rates for fragile materials. The system operates at 29.9" Hg., while maintaining low line velocities.

WAF Dense Vac System
Dilute Phase Conveying

Dilute Phase Conveying

Flue Gas De-Sulfurization (FGD) System

Conveying Reactant into Gas Steam

High velocity, low-pressure system conveys the product in suspension of the gas stream. Pressure or Vacuum. Dilute phase pneumatic conveying is the most common pneumatic conveying system.

A typical system will consist of a positive displacement blower package and a rotary airlock or venturi eductor. The airlock or eductor meters product into the air stream. The product is kept in suspension and conveyed with a much higher air to material ratio.

Vacuum systems work in a similar fashion although a filter receiver is generally required at the destination. Vacuum is preferred when “zero tolerance” standards are in place for emissions. 

As the conveying stream is continuous dilute phase is the obvious choice for FGD systems. 

FGD Systems1
WAF Bin Vent

Whirl-Air manufactures a comprehensive line of pulse-jet dust collection systems specifically designed for pneumatic conveying applications. High vacuum and ASME coded filters are designed and built for ratings up to 30" Hg and 100 PSIG.

All Whirl-Air Dust Collectors are shipped completely assembled with bags and cages or cartridges installed. The units are pre-piped and pre-wired and include bottom mounting ring, hardware and bag safety grating.

The Weigh-Veyor accurately weighs single or multiple free-flowing ingredients into a combination scale mounted transporter. The transporter then pneumatically conveys the weighed product(s) to one or more destinations. The Weigh-Veyor design allows direct connection to the silo or hopper.

Weigh  Veyor

Stage One Operation
Ready to begin cycle. Weigh scale is at zero. Inlet pinch valve (A) & vent valve (B) are closed. Internal space is atmospheric pressure.

Weigh  Veyor2

Stage Two Operation
Inlet pinch valve (A) & vent valve (B) are open and outlet pinch valve is closed on signal. Air #1 is on. Material is admitted until target weight is achieved. Valves A & B close.

Weigh  Veyor3

Stage Three Operation
Outlet pinch valve is opened, Air #2 is on and material is conveyed to receiving point until zero weight is achieved, assuring complete transfer.

  • Flue Gas De-Sulphurization Systems - Removal of SO2, SO3, SO4, and Mercury
  • Fiberglass Plants
  • Cement
  • Foundry
  • Steel

To visit Whirl-Air-Flow on the Web, click on www.whirlair.com.

To visit Fox Valves on the Web, click on www.foxvalve.com.

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