How has DUPUY improved the extraction of corrosive fertilizers?
Fertilizer Production and Packaging: Managing Corrosive Materials
In the fertilizer manufacturing industry, processing, handling, and packaging operations can result in material spills, leading to the dispersion of dust, granules, and residues throughout production areas.
This situation also characterized the industrial process at a company located in Greece, where the presence of corrosive fertilizers made harvesting and cleaning operations particularly challenging.
During the various stages of processing and bagging, the product could spill out of the equipment and accumulate on surfaces and in surrounding areas. Managing this residue therefore required targeted measures to keep the production areas clean and minimize manual labor.
The aggressive nature of the fertilizer posed an additional challenge: prolonged contact with the material could compromise the service life of components that were not sufficiently corrosion-resistant.
The customer therefore needed a vacuum system made of suitable materials, capable of effectively collecting the spilled product and integrating with the equipment already in place at the plant.
The goal was to develop a reliable and versatile system capable of improving spill management without disrupting the continuity of the production process.
Key Project Data
3
Integrated vacuum units
Three SILOVAC 100T units installed at critical points in the production line to collect spilled fertilizer and reduce the need for manual intervention.
100%
Stainless steel construction
Units made entirely of stainless steel to improve corrosion resistance and minimize wear and potential component replacement costs.
COUNTRY
Greece
SECTOR
Chemical Industry
APPLICATION
Industrial Vacuum Cleaning
Collecting Corrosive Fertilizers Without Damaging Equipment
The main challenge faced by the customer involved fertilizer spillage during production and packaging operations.
Spills could affect various areas of the plant, accumulating on surfaces and making cleaning and maintenance operations more difficult.
Unlike other granular materials, the treated fertilizer had corrosive properties that required special care in selecting the components of the vacuum system.
The solution therefore had to ensure effective collection of the product while also offering high resistance to the aggressive effects of the material.
Another challenge involved the distribution of collection points throughout the process. The customer needed a system capable of addressing critical areas through a fixed vacuum collection network, thereby avoiding the need to manage spills exclusively through manual operations.
It was also necessary to adapt the units to different production configurations, allowing for both the collection of material in Big Bags and direct installation on top of a silo.
The goal, therefore, was to find a solution that was durable, versatile, and easy to integrate into the existing system.
A controlled collection system designed to minimize corrosion, buildup, and manual intervention
In fertilizer production, material spills are a critical operational issue that can affect various stages of the process, from raw material processing to packaging.
When the product has corrosive properties, managing accumulations becomes even more important, as it requires the use of equipment designed to withstand contact with aggressive materials.
For the customer, the need was not only to vacuum up scattered residues, but also to have a system that would remain reliable over time and maintain its functionality even when used with corrosive fertilizers.
Another key requirement was to integrate the vacuum system directly into the critical points of the production line. A network of fixed pipes would have allowed for a more controlled collection of material, simplifying cleaning operations.
The solution also had to accommodate different methods of fertilizer handling, allowing for collection in Big Bags or direct connection to a silo.
The ultimate goal was to develop an industrial vacuum system capable of combining corrosion resistance, effective material collection, and integration with the existing process, thereby promoting greater operational continuity.
DUPUY SILOVAC 100T: Stainless Steel Industrial Vacuum System for Corrosive Materials
To meet the Greek company’s needs, DUPUY supplied three SILOVAC 100T industrial vacuum cleaners, specifically configured to handle spills of corrosive fertilizers during production and packaging operations.
The distinctive feature of this solution is its structure, which is made entirely of stainless steel—a choice made to improve resistance to corrosion and abrasion caused by the material being sucked in.
The main components that come into contact with the fertilizer—including the filter chamber, the hopper, and the butterfly valve—are also made of stainless steel, helping to ensure the system’s long-term reliability.
Each SILOVAC 100T is equipped with a 3-kW three-phase motor capable of delivering an air flow rate of 350 m³/h and a vacuum of 2,600 mmH₂O.
The project included two different installation configurations.
Two units have been equipped with a frame for unloading material into Big Bags, allowing the collected fertilizer to be handled using dedicated containers.
The third unit, on the other hand, was installed directly above a silo, integrating the extraction system with one of the pieces of equipment already present in the production facility.
A key component of the project is the network of fixed piping, designed and installed by the distributor specializing in centralized solutions.
This configuration allows for the collection of spilled fertilizer directly at critical points in the process, conveying the material in a more controlled and efficient manner to the SILOVAC units.
The combination of a stainless steel structure, various discharge configurations, and connection to fixed piping made it possible to create a solution tailored to the customer’s operational needs.
Less fertilizer buildup and greater efficiency in cleaning operations
The introduction of the three SILOVAC 100T units has enabled the customer to improve the management of corrosive fertilizer spills during production and packaging operations.
The all-stainless-steel construction allows for the processing of particularly aggressive materials, offering greater resistance to corrosion and abrasion than a design made from materials not specifically suited for this purpose.
Integration with the fixed piping network also allows for direct intervention at critical points in the system, making residue collection more effective and helping to reduce buildup on production surfaces.
The ability to configure the units for unloading into Big Bags or for direct installation on top of a silo made it possible to adapt the system to the characteristics of the existing process, without requiring an identical solution for all stations.
This flexibility helps simplify cleaning operations, improve organization in work areas, and support the continuity of production activities.
The main benefits achieved:
- Greater resistance to corrosion and abrasion thanks to the stainless steel construction.
- More effective collection of fertilizers scattered during production and packaging.
- Reduced material buildup in operational areas.
- Direct suction at critical points via a network of fixed pipes.
- Option to discharge the collected product into Big Bags.
- Direct integration of a suction unit above the silo.
- Simpler cleaning and more controlled management of spills.
- Greater system reliability to support continuous production.
The project demonstrates how a solution tailored to the material’s characteristics and the plant’s needs can improve spill management, even when dealing with particularly corrosive products.