Emulsion Plant
Emulsion Manufacturing
Tread Corporation has built many emulsion plants, our first in 1983. These units have been of varied capacities and have had a multitude of product manufacturing capabilities.
This experience has allowed us to create a modular emulsion manufacturing unit with a well–defined limit of supply. The two basic modules have separate and stand–alone capabilities. The Emulsion matrix is manufactured in the first module.
The second module is added if there is a need for the addition of glass micropheres to sensitize the product. Other solid additives can be added at this point also.
Both modules come prewired, plumbed and with all product piping in place. Other optional features can be added to either module for additional production capability. These modules are pre–run at our facility in your presence for approval prior to shipping.
The limit of supply from the site would be the following – oxidizer solution, fuel solution or salt solution, suitable 3 phase electrical power to operate a total of 70 horsepower, a 110 volt control voltage supply and suitable air supply.
Matrix
Module Blend Module Hydraulic Power Supply
I. GENERAL SPECIFICATIONS
– 500lb/minute production rate of finished product –
24 VDC 60Hz electric power
– Hydraulically driven
II. FRAME CONSTRUCTION
– Supports and frame are 3 x 3 Stainless Steel tubing
– Deck is 1/4" Stainless Steel plate
III. MATERIAL HANDLING
A. Oxidizer System
– ANSI flange
– SS suction strainer with reusable basket
– AN solution pump with adjustable internal relief
– Manually operated 3–way rotary full port valve for sam– ple/process
– Manually operated 3–way rotary full port valve for pro– cess/recycle
– Air blowdown line at pump discharge
– Digital scaleable readout for AN solution rate – Scaleable digital readout for AN solution total
– 0–250°F temperature gauge
– Isolated 0–300psi pressure gauge
B. Fuel System
– ANSI flange
– SS suction strainer with reusable basket
– Fuel oil pump with adjustable internal relief
– Manually operated 3–way rotary full port valve for sam– ple/process line– Manually operated 3–way rotary full port valve for process/recycle line
– Flowmeter with digital scaleable readout for fuel rate – Scaleable digital readout for fuel total
– 300psi pressure gauge on fuel line
– 0–250°F temperature gauge
C. Matrix Pre–Mix Tank
– 30 gallon SS jacketed tank with lid
– 0–250°F temperature gauge
– Variable speed mixer agitator
– Scaleable digital readout for mixer rate
D. Matrix Pre–Mix Pump
– Progressive cavity matrix pre–mix pump
– Tread PumpGard™ system to monitor:
– No flow of product
– Low product pressure output
– High product pressure output
– Optional auxiliary input
– 200psi SS burst disc assembly with graphite disc
– Sample port manually operated .5"SS ball valves on pro– cess line
– Sample port manually operated .5" SS ball valves on re– cycle line
– Air blowdown line at pump discharge
– 300psi gauge
– Scaleable digital readout for matrix emulsion rate
– Scaleable digital readout for matrix emulsion total
V. CONTROL SYSTEMS
A. Hydraulic System
– 6 station aluminum manifold
– Hydraulic pressure gauge for each circuit
– Main system hydraulic pressure gauge
– On/Off 24 VDC solenoid cartridge
– Relief valve
B. Air System
– Aluminum 6 station manifold
– System pressure gauge
– Non–corrosive valves and plumbing
C. Electrical System
– Control enclosure is pressurized and vented
– Ratemeter, flowmeter and totalizer inputs are intrinsically safe
Matrix Module Hydraulic Power Supply top of page
This module meters glass microspheres into a variable speed twin screw blender and is mixed with un–sensitized emulsion product. The sensitized product is then pump through a progressive cavity pump to a storage vessel.I. GENERAL SPECIFICATIONS
– 500lb/minute production rate of finished product
– 24 VDC 60Hz electric power
– Hydraulically driven
II. FRAME CONSTRUCTION
– Supports and frame are 3 x 3 Stainless Steel tubing
– Deck is 1/4" Stainless Steel plate
I. MATERIAL HANDLING
A. Blender
– Stainless steel construction
– Hydraulic driven twin paddle blender
– Jacketed for optional low pressure hot water heating
– Two piece mechanical shaft seals
– Scaleable digital readout for product rate
– Scaleable digital readout for product total
– Opening with a lid and a guard to return samples to blender
B. Microsphere Conditioning Hopper
– Aluminum construction
– Air driven stirrer
– Sight window
– Low level indicator with alarm
C. Microsphere Additive System
1. Vac–U–Max receiver
2. Microsphere pump
– Metered to blender through pump
– Pump has scaleable digital readout for microsphere rate
– Pump has scaleable digital readout for microsphere total
D. Blender Unload Pump
– Progressive cavity product unload pump
– Tread PumpGard™ system to monitor:
– No flow of product
– Low product pressure output
– High product pressure output
– Optional auxiliary input
– 200psi SS burst disc assembly with graphite disc
– Air blowdown line at pump discharge
– Scaleable digital readout for product rate
– Scaleable digital readout for product total
V. CONTROL SYSTEMS
A. Hydraulic System
– 6 station aluminum manifold
– Hydraulic flow controls for each circuit
– Hydraulic pressure gauge for each circuit
– Main system hydraulic pressure gauge
– Relief valve
– On/Off 24VDC solenoid cartridge
B. Air System
– Aluminum 6 station manifold
– System pressure gauge
– Non–corrosive valves and plumbing
C. Electrical System
– Control enclosure is pressurized and vented
– Ratemeter, flowmeter, and totalizer inputs are intrinsi– cally safe.
Matrix Module Blend Module top of page
I. GENERAL SPECIFICATIONS
– 30 HP motor with 30 GPM pump capacity– 440V 3 phase 60 cycle motor
– TEFC motor
– High temperature/low level alarms
– Oil cooler remote mounted with fan
– 150 gallon overhead reservoir
– Return filter in tank
– High pressure filter