Process efficiency is further enhanced by the compact design of the system, resulting in greater productivity from less floor space.
Products well suited to double belt cooling / flaking include waxes and resins – which tend to curl away from a single belt – and refinery residues such as pitch. The process can also be used to cool thicker products, ensuring uniform discharge temperature over the whole cross section.
The closed design of the double belt system also helps to minimize the release of vapors and fumes, resulting in a cleaner operating environment.
The principle of double belt cooling / flaking systems
The IPCO double belt cooling & flaking system is a continuous process designed to solidify molten product into a solid, free flowing form.
The molten product is pumped through heated piping into the feed manifold of the double belt cooler, where it is spread evenly across the full width of the lower steel belt. The feed device also helps control the layer thickness of the molten product, which is then conveyed to the intermediate section of the double belt cooler.
Vapor released as the product is deposited is collected by an exhaust hood and – if necessary – treated before being exhausted to the atmosphere.
The molten product begins to solidify as it is sandwiched between the lower and upper steel belts. Cooling water is sprayed on the non-product side of both steel belts and the heat of the melt is transferred via the belts to the water. There is no direct contact between the product and the cooling water.
The warm water is collected in a central water tank or pit and pumped to a heat exchanger. Once cooled, it is returned to the double belt cooler, forming a closed loop cooling water circuit.
Solidification of the product layer/sheet takes place as it travels through the intermediate section of the double belt cooler. The gap between the upper and lower belt determines the final thickness of the solidified product sheet.
Once solidified, the sheet discharges the double belt cooler and flows into the product breaker assembly where it is reduced into free-flowing random sized flake particles. These are then transported to the storage system via a take-away conveyor.
The complete process is controlled by a PLC based system with local operator panels at each double belt cooling unit. To optimize performance, speed control of the conveyor drive(s) and product pump(s) is by variable frequency drives.
Up- and downstream equipment
We offer a wide choice of feeding devices and discharge methods (including breaker equipment) to suit individual product and process requirements.