A major distributor of fine granular soda ash required a compact, high-capacity system to transfer product from railcars to trucks at a Pennsylvania transportation hub. B.W. Sinclair Inc. designed and installed a 90° Z-Flow Vertical Flexible Sidewall Belt Conveyor delivering 250 short tons per hour in a dust-tight enclosed system engineered for continuous industrial service.
The Challenge
Soda ash (sodium carbonate) is a fine granular material at approximately 63 lbs/cu. ft., presenting significant dust and containment challenges in transfer applications. The client needed a system that could:
- Transfer material from low-level railcar discharge to elevated truck loading height in a single compact unit
- Achieve 250 short tons per hour (227 metric tons per hour) throughput capacity
- Provide dust-tight operation throughout to meet facility environmental requirements
- Fit within the physical constraints of an existing transportation hub infrastructure
- Deliver long-term reliability with minimal maintenance interruption
The B.W. Sinclair Solution
B.W. Sinclair supplied a Model 0660-90Z Flexible Sidewall Belt Conveyor: a 60-inch wide belt with a 90° Z-flow configuration providing 150 feet of vertical lift on a 60 HP drive. The Z-flow design allows the conveyor to transition from horizontal feed at the railcar discharge to vertical elevation and back to horizontal discharge into the truck loading spout — all within a single continuous belt system.
System Specifications
Model: BWSi 0660-90Z, 90° Z-Flow Configuration
Belt Width: 60 inches
Vertical Lift: 150 feet
Drive Power: 60 HP
Capacity: 250 STPH (227 MTPH) of fine granular soda ash (~63 lbs/cu. ft.)
Enclosure: Totally enclosed, dust-tight construction
Discharge: BWSi Model 1036SB6-EL Electric Two-Way Diverter Valve to two storage silos
Key Engineering Features
Dust Containment
The conveyor is totally enclosed for dust-tight operation throughout its full 150-foot run. BWSi Cam-Lock™ quick-access inspection and cleanout doors are positioned at key locations for routine maintenance without compromising the sealed enclosure.
Fine-Particle Belt Design
The belt features special stainless steel side-wings in each conveying pocket, preventing fine soda ash particles from migrating back to the next pocket. This is a critical design requirement for fine granular materials that would otherwise bypass the sidewall containment. SINCLAIR flexible sidewall belts use a unique combination of fiberglass cross-rigid plies with high-strength rubber construction; the sidewall compound uses fiber-loaded materials for superior performance and service life.
Controlled Feed
An electromechanical vibrating feeder meters soda ash into the horizontal inlet section at a controlled rate, guaranteeing efficient pocket loading and ensuring a clean material transition at the lower horizontal-to-vertical deflection point.
Belt Cleaning & Monitoring
- BWSi 0660-BBS Belt Beater. An independently powered eccentric roll removes residual material from belt pockets after discharge.
- Belt alignment, zero speed, and plugged chute instruments. All pre-installed at factory before shipment.
Corrosion Protection
All mild steel external surfaces were commercial blast cleaned (SSPC-SP6) and coated with a three-part epoxy system for long-term corrosion resistance in the outdoor Pennsylvania environment.
Result
The B.W. Sinclair Z-Flow Flexible Sidewall Belt Conveyor provided the client with a compact, high-capacity, dust-controlled transfer solution within the footprint constraints of the existing transportation hub. The system’s factory-pre-installed monitoring instruments and quick-access maintenance doors reduce downtime during routine service.
Equipment Used
Flexible Sidewall Conveyors, Diverter Valves, Slide Gates, Belt Conveyors and Feeders, Conveying Layout System Design
