Rethinking Airlock Technology: Aerodyne’s Solutions to the Rotary Valve Conundrum
Industrial dust problems are business problems, because dust collection is an inherent part of manufacturing. Known for being maintenance and repair money pits, rotary valves are a common source of frustration.
Common problems we notice with the average rotary valve:
- Air leaks— By design, as dust enters the material inlet and travels through the rotors, air leaks out through both the rotor pockets and the gap between the rotor tips and the housing. This disrupts airflow and reduces dust collector efficiency.
- Got power?— Rotary valves require continuous power to operate, which can create issues for manufacturing operations like mining, which often operate in remote areas where electricity is limited and finnicky at best. When every kilowatt counts, the rotary valve isn’t always ideal.
- Maintenance money pit— Because parts and motors wear out and will always need lubricated, maintained, and eventually replaced, servicing can mean full system shutdowns.
Worn out traditional rotary airlock valve
There are simpler, less frustrating solutions—solutions that Aerodyne’s engineers have designed to alleviate these issues for the maintenance managers, technicians, supervisors, process engineers, plant operators, and safety and environmental officers that deal with them.
When traditional rotary valves and their airlocks fail, the Vacu-Valve and the tougher Double Dump Valve shine.
The Vacu-Valve is a passive, gravity-based trickle valve designed for fine, free-flowing material under negative pressure systems like baghouses and cyclones. Instead of using motors or tight tolerances, the Vacu-Valve seals using vacuum pressure. When enough material builds above the sleeve, gravity gently pulls it through, maintaining a consistent flow without leaking air or jamming, common issues that come with traditional rotary valve design.
Aerodyne’s Vacu-Valve
Key Benefits:
- No motor, bearings, or electricity required
- No air leakage thanks to vacuum-sealed flexible sleeve
- Minimal maintenance—just a quick sleeve swap
- Quiet operation
- Handles up to 550°F
- Best for fine, non-bridging material
**Please note that the Vacu-Valve is not suitable for explosive environments or bulky solids.
In the right environment, this valve delivers unmatched simplicity and reliability. Aerodyne has seen particular success with the Vacu-Valve in mining operations, one of the most challenging environments for dust collection equipment. In mining, large volumes of dust, abrasive or extremely fine material, and demanding operating conditions can push equipment to its limits.
The Vacu-Valve was created with a motor free design to avoid the inevitable wear and tear failures associated with traditional rotary valves, because it can run longer and more reliably without rotors grinding against housings or seals failing.
Aerodyne’s Double Dump Valve
When applications deal with tougher dust, like chunky, fibrous, abrasive, or irregular materials notorious for jamming and wearing out rotary valves, a smarter alternative is needed. Aerodyne’s engineers designed the Double Dump Valve as a heavy-duty solution, built with an alternating flap design that keeps one of two chambers sealed while the other discharges material and provides a tight airlock that doesn’t rely on a fragile rotor clearance. Like the Vacu-Valve, the Double Dump is easy to service, but is customizable for hazardous, high temperature, or high-pressure environments.
GatorGate Double Dump Valve
Key Benefits:
- Ideal for material that would normally jam rotary valves
- Minimal air leakage with alternating chamber design
- Handles abrasive, fibrous, or large solids
- Build for rugged, high-demand environments
- Stainless-steel options available
- Easy maintenance with quick-remove doors
The Double Dump Valve uses tandem gates to maintain proper pressure above and below the valve and has a reinforced closure mechanism to prevent air seepage. This double flap valve can be configured to operate using air or electricity and requires little maintenance. It’s designed with heavy duty carbon steel fabrication, a heavy-duty gear reducer and cam mechanism, and low air leakage technology.
As the motor driven cam rotates, it actuates the upper and lower flap gates in sequences to allow the discharge of material with minimal air leakage. The unique cam-operated drive mechanism provides reliable service without the use of expensive and problematic pneumatic controls. Quick removal inspection doors provide easy access to internal components for regular maintenance. Available in a variety of sizes, this valve is a cost effective, reliable alternative for applications struggling with traditional rotary airlock valves.
This is your reminder that traditional rotary airlock valves are not suitable for every application!
If your operation is looking for a quality alternative to rotary valves, the Aerodyne Vacu-Valve is a cost-effective, simple solution built for fine, flowing materials in lower maintenance applications. In operations where heavy-duty reliability is the priority, Aerodyne’s Double Dump Valves are built to handle tough, irregular materials where jams, leaks, and wear are par for the course.
The right valve can help you eliminate air leakage (and many more!) issues at the source, and our experienced engineers are here to help you every step of the way. Call us at 440-543-7400 to schedule your free consultation today.
