WO2014032116A1

WO2014032116A1 - Low density bulk material handling and storage system

Info

Publication number: WO2014032116A1
Application number: PCT/AU2013/000982
Authority: WO
Inventors: Geoff STEVENSON; Adam RIBOLDI; Peter Flynn
Original assignee: Orica International Pte Ltd
Priority date: 2012-08-31
Filing date: 2013-08-30
Publication date: 2014-03-06

Abstract

There is disclosed a mobile storage facility (10) for a low density bulk material. The facility (10) includes a container (12) having a floor (14), external walls (16) and a roof (18) that define an internal space. The facility also has ingress ducting through which bulk material enters the facility, the ingress ducting having at least one inlet pipe (20), at least one manifold (22) that is in communication with the at least one inlet pipe, and plurality of secondary pipes (24) that each extend from the at least one manifold and open into the internal space. Bulk material is discharged from the facility (10) though discharge ducting. The discharge ducting includes an outlet pipe (26) that is in communication with the internal space via apertures in the floor (14) of the container (12).

Description

Low density bulk material handling and storage system

Field of the invention

The present invention relates to a low density bulk material handling and storage system.

Background

Low density bulk materials can be conveniently transported by pneumatic conveying systems. Lean phase conveying is particular mode of pneumatic conveying in which the bulk material is entrained in a carrier gas moving at a sufficient velocity from one point to another. Lean phase conveying, which is also known as dilute phase conveying, is a continuous process that is characterized by high velocity, low pressure gas flow, and low product to gas ratios. This mode of pneumatic conveying can involve pushing and/or pulling the bulk material.

Lean phase conveying can be problematic when used in non-permanent applications, and/or outdoor environments. For example, material containment can be important due to the environmental consequences of a loss of product. In one example, expanded polystyrene (EPS) beads can be moved by pneumatic conveying equipment, in which air is the carrier gas. EPS beads have a low density (which is typically in the range of approximately 5 to 30 kg/m³), and consequently when these beads escape the handling system they are readily spread by natural wind, and can also cause slip hazards. Furthermore, EPS beads build up a static charge when conveyed pneumatically, which can result in the beads attaching to foreign objects and being transported with those objects.

Accordingly, there is a need to address the above, and/or at least provide a useful alternative.

Summary of the invention

The present invention provides a mobile storage facility for a low density bulk material, the facility comprising:

a container having a floor, external walls and a roof that define an internal space; ingress ducting through which bulk material enters the facility, the ingress ducting having at least one inlet pipe, at least one manifold that is in communication with the at least one inlet pipe, and plurality of secondary pipes that each extend from the at least one manifold and open into the internal space; and

discharge ducting through which to discharge bulk material from the facility, the discharge ducting having an outlet pipe, and being in communication with the internal space via apertures in the floor of the container.

Preferably, the at least one manifold is positioned centrally with respect to the container. Alternatively or additionally, the at least one manifold is positioned on a side wall or an end wall of the container.

• Each secondary pipe can have a sight glass adjacent the manifold. Preferably, the at least one manifold includes one or more valves to selectively distribute bulk material to the secondary pipes.

In certain embodiments, the floor is shaped to provide one or more sumps, and each aperture is located at the lowest point of a respective one of the sumps. In at least some of these embodiments, at least a portion of the discharge ducting extends beneath the floor.

The discharge ducting can further include junction members that each bring the internal space in communication with the outlet pipe via the respective aperture. In such embodiments, the outlet pipe has sight windows that are each located downstream of one of the junction members.

Preferably, the mobile storage facility further comprises knife gate valves to selectively allow bulk material to discharge from a respective one of the apertures to the outlet pipe.

Preferably, the mobile storage facility further comprises supports that are arranged to support the container above a ground surface. In some embodiments, the length of each support is adjustable. In some embodiments, the facility comprises at least one internal partition to divide the internal space into discrete compartments.

The present invention also provides a pneumatic transfer assembly for conveying low density bulk material from a first containment facility to a second containment facility, the transfer assembly comprising:

a device for inducing an air flow, the device having a bulk material inlet port, and a bulk material outlet port;

a bulk material inlet pipe that is arranged to extend from the first containment facility to the inlet port of the device;

an outlet nozzle that is releasably connectable to the second containment facility; and

a bulk material discharge pipe that is arranged to extend from the outlet port of the device to the outlet nozzle.

Preferably, the outlet nozzle has grooves that co-operate with pins on the second containment facility to provide the releasable connection. In some embodiments, the grooves are shaped to cause the outlet nozzle to rotate during connection with the second containment facility. In some further embodiments, the grooves are shaped to prevent rotation of the outlet nozzle when the pins are located at closed ends of the grooves.

The outlet nozzle can further include a slide gate valve to selectively discharge bulk material. In at least some embodiments, the transfer assembly comprises a slide gate on inlet port of the device to selectively allow product to be drawn into the device. In such embodiments, the transfer assembly may further comprise an actuator that is operable to open and/or close the slide gate. The transfer assembly can include a control unit to control the actuator. Preferably, the transfer assembly includes a remote control device to enable remote control of the control unit.

The transfer assembly may further comprise flow reduction mechanism. The flow reduction mechanism may be provided on the inlet port of the device. In such embodiments, the flow reduction mechanism can be a port and a movable closure to selectively open and close the port. The transfer assembly can further comprise a mast to support the outlet nozzle at a position elevated above the device for inducing an air flow, and a boom to support the outlet nozzle outwardly of the mast. Preferably, the height of the mast is adjustable. The boom may be rotatable on the mast. In some embodiments, the mast is telescopic, and the transfer assembly includes an actuator to raise and lower the mast.

Preferably, the boom includes a hoist to support the outlet nozzle. In some embodiments, the hoist is biased to provide a vertically upward force on the outlet nozzle. The upward force can be less than or equal to weight of the outlet nozzle.

In some embodiments, at least part of the bulk material inlet pipe is a flexible conduit. Alternatively or additionally, at least part of the bulk material discharge pipe is a flexible conduit. The transfer assembly can further comprise a generator/air compressing unit that provides electrical power for the transfer assembly, and a source of compressed air.

Preferably, the transfer assembly includes a floor on which the other components of the assembly are mounted. The floor may include through holes to receive the tynes of a forklift.

The present invention provides a hatch closure for a low density bulk material storage bin having a hatch, the hatch closure comprising:

an outer rim that mates with the hatch;

a locking arrangement to releasable secure the hatch closure to the storage bin; a screen that is connected to the rim and prevents bulk material exiting the bin through the hatch;

a first opening in the screen through which to pass bulk material, the opening having a locking collar to which an outlet nozzle of a pneumatic transfer assembly is connectable;

a closure associated with the first opening, the closure having a normally closed configuration, and is movable into an open configuration with insertion of the outlet nozzle into the first opening;

an overflow air vent through which to discharge excess air. Ιπ some embodiments, the screen is perforated to provide the overflow air vent. In one example, the screen includes a mesh screen that provide perforations for the overflow air vent. In certain embodiments, the screen has a second opening that is covered by a transparent material that allows visual inspection of the internal space within the storage bin.

The present invention provides a mobile processing unit for processing a low density bulk material, the unit comprising:

a bin within which to store the bulk material;

a hatch through which to pass material into the bin; and

a hatch screen, as previously described. The present invention provides a low density bulk material spill clean up assembly comprising a container having a floor surrounded by walls that define an opening, and an insert that is supported by the walls at or adjacent the opening to close the container, the insert having:

an opening through which to pass bulk material

a closure associated with the opening, the closure having a normally closed configuration, and is movable into an open configuration with insertion of a hose into the opening;

an overflow air vent through which to discharge excess air. The assembly can further comprise one or more accessories for use in transporting spilled bulk material to the container, the accessories being selected from a list including: a vacuum nozzle, a flexible hose, and one or more rigid tubes. In such embodiments, the insert has a well shape to receive the accessories. The present invention also provides a low density bulk material handling and storage system, that comprises any one or more of.

a mobile storage facility for a low density bulk material, as previously described; a pneumatic transfer assembly, as previously described;

a hatch closure for a low density bulk material storage bin, as previously described; a mobile processing unit for processing a low density bulk material, as previously described; and

a low density bulk material spill clean up assembly, as previously described.

Brief description of the drawings

In order that the invention may be more easily understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 : is a top perspective view of a mobile storage facility for storing a low density bulk material according to a first embodiment of the present invention;

Figure 2: is a bottom perspective view of the mobile storage facility of Figure 1 ; Figure 3: is a side view of the mobile storage facility of Figure 1 , showing the supports in a raised configuration;

Figure 4: is a side view of the mobile storage facility of Figure 1 , showing the supports in a lowered configuration;

Figure 5: is an end view of the mobile storage facility of Figure ;

Figure 6: is an end view of a mobile processing unit for processing a low density bulk material according to a second embodiment of the present invention, and a pneumatic transfer assembly according to a third embodiment of the present invention;

Figure 7 is a perspective view of the pneumatic transfer assembly of Figure 6; Figure 8 is a plan view of the pneumatic transfer assembly of Figure 6,

FFiigguurree 99: is a side view of the pneumatic transfer assembly of Figure 6, showing the mast in a lowered configuration;

Figure 10: is a side view of the pneumatic transfer assembly of Figure 6, showing the mast in a raised configuration;

Figure 1 1 : is a front view of the outlet nozzle of the pneumatic transfer assembly of Figure 6;

Figure 12: is a side view of the outlet nozzle of Figure 1 1 ;

Figure 13: is a top perspective view of a hatch closure for a low density bulk material storage bin according to a fourth embodiment of the present invention;

Figure 14: is an enlarged view of region A in Figure 13;

Figure 15: is a bottom perspective view of the hatch closure of Figure 13; Figure 16: is a perspective view of the outlet nozzle of Figure 11 connected to the hatch cover of Figure 13;

Figure 17: is a perspective view of a low density bulk material spill clean up assembly according to a fifth embodiment of the present invention; Figure 18: is a perspective view of the insert of the spill clean up assembly of

Figure 17;

Figure 19: is a top perspective view of a mobile storage facility for storing a low density bulk material according to a sixth embodiment of the present invention;

Figure 20: is a top perspective view of a mobile storage facility for storing a low density bulk material according to a seventh embodiment of the present invention;

Figure 21: is a bottom perspective view of the mobile storage facility of Figure 20; Figure 22: is a side view of the mobile storage facility of Figure 20, showing the supports in a lowered configuration;

Figure 23: is a perspective view of a pneumatic transfer assembly according to an eighth embodiment of the present invention;

Figure 24: is a side view of the pneumatic transfer assembly of Figure 23, showing the mast in a raised configuration;

Figure 25: is a top perspective view of a mobile storage facility for storing a low density bulk material according to a ninth embodiment of the present invention;

Figure 26: is a perspective view of a pneumatic transfer assembly according to an tenth embodiment of the present invention;

Figure 27: is a perspective view of the outlet nozzle of the pneumatic transfer assembly of Figure 26;

Figure 28: is a perspective view of a semi-trailer according to an eleventh embodiment of the present invention; and

Figure 29: is an end view of the mobile processing unit of Figure 6, and a transfer station according to a twelfth embodiment of the present invention.

Detailed description

Figures 1 to 5 show a mobile storage facility 10 for storing low density bulk materials according to a first embodiment of the present invention. The facility 10 is particularly suitable for storing expanded polystyrene beads (hereinafter referred to as "EPS beads").

For convenience, the description that follows will refer to EPS beads, but it will be appreciated that any low density bulk material may be used with embodiments according to the present invention.

The facility 10 has a container 12 with a floor 14, external walls 16, and a roof 18, which together define an internal space. The internal space is sealed to a sufficient degree as to prevent EPS beads from escaping the facility 10, and/or to prevent ingress of water.

The facility 10 has ingress ducting through which bulk material enters the facility 10. The ingress ducting includes an inlet pipe 20, a manifold 22 that is in communication with the inlet pipe 20, and secondary pipes 24 that each extend from the manifold 22 and open into the internal space. Discharge ducting is provided through which to discharge bulk material from the facility. The discharge ducting includes an outlet pipe 26 that is in communication with the internal space via apertures (not shown) in the floor 14 of the container 12.

The configuration of the ingress ducting and discharge ducting of the facility 10 have the distinct advantage of enabling comparatively rapid filling and emptying of EPS beads to/from the container 12. The multiple secondary pipes 24 allow the internal space to be filled with EPS beads at selected locations to facilitate even filling to the maximum capacity of the facility 10. Furthermore, as the container 12 prevents unintentional release of EPS beads, and consequently the facility 10 provides an environmentally sound storage facility.

As shown most clearly in Figures 1, 3 and 4, the manifold 22 is positioned centrally with respect to the internal space. Further, the manifold 22 is positioned on a side wall 16 of the container 12. This has the benefit of minimizing the combined length of the secondary pipes 24, which aids in rapid filling of the container 12.

Each of the secondary pipes 24 has a sight glass 28 adjacent the manifold 22. The sight glasses 28 enable an operator to visually observe flow of EPS beads through the respective secondary pipe 24. The manifold 22 includes valves 30 to enable selective distribution of EPS beads to the secondary pipes 24, and thus to selected entry points to the internal space. As can be seen from the Figures, the manifold 22 initially divides the inlet pipe into two branches, which are then further divided into the four secondary pipes 24. Thus, in this embodiment, the manifold has three valves 30. The manifold 22 also has clean out doors (not shown) that provide internal access to the manifdld 22, which may be used to manually clear a blockage. As shown in Figures 2 to 4, the floor 14 is shaped to provide one or more sumps to the internal space. In this particular embodiment, the floor forms four sumps, that each have four inclined sections meeting at a central location. An aperture (not shown) is located at the lowest point of each sump. The multiple sumps and apertures allow the EPS beads to be extracted from the internal space at selected locations to facilitate even unloading of substantially all EPS beads stored within the facility 10.

The floor 14 includes bash plates 32 adjacent each aperture. The bash plates 32 provide a surface that can be readily knocked (for example, with a hammer) to facilitate moving the EPS beads towards the respective aperture.

The walls 16 are provided with floor-to-roof sight windows 34. In this embodiment, each sight window 34 forms part of one of the external walls 16, and provides an operator with the ability to visually determine the amount of EPS beads at various locations within the container 12.

At least a portion of the discharge ducting extends beneath the floor 14. In particular, the outlet pipe 26 extends beneath the floor 14, and thus beneath the container 12. The discharge ducting further includes junction members 36 that each bring the internal space in communication with the outlet pipe 26 via the respective aperture. As shown in Figures 3 and 4, the junction members 36 are connected to the floor 14 at one of the sumps to draw EPS beads from the lowest point of the internal space. The junction members 36 are in the form of T-connectors that intersect portions of the outlet pipe 26. The outlet pipe 26 also has sight windows 38 that are each located downstream of one of the junction members 36. In this way, an operator can visually determine whether EPS beads are flowing out of the respective aperture, and through the outlet pipe 26. The facility 10 further has knife gate valves 40 that are each associated with one of the junction members 36. An operator can open/close the knife gate valves 40, via handles adjacent one of the side walls 16, to selectively allow EPS beads to discharge from sump into the outlet pipe 26. The facility 10 further comprises supports 42 that are arranged to support the container 12 above a ground surface. There are four supports 42, each to one corner of the container 12. The length of each support 42 is adjustable to enable the elevation of the container 12 to be set. Figure 3 shows the supports 42 in a raised (or fully retracted) configuration, as might be used during transport of the facility 10 on, for example, a flat-, bed loader. Figure 4 shows the supports 42 is a lowered (or fully extended) configuration, as might be used when the facility 10 is placed on a ground surface. The extension of each support 42 can be set independently of the others, which enables the container 12 to be levelled on an uneven ground surface. The side walls 16 have vents 44 that allow air to enter/exit the internal space during loading/emptying of the container 12. Further, the vents 44 allow the pressure within the container 12 to equalize to changes in ambient pressure.

The facility 10 further has a stowable ladder 46 to facilitate access to the roof 8, and a walkway 48 to facilitate safe passage across the roof 18.

The facility 10 may be provided with a sampling valve in one or more of the sumps. This enables an operator to sample EPS beads stored in the facility 10 for subsequent analysis.

Figure 6 shows a mobile processing unit 50 according to a second embodiment of the present invention - which is for processing a bulk material, such as EPS beads, together with other product - and a pneumatic transfer assembly 60 according to a third embodiment of the present invention. The processing unit 50 has one or more bins within which to store EPS beads, a hatch 52 through which to pass EPS beads into the bin, and a hatch screen, which will described in further detail below. Figures 7 to 12 show the assembly 60 in further detail. The assembly 60 facilitates conveying EPS beads from a first containment facility, such as the facility 10, to a second containment facility, such as the unit 50. The conveyer 60 has a device for inducing an air flow, which in this embodiment is in the form of a blower fan 62. The fan 62 has a bulk material inlet port 64, and a bulk material outlet port 66.

The assembly 60 also has an outlet nozzle 68 that is releasably connectable to the unit 50. The outlet nozzle 68 will be described in further detail below. Additionally, the connection of the outlet nozzle 68 to the unit 50 will also be described in further detail below.

The assembly 60 has a bulk material inlet pipe 70 that is arranged to extend from the first containment facility to the inlet port 64, and a bulk material discharge pipe 72 that is arranged to extend from the outlet port 66 to the outlet nozzle 68. Thus, in use, the fan 62 generates an air flow that draws EPS beads from the first containment facility, and pushes EPS beads to the second containment facility. For clarity, the inlet pipe 70 is omitted from Figures 6 to 1 1 , and the discharge pipe 72 is omitted from Figures 7 to 1 1 . The assembly 60 has a slide gate 74 arranged on the inlet port 64 of the fan 62.

The slide gate 74 selectively allows EPS beads to be drawn through the fan 62. In operation, this allows an operator to prevent flow of EPS beads through the fan 62 and discharge pipe 72, whilst still providing a flow of air through the pipe 72. Thus, an operator is able to purge the discharge pipe 72 of EPS beads by closing the slide gate 74.

In operation of the assembly 60, an operator can observe that the second containment facility is approaching its capacity. The operator can the close the slide gate 74, and the fan 62 can be run for a sufficient period to purge the discharge pipe 72 of EPS beads. Accordingly, when the outlet nozzle 68 and/or the discharge pipe 72 are disconnected, the risk of EPS beads.escaping the assembly 60 is greatly reduced.

The assembly 60 has an actuator (not shown) that is operable to open and/or close the slide gate. In this particular embodiment, the actuator is pneumatically operated. A control unit 76 is provided to control various operations of the assembly 60, including the actuator for the slide gate 74. The assembly 60 also includes a remote control device (not shown) that enables remote control of the control unit 76, for example by an operator on top of the unit 50.

A flow reduction mechanism 78 is provided on the inlet port 64 of the fan 62. In this embodiment, the flow reduction mechanism is in the form of a port and a movable closure to selectively open and close the port. The movable closure is a rotatable collar with an aperture that can be located over the port to lower the vacuum pressure at the inlet port 64. With the aperture over the port, the suction pressure of the fan is lowered, which reduces the flow rate of EPS beads through the fan 62, and thus reduces the delivery rate of EPS beads from the assembly 60.

The assembly 60 has a mast 80 that is to support the outlet nozzle 68 at a position elevated above the fan 62, and a boom 82 that is to support the outlet nozzle 68 outwardly of the mast 80. Further, the boom 82 can rotate on the head of the mast 80 As is evident from Figures 9 and 1 1 , the height of the mast 80 is adjustable between a lowered position (shown in Figure 9), and a raised position (shown in Figure 1 1 ). In this embodiment, the mast 80 is telescopic, and the assembly 60 includes an actuator (not shown) to raise and lower the mast 80. The actuator can be integral with the mast 80. The boom 82 includes a hoist 84 from which the outlet nozzle 68 hangs. The hoist

84 is biased to provide a vertically upward force on the outlet nozzle 68. In this embodiment, the upward force is equal to weight of the outlet nozzle 68. This enables an operator to easily raise and lower the outlet nozzle 68 for connection/removal of the nozzle 68 from the unit 50. The hoist 84 is able to slide along an end portion of the boom 82. By this arrangement, the outlet nozzle 68 can be raised from the approximate level of the fan 62, up and over the unit 50. In embodiments in which the unit 50 has multiple storage bins, the outlet nozzle 68 can be easily manipulated for connection to each of the bins without moving the unit 50. To facilitate this, at least part of the inlet pipe 64 is a flexible conduit.

The assembly 60 further has a generator/air-compressing unit 86 that provides electrical power for the various components of the assembly 60, such as the control unit 76, and a source of compressed air, which provides compressed air for operation of at least the actuators for the slide gate 74 and the mast 80. The control unit 76 can also provide control for the generator/air-compressing unit 86, the actuator for the mast 80, and/or the fan 62.

The assembly 60 has a floor 88 on which the other components of the assembly 60 are mounted. As shown in Figures 7 and 9, the floor 88 has through holes 90 that can receive the tynes of a forklift. In some alternative embodiments, the floor 88 may alternatively or additionally be provided with lifting lugs for moving by vehicle, such as a crane. Thus, the assembly 60 can be easily lifted and moved. The assembly 60 further has a cage 87 within which the inlet and discharge pipes 70, 72 can be stored. In addition, the assembly 60 has a reeled hose 89 that can provide compressed air to other components, as described below.

The outlet nozzle 68 is shown in further detail in Figures 1 1 and 12. The lower end 91 a of the outlet nozzle 68 has grooves 92 that co-operate with pins on the second containment facility to provide the releasably connection, as will be described in further detail in reference to Figures 13 to 16.

The outlet nozzle 68 includes a slide gate valve 94 to selectively discharge bulk material. An operator on top of the unit 50 can selectively open/close the slide gate valve 94 to allow/prevent discharge of EPS beads from the outlet nozzle 68. Thus, when filling a unit 50 with multiple storage bins, the operator can close the valve 94 when one bin is full, transfer and connect the outlet nozzle to another bin, and open the valve 94 to commence filling. Control of the assembly 60 to commence or cease filling can be controlled via the remote control.

The upper end 91 b of the outlet nozzle 68 is configured to connect to the discharge pipe 72. Adjacent the upper end 91b, a handle 96 is provided to assist an operator in manipulating the outlet nozzle 68, and a lifting point 98 is provided for connection to the hoist 84.

The transfer assembly 60 can be used to transfer EPS beads between any two suitable facilities. For example, the assembly 60 can be used to transfer EPS beads from a delivery container, such as a tip truck, to the mobile storage facility 10, or a permanent silo. Figures 13 to 16 show the hatch closure 100 according to a fourth embodiment of the present invention, which is to co-operates with the hatch 52 of the unit 50. The hatch closure 100 has an outer rim 102 that mates with the hatch 52. A locking arrangement releasably secures the hatch closure 100 to the storage bin. In this embodiment, the locking arrangement is in the form of six quick release locking pins 104.

A screen 106 is connected to the rim 102 and prevents EPS beads exiting the bin through the hatch 52. A first opening 108 is formed in the screen 106 through which to pass EPS beads. The opening 108 has a locking collar 110 to which an outlet nozzle 68 connects. To this end, the locking collar 110 has pins 112 that mate with the grooves 92 of the outlet nozzle 68. A closure 114 is associated with the opening 108, which has a normally closed configuration, as shown in Figure 13. In this embodiment, the closure 1 14 is in the form of a polyurethane sheet that has a series of radial cuts with respect to the opening 108 to form a series of segments. The segments move into an open configuration with insertion of the outlet nozzle 68 into the opening 108. In particular, the segments splay when the lower end 91a of the outlet nozzle 68 bears against the closure 1 14. Due to the resilience of the rubber, the closure 1 14 returns to the closed configuration with removal of the outlet nozzle 68. The hatch closure 100 further has an overflow air vent through which to discharge excess air.

In this particular embodiment, the screen 106 has perforations to provide the overflow air vent. The screen 106 also has a second opening 116 that is covered by a transparent material 118 that allows visual inspection of the internal space within the storage bin. Thus, an operator can look into the bin of the unit 50 during filling, and inspect the level of EPS beads within the bin.

As shown in Figure 13, the hatch closure 100 further has handles 1 19 to facilitate insertion and removal of the closure 100 from the hatch 52 of the unit 50. The grooves 92 are shaped to cause the outlet nozzle 68 to rotate during connection with the locking collar of the hatch closure 100. Further, the grooves 92 are shaped to prevent rotation of the outlet nozzle when the pins 1 12 are located at closed ends of the grooves 92. As the outlet nozzle 68 is connected to the locking collar, the outlet nozzle 68 is initially simultaneously rotated and lowered, and then lowered into a locking position. Conversely, as the outlet nozzle 68 is removed to the locking collar, the outlet nozzle 68 is initially raised away from the locking collar, and then simultaneously rotated and raised.

Figure 17 shows a low density bulk material spill clean up assembly 120 for cleaning up spilled EPS beads according to a fifth embodiment of the present invention. The assembly 120 has a container 122 with a floor 124 surrounded by walls 126 that define an opening. As will be appreciated from Figure 17, the container 122 is a "wheelie bin". An insert 128 is supported by the walls 126 at or adjacent the opening to close the container 122. The insert 128 has an opening 130 through which to pass EPS beads, as will be discussed in further detail below. A closure 132 is associated with the opening, the closure 132 has a normally closed configuration, and is movable into an open configuration with insertion of a hose into the opening. The closure 132 has a similar construction to the closure 114 of the hatch closure 100. Further, the insert 128 has an overflow air vent 134 through which to discharge excess air during filling of the container.

The assembly 120 has accessories that are to be used for collecting and transporting spilled EPS beads to the container 122. The accessories include a vacuum nozzle 136, a flexible hose 138, and rigid tubes 140. In use, the vacuum nozzle 136 can be connected to a source of compressed air, such as the hose 89 on the reel of the assembly 60. One end of the hose 138 is connected to the high pressure side of the vacuum nozzle 136, and the other end is pushed through the opening 130, causing the closure 132 to splay and open. Spilled EPS beads can be sucked through the vacuum nozzle 136 and passed into the container 122. If desired, the rigid tubes can be sequentially connected to the suction side of the vacuum nozzle 136 to facilitate collection of spilled EPS beads.

As shown most clearly in Figure 18, the insert 128 has lips 142 that locate on the upper edge of the walls 126 of the container 122. Further, the insert 128 has handles 144 to facilitate location and removal of the insert 128 at the opening of the container 122.

The insert 128 has a well shape within which to receive the accessories. Further, the assembly 120 has a lid 146 that closes onto the top of the walls of the container 122.

Figure 19 shows a mobile storage facility 210 for storing low density bulk materials according to a sixth embodiment of the present invention. The facility 210 is similar to the facility 10 described in reference to Figures 1 to 5. Accordingly, features of the facility 210 that are similar to corresponding features of the facility 10 have the same reference numerals with the prefix "2".

The principal difference between the facility 210 and the facility 10 is the configuration of the ingress ducting. In particular, the manifold 222 is positioned on an end wall 216 of the container. This configuration has the advantage that the ingress ducting is spaced from the side walls 216, may be less susceptible to damage, and can conform to various road transport regulations. Figures 20 to 22 show a mobile storage facility 310 for storing low density bulk materials according to a seventh embodiment of the present invention. The facility 310 is similar to the facility 10 described in reference to Figures 1 to 5. Accordingly, features of the facility 310 that are similar to corresponding features of the facility 10 have the same reference numerals with the prefix "3".

The principal difference between the facility 310 and the facility 10 is the configuration of the ingress ducting. The ingress ducting includes two inlet pipes 320a, 320b, two manifolds 322a, 322b that are each in communication with a respective one of the inlet pipes 320a, 320b. The facility 310 includes four secondary pipes 24 that are arranged in two pairs, with each pair of secondary pipes 324 extending from a respective one of the manifolds 322 and open into the internal space.

Figures 23 and 24 show a pneumatic transfer assembly 460 according to an eighth embodiment of the present invention. The transfer assembly 460 is similar to the transfer assembly 60 described in reference to Figures 6 to 12. Accordingly, features of the transfer assembly 460 that are similar to corresponding features of the transfer assembly 60 have the same reference numerals with the prefix "4".

In this embodiment, the transfer assembly 460 includes a spar 483 that is attached by a pivot joint to the boom 482 adjacent the mast 480, and at the opposite end of the boom 482 to the hoist 484. The spar 483 can be pivoted between a stowed position as shown in Figure 23, and a deployed position as shown in Figure 24. Counterweights 485 can be attached to the spar 483 in order to counterbalance the weight of the boom 462, hoist 484, outlet nozzle 468, and discharge pipe (not shown). The counterweights 485 can be removed from the spar 483, if required. The outlet nozzle 468 is shown in further detail in Figure 27.

The transfer assembly 60 of Figure 6 to 12 includes a slide gate 74 that can be used in purging the discharge pipe 72 of EPS beads. In contrast, the transfer assembly 460 does not include a slide gate.

The transfer assembly has a separate electricity generator 486a and separate air compressing unit 486b. Figure 25 shows a mobile storage facility 510 for storing a low density bulk material according to a ninth embodiment of the present invention. The facility 510 is similar to the facility 10 described in reference to Figures 1 to 5. Accordingly, features of the facility 510 that are similar to corresponding features of the facility 10 have the same reference numerals with the prefix "5". Further, the facility 510 is substantially similar to the facility 310 shown in Figures 20 to 22, the primary difference being that the facility 510 does not have an integral ladder or walkway.

Figure 26 is a perspective view of a pneumatic transfer assembly 660 according to an tenth embodiment of the present invention. The transfer assembly 660 is similar to the transfer assembly 60 described in reference to Figures 6 to 12. Accordingly, features of the transfer assembly 660 that are similar to corresponding features of the transfer assembly 60 have the same reference numerals with the prefix "6".

Further, the transfer assembly 660 is substantially similar to the assembly 460 shown in Figures 23 and 24. However, in contrast to both the assemblies 60, 460, the transfer assembly 660 does not include a generator or air compressor unit. Accordingly, the transfer assembly 660 is to be connected to independent sources of electricity and compressed air in use. Figure 27 shows the outlet nozzle 468, 668 (hereinafter referred to collectively as outlet nozzle 468) of the pneumatic transfer assemblies 460, 660 shown in Figures 23, 24 and 27. The outlet nozzle 468 is similar to the outlet nozzle 68 described in reference to Figures 1 1 and 12. Accordingly, features of the outlet nozzle 468 that are similar to corresponding features of the outlet nozzle 68 have the same reference numerals with the prefix "4". When compared with the outlet nozzle 68, the length of the duct in the outlet nozzle 468 between the upper and lower ends 491 a, 491 b is substantially truncated. The handle 496 forms a cage that includes hoops 497 through which the discharge pipe from a transfer assembly can pass to connect with the upper end 491 b of the outlet nozzle 468. The lifting point 498 is integral with the handle 496.

Figure 28 shows a semi-trailer 700 according to an eleventh embodiment of the present invention. The semi-trailer 700 includes a flat bed 702, bogies 704, and a kingpin (not shown) for connecting the trailer 700 to the fifth wheel of a prime mover.

The bed 702 supports a storage facility 710 within which low density bulk materials can be stored, and a pneumatic transfer assembly 760. Features of the storage facility 710 that are similar to corresponding features of the storage facility 10 of Figure 1 have the same reference numerals with the prefix "7". Features of the transfer assembly 760 that are similar to corresponding features of the transfer assembly 60 have the same, reference numerals with the prefix "7".

In similar embodiments, the semi-trailer can alternatively be a step or drop deck trailer.

Figure 29 shows the mobile processing unit 50 of Figure 6, and a transfer station 800 according to a twelfth embodiment of the present invention. The transfer station 800 includes a collapsible shelter 802 within which a bin 804 and support frame 806 can be disposed. The support frame 806 is to support a bag B of EPS beads over the bin 804. A transfer pipe 808 extends from the bin 804 through the shelter 802 and to a hatch on the unit 50.

A compressed air driven in-line conveyor 810 is provided midway along the transfer pipe 808. The conveyor 810 induces as air flow through the transfer pipe 808 to convey EPS beads from the bin 804 to the unit 50. The conveyor 810 can be mounted at the inlet of the transfer pipe 808. In this embodiment, the conveyor 810 is mounted on a stand. However, in alternative embodiments, the conveyor can be handheld.

As previously discussed, EPS beads can be spread easily by wind. The shelter 802 provides protection from wind and other elements, and also assists containment of beads during unloading from a bag B. A sixth embodiment of the present invention is a low density bulk material handling and storage system. The system can include any one or more of:

the mobile storage facility for a low density bulk material 10, 210, 310, 510, 710; the pneumatic transfer assembly 60, 460, 660, 760;

the hatch closure 100 for a low density bulk material storage bin;

the mobile processing unit for processing a low density bulk material 50;

the low density bulk material spill clean up assembly 120; and

the transfer station 800.

Some alternative embodiments of the mobile storage facility can be provided with internal partitions to divide the internal space into discrete compartments. In this embodiment, there are three internal partitions, such that there are four discrete compartments. The partitions provide a sufficient barrier between the compartments as to prevent EPS beads from passing between the compartments. In this embodiment, the partitions are vertical, and extend perpendicularly to the long side walls of the container. The four compartments are of approximately equal size.

Some further alternative embodiments of the mobile storage facility may be constructed to have any of the ingress ducting, discharge ducting, and supports wholly contained within internal space. In such embodiments, the walls, roof, and/or floor may have access points to enable operation of the manifold, clean out doors, knife gate valves, and/or supports. In such embodiments, the facility may have a false floor mounted within the internal space, the false floor forming the sump(s). The discharge ducting may be positioned between the false floor, and the floor of the container.

The roof of the container can also be provided with sight windows to enable inspection into the internal space from above the roof. Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims

CLAIMS:

1. A mobile storage facility for a low density bulk material, the facility comprising: a container having a floor, external walls and a roof that define an internal space; ingress ducting through which bulk material enters the facility, the ingress ducting having at least one inlet pipe, at least one manifold that is in communication with the at least one inlet pipe, and plurality of secondary pipes that each extend from the at least one manifold and open into the internal space; and

2. A mobile storage facility according to claim 1 , wherein the at least one manifold is positioned centrally with respect to the container.

3. A mobile storage facility according to either claim 1 or 2, wherein the floor is shaped to provide one or more sumps, and each aperture is located at the lowest point of a respective one of the sumps.

4. A mobile storage facility according to any one of claims 1 to 3, wherein the discharge ducting further include junction members that each bring the internal space in communication with the outlet pipe via the respective aperture.

5. A mobile storage facility according to claim 4, wherein the outlet pipe has sight windows that are each located downstream of one of the junction members.

6. A mobile storage facility according to either claim 4 or 5, wherein the mobile storage facility further comprises knife gate valves to selectively allow bulk material to discharge from a respective one of the apertures to the outlet pipe.

7. A mobile storage facility according to any one of claims 1 to 3, further comprising supports that are arranged to support the container above a ground surface.

8. A pneumatic transfer assembly for conveying low density bulk material from a first containment facility to a second containment facility, the transfer assembly comprising: a device for inducing an air flow, the device having a bulk material inlet port, and a bulk material outlet port;

9. A pneumatic transfer assembly according to claim 8, wherein the outlet nozzle has grooves that co-operate with pins on the second containment facility to provide the releasable connection.

10. A pneumatic transfer assembly according to either claim 8 or 9, wherein the outlet nozzle further includes a slide gate valve to selectively discharge bulk material.

11. A pneumatic transfer assembly according to any one of claims 8 to 10, further comprising a slide gate on inlet port of the device to selectively allow product to be drawn into the device.

12. A pneumatic transfer assembly according to claim 1 1 , further comprising an actuator that is operable to open and/or close the slide gate.

13. A pneumatic transfer assembly according to any one of claims 8 to 10, further comprising flow reduction mechanism.

14. A pneumatic transfer assembly according to claim 13, wherein the flow reduction mechanism is provided on the inlet port of the device.

15. A pneumatic transfer assembly according to any one of claims 8 to 14, further comprising a mast to support the outlet nozzle at a position elevated above the device for inducing an air flow, and a boom to support the outlet nozzle outwardly of the mast.

16. A pneumatic transfer assembly according to claim 15, wherein the boom includes a hoist to support the outlet nozzle.

17. A pneumatic transfer assembly according to claim 16, wherein the hoist is biased to provide a vertically upward force on the outlet nozzle.

18. A pneumatic transfer assembly according to any one of claims 8 to 17, wherein at least part of the bulk material inlet pipe is a flexible conduit, and/or at least part of the bulk material discharge pipe is a flexible conduit.

19. A pneumatic transfer assembly according to any one of claims 8 to 18, further comprising a generator/air compressing unit that provides electrical power for the transfer assembly, and a source of compressed air.

20. A pneumatic transfer assembly according to any one of claims 8 to 18, further comprising a floor on which the other components of the assembly are mounted.

21. A pneumatic transfer assembly according to claim 20, wherein the floor includes through holes to receive the tynes of a forklift, and/or lifting lugs.

22. A hatch closure for a low density bulk material storage bin having a hatch, the hatch closure comprising:

an outer rim that mates with the hatch;

an overflow air vent through which to discharge excess air.

23. A hatch closure according to claim 22, wherein the screen is perforated to provide the overflow air vent.

24. A hatch closure according to either claim 22 or 23, wherein the screen has a second opening that is covered by a transparent material that allows visual inspection of the internal space within the storage bin.

25. A mobile processing unit for processing a low density bulk material, the unit comprising:

a bin within which to store the bulk material;

a hatch through which to pass material into the bin; and,

a hatch screen according to any one of claims 22 to 24.

26. A low density bulk material spill clean up assembly comprising a container having a floor surrounded by walls that define an opening, and an insert that is supported by the walls at or adjacent the opening to close the container, the insert having:

an opening through which to pass bulk material

an overflow air vent through which to discharge excess air.

27. A low density bulk material spill clean up assembly according to claim 26, further comprising one or more accessories for use in transporting spilled bulk material to the container, the accessories being selected from a list including: a vacuum nozzle, a flexible hose, and one or more rigid tubes.

28. A low density bulk material spill clean up assembly according to claim 27, wherein the insert has a well shape to receive the accessories. 30. A low density bulk material handling and storage system, that comprises any one or more of:

a mobile storage facility for a low density bulk material according to any one of claims 1 to 7;

a pneumatic transfer assembly according to any one of claims 8 to 21;

a hatch closure for a low density bulk material storage bin according to any one of claims 22 to 25;

a mobile processing unit for processing a low density bulk material according to claim 26; and

a low density bulk material spill clean up assembly according to any one of claims 27 to 29.