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Clean and efficient cement process

Größe: 12 cm x 12 cm Position: 0 cm / 0 cm Rahmen: 1,25 Pt weiß. Clean and efficient cement process. Silo / Bagging / Conveyance. Contents. Overview Silo Technology Packing and Dispatch Technology Fluidcon – Pneumatic Conveying System. Storage Silo and Packing/Dispatch Systems.

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Clean and efficient cement process

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  1. Größe: 12 cm x 12 cm Position: 0 cm / 0 cm Rahmen: 1,25 Pt weiß Clean and efficient cement process Silo / Bagging / Conveyance

  2. Contents • Overview • Silo Technology • Packing and Dispatch Technology • Fluidcon – Pneumatic Conveying System

  3. Storage Silo and Packing/Dispatch Systems Storage Silo • withExpansion Chamber – EC • withInspection Chamber - IC • withMulti Extraction - ME • withConventionalCone - CC • Packing Plant • Rotary Packing Machine • In-Line Packing Machine • Automatic Bag Applicator • Bag Transport • Loading Plants • Truck Loader • Waggon Loader • Palletising Systems • incl. Loading security systems

  4. Pneumatic Conveying System -FLUIDCON- System Receiving bin / Storage silo Feeding device Aerated FLUIDCON- pipe FLUIDCON-Pipe consisting of: 1.) Standard pipe 2.) Fabric 3.) Aeration pad 4.) Fasteners 5.) Air socket

  5. Contents • Overview • Silo Technology • Packing and Dispatch Technology • Fluidcon – Pneumatic Conveying System

  6. CLAUDIUS PETERS silotypes - Overview of features and advantages

  7. CLAUDIUS PETERS silotypes - Expansions chamber technology EC Features • Maximum storage capacity • Small installation height • Discharge capacity up to 1,000 t/h • Silo diameter from 10 – 30 m • 1 central discharge dd • Radial disposal of aeroslides • Reclaim discharge rate > 99% Advantages • Use of expansion chambers • Saving silo corpus • Short loading and unloading time • Optimal utilization of spaces • Saving of discharge equipment • No dead zones at remnant discharge • Purity of variety

  8. CLAUDIUS PETERS silotypes - Inspection chamber technology - IC Features • Maximum storage capacity • Small installation height • Installation of equipment in the chamber • Discharge capacity up to 1,000 t/h • Silo diameter from 10 – 30 m • 2 or more standard discharges • Relclaim discharge rate > 99% • low energy needs • Inspection by IC- chamber Advantages • Use of ring chamber f • Saving silo corpus • Small installation height f • Short loading and unloading time • Optimal utilization of spaces • High flexibility f • Purity of variety f • Saving operation costs • During operation

  9. CLAUDIUS PETERS silotypes - Multiextractionsilo ME Features • Simple silo body • Installation of equipment underneath the cone • Applicable for multicellsilo • Discharge capacity up to 1,000 t/h • Silo diameter 10 – 30 m k • 5 to 15 standard discharges • Relclaim discharge rate > 98% • low energy needs k Advantages • Short installation time • Low space needs m • Flexible range of applications • Short loading and unloading time • Optimized use of space m • High availability f • Purity of variety m • Saving operation costs

  10. Storage Silos - Facts • Maximum storage capacity • Optimized reclaim discharge capacity • Dust free operation • Low energy and operation costs • Up to 45,000 m³ storage capacity • More than 1,000 storage silos worldwide in operation

  11. Reference: Votorantim Santa Cruz, Brazil In operation: October 2010 1 x Multi Chamber Silo, 23 m diameter, 25,000 m³ 1 x Mixing plant 180 t/h 3 x Bulk loader 250 t/h

  12. Contents • Overview • Silo Technology • Packing and Dispatch Technology • Fluidcon – Pneumatic Conveying System

  13. Scope of supply for Packing and Dispatch Systems • Bucket elevator • Vibration screen • Pre-bin with level indicator • Rotary or In-Line packing machine • Automatic empty bag applicator • Bag discharge and rejection systems • Bag transport system • Spillage return system • Dedusting filter system • Loading systems • Palletizing • Electrical equipment

  14. Packing Machines Types • Rotary Packing Machine • Capacity up to 4,500 bags/h (25 kg bag) • No. of modules 3 – 12 • 14 and 16-Spout machine designed In-Line Packing Machine • Capacity up to 1,500 bags/h(25 kg bag) • No. of modules 1 – 4

  15. Filling systems for valve bags:Horizontal (rotating) turbine system Aeration in front ofthe filling spout Labyrinth with airsealing system Sealing airconnection • Advantages: • No additional bearings necessary • Shortest filling times for Cement products • No additional greasing(s) necessary • No V-belt drive necessary • No dust penetration into motor bearings • To be considered as maintenance free

  16. Modular Design - Advantages • Compact Design • Easy exchange ofmodules • Upgrading for existingmachines • Less maintenance andlow repair works

  17. Central dedusting direct to the filter Dedusting at the filling spout Dust volume per spout: ~ 20 m³/min Upstream Dustflow and Central Dedusting Upstream 2 dedusting channel per module Spillage material duct with integrated rotating scraper

  18. Controlling of Packer Feeding Flow Control gateType PCD Two way airslide Dosing gate PackerPre Bin • Features • Continous feeding of several Packer Pre bins with one airslide • Dynamic material flow, depending filling lever packer pre bins • Continous level of Packer pre bin • Optimization size of Packer pre bin • No additional aeration of packer pre-bin necessary

  19. Ultrasonic bag sealing systems for Packing Plants Advantages: • Dust free filling process • Clean bags for the end client • Bag handling after filling more simple (Palletizing & Loading) • Bag cleaning equipment not necessary • Long storage of the bags

  20. Bag Sealing with Ultrasonic • Filling module equipped with: • Ultrasonic valve sealing • Parallel guided bag chair • Automatic bag seat adjustment

  21. Automatic bag application • Roller Magazine • Application capacity up to 4,500 bags/h • Roller magazine- Single Roller - Double Roller Carousse • Option: Automatic bag size adjustment • Suitable for all brands of rotary packing machines Cassette Magazine • Application capacity up to 4,500 bags/h • Cassette magazine (Empty bag storage capacity):3 m – 750 bags equivalent5 m – 1,250 bags equivalent • Option: Automatic bag size adjustment • Suitable for all brands of rotarypacking machines

  22. Packing Plants: References 2002 -2011

  23. Packing Plants - Facts • Upstream dedusting • Different filling systems • Ultrasonic valve sealing system (dust free) • Modular design • Low maintenance and operation cost • Up to 4,500 bags/h • More than 190 Packing Plants worldwide in operation

  24. Reference:P.T. Semen Gresik, TUBAN III & IV, Indonesia In operation: April 2012 4 x EC-Silos, 22 m diameter, 20,000 m³ 4 x Bulk mobile loader, 120 t/h 6 x Packing Plant, 2,500 bag/h

  25. Reference:P.T. Semen Gresik (Banyuwangi), Indonesia In operation: February 2012 1 x EC-Silos, 18 m diameter, 10,000 m³ 1 x Bulk Loader, 120 t/h 1 x Packing Plant, 2,500 bag/h

  26. Contents • Overview • Silo Technology • Packing Process • Fluidcon – Pneumatic Conveying System

  27. Introduction - Why FLUIDCON? Combine advantages – … • Advantages • Flexible piperouting • Horizontal an verticalconveying • Dusttight • Advanatges • Low conveyingvelocities • Low wear / abrasion • Low energyconsumption … eliminate disadvantages • Disadvantages • High conveyingvelocities • Inclinedconveyance not applicable • High power consumption • Disadvantages • High installationheightrequired • Inflexible routing • Onlyinclinedconveyanceapplicable

  28. Conveying System -Design of the FLUIDCON-system Bulk material Feeding device • Pump • Pressure vessel • Rotary lock • Double pendulum flap FLUIDCON- conveying pipe • Blower • Compressor • Network • Cyclone • Troughed filter • Bin mounted filter Separator Conveying air Pressure generator Bulk material

  29. Introduction - What offers FLUIDCON? Advantages • Optimizationofexistingconveyingplants • Optimizedpiperouting • Operation costsavingsd • Reductionofwear, lowgrainsizedestruction • d • Useofblower / screwpumpsd • High availabilityd • Optimal burnerfeeding • Characteristics • Usage of all known feeding devices • Horizontal, vertical and diagonal conveying steps • Energy savings up to 75% n • Low conveying velocities n • Low conveying pressure • Easy re-start, e.g. after power failure • Low pulsation

  30. Fluidcon - References 2002 -2011

  31. FLUIDCON- system - Facts • Mass throughputs from 1 – 600t/h • Conveying distances from 20 – 600m • Applicable for Cement, Raw Meal, Alumina, Fly Ash, Blast Furnace Slag etc. • X-Pump, rotary Lock, pressure vessel and double pendulum flap as feeding device • 79 references all over the world

  32. Thank you for your kind attention

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