10.00 heinrich höse, aumund fördertechnik gmbh
Post on 25-Dec-2015
74 Views
Preview:
DESCRIPTION
TRANSCRIPT
1
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 1
efficient and effective raw material handling plus clinker and cement handling
in modern mammoth cement plants
The Cement IndustryCemtech – Dubai – 2011
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 2
Mega Cement Plant – 12,000 tons per day
Critical Choices in Concept and Components
2
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 3
Holcim Ste. Genevieve
At over 12,000 tons per day actual clinker
capacity; this is the world’s largest kiln line
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 4
Raw Mill Feeding
Aumund type DPB-B Weigh Plate Feeder controls the main Limestone proportional feed rate at a nominal
1,250 tons per hour
3
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 5
Apron Weigh Feeders – Limestone and Clay Bins
Aumund Type BPB Weigh Plate Feeders provide a controlled
feeding rate from the raw material bins to the mill intake…See the Weigh Rail above…
Load Cell Mounted Weigh Rail
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 6
Clay Feeders – Width – 2600 mm
Two type BPB-SF Apron Feeders extract clay from divergent bunkers, each feeder
alone weighs in at 100 tons…Rotary Clay Picker
Caterpillar Chains
4
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 7
Railborne Intake Back-to-Back Feeders
Based on Tracked Vehicle chains and rollers with overlapping steel plates ensuring clean operation
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 8
Feeding of Secondary Crusher Limestone
BPB-S Apron Feeder with integral round link chain
scraper cleanup conveyor
5
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 9
Vertical Mills – Basic Data
Vertical Cement Mill: -• Four Units• 165 t.p.h (each) O.P.C.• Main drive 3,900 kW• Mill fan 2,200 kW• Table diameter: 4,000 mm• Roll diameter: 2,100 mm
Vertical Raw Mill: -• Two Units• 515 t.p.h (each) raw meal• Main drive 3,900 kW• Mill fan 3,900 kW• Table diameter: 5,000 mm• Roll diameter: 3,000 mm
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 10
Twin Vertical Mills with Chain Elevator Recirculation
Recirculation Elevators by Aumund: -• 2 X BWZ-S 450/350 Central Chain Elevators• Lift Height – 32 metres.• Capacity Rate – 260 tons per hour
6
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 11
Aumund BWZ Central Chain Bucket Elevator
...Proven...High
AvailabilityTotal
Reliability
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 12
Raw Meal Feed to Prehheater
Aumund Belt Bucket Elevators trusted with the Critical Paths to
Blending Silo and Preheater
7
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 13
Raw Meal Elevators
Blending Silo Elevators: -• 2 X BWG 1250/360 Belt Elevators• Lift Height – 90 metres.• Capacity Rate – 660 t.p.h. (each)
Preheater Elevators: -• 2 X BWG 1250/360 Belt Elevators• Lift Height – 120 metres.• Capacity Rate – 625 t.p.h. (each)
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 14
Preheater and Kiln
Two String preheater with five stages and a single calciner.
Rotary Kiln: 6.6 x 93m
8
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 15
Dual Clinker Transport from Cooler to Silo
Clinker Transport to Silo: -• 2 X KZB-Q 1250/400 Pan Conveyors• Length – 146 metres.• Lift Height – 86 metres.• Capacity Rate – 375 t.p.h. (each)
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 16
Pan Conveyors with Precision Laser Chains
...Legendry – Proven......Performance...
9
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 17
Silo Distribution with Three Way Diverter Chute
Clinker Distribution to Silos: -• 2 X KZB 1600/450 Pan Conveyors• Length – 33 metres - Horizontal• Capacity Rate – 750 t.p.h. (each)
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 18
Beneath the Clinker Silos
18 discharge gates combined with variable speed drive permit Pan Conveyors to operate as extractors to
regulate clinker feed rate to the four vertical cement mills.
4 spillage returns “C” Type Cleanup Conveyors at the tail of the Silo
Discharge Pan Conveyors minimize housekeeping demands
10
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 19
4 Pan Conveyors Transfer Clinker Direct to Mills
Clinker Transport to Mill: -• 4 X KZB 800/300 Pan Conveyors• Length – 158 metres.• Lift Height – 26 metres.• Capacity Rate – 375 t.p.h. (each)
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 20
Clinker Transport Cooler to Silo
Two Pan Conveyors transfer the clinker to
2 X 90,000 ton silos via a flexible distribution system
allowing delivery to any combination of main silos
or to the rejects silo
3-way Distribution
Gate
Additives Bins
11
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 21
Clinker Distribution to Silos
Four pairs of silos for Gypsum and
Additives
Gypsum and other Additives are metered to the clinker stream
directly to the pan conveyors on the
clinker burden extracted from each
clinker silo
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 22
One Pan Conveyor Feeding One Cement Mill
Using a VFD to control the Pan Conveyors operating as extractors linked to a Belt Weigher between Pan Conveyor
and Mill controls the Clinker delivery from the silo
Recirculation Elevators by Aumund: -• 4 X BWZ 450/210 Central Chain Elevators• Lift Height – 28 metres.• Capacity Rate – 83 tons per hour (each)
12
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 23
Clinker Transport – Silo to Mill
Clinker Silo
Silo Discharge
Gates
Gypsum Additive
SiloType KZB-Q
Clinker Transport
Centrex Silo
Discharger
Weigh Belt Feeder
Weigh Belt Conveyor with Metal Detector
Cement Mill
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 24
Additives Metered Direct to Pan Conveyor
A single pan conveyor takes clinker from silo to mill onto which Gypsum and other
additives are metered thus eliminating the mill feed bins
Layer of Gypsum above the Clinker Burden
13
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 25
4 X CentrexTM Silo Extractors
CentrexTM pictured during erection. Typical design with
integrated Weigh Belt Feeder for Gypsum etc..
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 26
Clinker Dust Collecting and Transfer
Aumund type TKF drag chain conveyors for Clinker Dust fully sealed, spillage free and dust tight, multiple inlets & outlets
14
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 27
Finished Cement Silo Elevation
A nest of 8 slip formed concrete silos each 84 m. high and 24 m.
in diameter receive finished cement from two Aumund type
BWG belt bucket elevators
Total 260,000 tons cement storage capacity
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 28
Cement Silos at Barge Berth and Train Loadout
Finished Cement Elevators: -• Total of 8 units• Capacity Range – 400 to 750 t.p.h.• Lift Range – 18 to 100 metresThat is in addition to the 4 units at the raw meal silos and preheater
15
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 29
Raw Material and Fuel Import – Cement Export
Approximately 75% of all material movements are by bulk barge on the Mississippi covering in total 19 states
Enclosed cement loading facility with dust control down to the barge inlet
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 30
Latest News
In total Aumund supplied 1,240 metric tons of machinery for this project and are very proud to be involved and contribute
to the overall success of the Ste. Genevieve project.
This plant has been in operation now for around 2 years and, it was reported by Holcim, "On 21 November 2009, Ste. Genevieve's kiln clinker production reached 13,160 tonnes
per day (TPD)
Ste. Genevieve is the first single kiln production lineto break the 13,000 TPD barrier
Congratulations Holcim and Ste. Genevieve.
16
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 31
Conch Tongling – China, 10,000 t/d
A Mega Plant on the Yangtze with the latest order just announced this will become a 32,000
ton per day clinker facility but no cement…
Conch rely on Aumund BWG Elevators to feed the Raw Meal to the Preheater
BWG Present Design Limits: -• Lift Height – 175 metres..
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 32
Asia Cement Group – Jiangxi-Ya-Dong
An integrated cement plant on the Yangtze with four lines serviced by waterborne logistics
17
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 33
An Enduring Relationship
Since 1982 Schade (Aumund Group) have supplied Stacker and Reclaimer equipment for the many cement plants
of Asia Cement Group
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 34
Cong Thanh Cement Plant – Vietnam
Probably the Latest Mega Plant in progress is for Cong Thanh Cement in Vietnam at 12,000 t.p.d. largest in AsiaRaw Meal Elevators and Clinker Transport by Aumund
In this area of outstanding landscape beauty and limited rail/road links waterborne
transportation is the only viable solution
18
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 35
Limestone Loading at Yen Bai Cement – Vietnam
The Mobile Shiploader by B&W (Aumund Group) loads barges
using a dust controlled telescopic chute to eliminate
fugitive dust pollution
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 36
Mobile Shiploader for Cong Thanh Cement
Fully Mobile Shiploader at Nghi Son Port for loading
larger ships to 30,000 DWT
19
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 37
Waterborne Logistics for Import and Export
…The key feature of the Mega-Plant… controlling the carbon footprint and
living at peace with your neighbors on the Mississippi, Yangtze or Volga or ??
Dust Controlled Grab Discharge to Eco-Hopper
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 38
Terminal and Plant Upgrades
Refurbishing existing elevators and conveyors
for improved performance and reliability
Lowering a new chain/bucket strand
into an existing elevator casing
EconomicalLess Disruption
20
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 39
Case Study – Elevator Upgrade
Original Elevator…Type – Twin Chain.Feed Design – Dredge Boot.Vertical Lift – 21.6 m.Handling Rate – 50 t.p.h..
Upgrade to Aumund Design…Type – Central Forged Chain.Feed Design – Direct Feed Boot.Vertical Lift – 22.1 m.Handling Rate – 90 t.p.h..
Comparison Cost to Direct Replacement…Cost Saving – 30%.
New Chains, Buckets, Wheels and Shafts
Structure and Casing Retained
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 40
Upgrading a Steep Inclined Bucket Conveyor
Converting an existing deep bucket conveyor to the standard
Aumund BZB specification retaining the existing supporting
steelwork and galleries
21
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 41
New Head Shaft and Sprockets
The drive head including shaft, bearings and
segmented sprockets configured to suit the existing
steelwork and supports
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 42
New Conveyor Buckets and Chains by Aumund
New bucket strands pre-assembled in manageable sections before installation
and jointing on the new rails and guides
Robust rollers with large ball bearings and labyrinth grease
seals for long life
Laser cut precision conveyor chains for maximum reliability
Press tool for chain pin assembly with interference
fit to chain side plates
22
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 43
Installing the New Conveyor
Working in a confined space the Aumund supervisors guide the conveyor strand onto the return
side and align the feed point with the existing feed chute
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 44
Case Study – Bucket Conveyor Upgrade
Original Conveyor…Type – Deep Bucket Conveyor.Centres Length – 89.14 m.Handling Rate – 220 t.p.h.
Upgrade to Aumund Design…Type – BZB 250 – 1200/350/5Handling Rate – 272 t.p.h.
Comparison Cost to Direct Replacement…Cost Saving – 20%.
Improved performance and
reliability with Aumund
23
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 45
The Aumund Group - Fully Integrated Service
IntakeIntake
StockpilingStockpiling
ReclaimReclaim Vertical ElevatorVertical Elevator
FeedingFeeding
ConveyingConveying
Knowledgewith thePower
toPerform
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 46
Engineering and Design
Experience + Know-How = Performance
YourOne-Stop-Shop
forBulk Materials
Handling
24
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 47
The Aumund Group
Established 1922
Headquarters in Rheinberg GermanyAumund Fördertechnik
1956 2011
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 48
Aumund – International Sales and Service
Aumund USAAtlanta, GA
B&W Mechanical HandlingEngland
AUMUND FördertechnikSCHADE LagertechnikLOUISE FördertechnikGermany.
AumundChinaBeijing
AumundIndia
Chennai
Aumund BrazilSao Paulo
Aumund FranceParis
AumundAsia
Hong Kong
AumundSwitzerland
Zug
AumundRussia
Moscow
AumundMiddleEast
25
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 49
Aumund Group in the Cement Plant and Terminal
Feeding and Conveying in
the Mine
Raw Meal Elevation to the
Pre-CalcinerClinker
Transport and Storage
Clinker Recovery and
Handling
Imported Clinker Intake and Handling
Clinker Export and Ship Loading
Additions Intake Storage and Blending
Mill Feeding and
RecirculationCement
Elevation to silo storage
Coal Fuel and Pet Coke Intake and
Storage
Alternative Fuel Intake
and Handling
Aumund Group Products at every stage in the cement process from mine to terminal (yellow)
Raw Material Storage and
Blending
Elevation to Silo storage
Extraction and Blending
Raw Material Intake and Feeding
Feeding, Blending, Conveying and
Recirculation in the Raw Meal mill
circuit
W E C O N V E Y Q U A L I T Y
Presented by Heinrich HOESE Slide 50
THANK YOU FOR LISTENING
top related