Download - 6th Brazilian Cement Conference CBC - ABCP
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PREMAS®
6th Brazilian Cement Conference CBC 19-21 May, 2014 – São Paulo
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INNOVATIVE AND EFFICIENT
PLANT OPTIMIZATION
APPROACH
Klaus Gruene
General Manager
AUMUND PREMAS®
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PROFILE
The AUMUNDGROUP specializes in conveying,
storage and bulk handling solutions, particularly for abrasive,
hot or sticky bulk materials.
Comprehensive know-how is available in the following industries:
Cement, Lime, Gypsum
Mining, Minerals, Fertilizers
Iron- and Steel plants, esp. alternative routes (DRI)
Primary Aluminium Production
Ports and Terminals
Power Plants
Recycling Industry / Alternative Energy / Biomass
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Equipment in the Cement Industry
From the quarry to dispatch of clinker and cement
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Clinker Storage
Bucket
Elevators Pan Conveyors Truck Intake Stacker/Reclaimers
Equipment in the Cement Industry
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Mechanical Elevation
Cong Thanh Cement in Vietnam at 12,000 t.p.d. the largest line in Asia
…Elevators by AUMUND...
Belt Bucket Elevators for
Mission Critical Performance
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Ste. Genevieve
Elevators. Clinker Transport. Feeders.
...AUMUND...
Mississippi Mega Plant – 13,000 tons per day
Mechanical Elevation
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Raises raw meal to the pre-heater Using simple pneumatic transfer from the Blending silos
Raises finished cement to silo storage and dispatch
Air Lift compared to Mechanical Elevation
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Benefits of Air-Lift
Simplicity
Easy installation
Low capital cost
Drawbacks of Air-Lift
High energy input
High noise levels
High de-dusting cost
High ID fan load
High carbon footprint
High wear rate#
High operating cost
Extra machinery space
Positives & Negatives
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Moving vast volumes of air absorbs heat and energy
Only 23% of the total energy consumed by the air-lift typically are absorbed in conveying the material, either raw meal or cement
Compared to mechanical elevation where over 90% of the installed power are used to raise the material
Waste of Energy & Money
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Air-lifts force into the preheater section vast volumes of unwanted cold air
Increasing the ID fan loading
Absorbing heat
Consuming energy
If other factors permit... the heat energy and ID fan capacity released after conversion to mechanical elevation may be used to improve the kiln performance.
Secondary Benefits
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For silo intake the air-lift may generate 20,000 m3 of air movement into the silo
To prevent dust escape, the silo de-dusting system must be at least equal in capacity to the incoming air flow
Waste of Energy to convey the cement
Waste of Energy
to clean the exhausted air
Air-Lift Silo De-Dusting
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Based on Handling Rate - 200 t.p.h. Power [kW]
Belt Bucket Elevator
Pneumatic Handling
Operational and environmental savings by huge reduction in energy consumption
20
m
30
m
40
m
50
m
60
m
70
m
80
m
90
m
0
50
100
150
200
250
Po
we
r re
qu
ire
me
nt
[ k
W ]
pneumatic
mechanical
Pneumatic vs. Mechanical Elevation
Lift Height [m]
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Converting a typical 3,000 t.p.d. plant with air-lifts at the blending, pre-heater and finished cement silos
Overall Comparison
0
200
400
600
800
1000
Air Lift Mechanical Saving
Energy
[kW]
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Potential Carbon Credit Saving - $ 50,000 USD per year
Potential ROI – 3.4 years
Potential Carbon Credit Saving - $ 50,000 USD per year
Potential ROI – 3.4 years
Relative Costs and Return on Investment
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Elevators. Clinker Transport. Feeders.
...AUMUND... Elevator head with typical de-dusting ducting using around 6,000 m3 per hour extraction
Elevator Head and Silo De-Dusting
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Easy installation to the pre-heater simply strapped to the tower steelwork outside without disturbing internal plant layout
For retrofits the air-lift may stay in position minimising disruption
Easy Planning and Installation
Original or Retrofit
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Benefits
Smaller buckets with close spacing for better filling efficiency, smooth running, and less fixing stress...
Rubber plates prevent particles penetrating between buckets and belt...
Easy assembly…
Standard belt with normal steel cord pattern...
Rubber Plates
Bucket Design and Fixing
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Counterweight buckets
Weight compensation for smooth operation
Balanced by Design
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Longitudinal cords for driving traction with cross cords to stabilize the belt laterally for safe bucket fixing
Cross Stabilised Steel Cord Belts
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Punching rig developed to automated belt manufacture and ensure accurate and repeatable bucket alignment
Automated Belt Manufacture
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Clamping connection with resin bonded encapsulated connection of the steel cords
Effective and Reliable Belt Jointing
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Elevators. Clinker Transport. Feeders.
...AUMUND...
0
1000
2000
3000
4000
5000
1995 1998 2001 2004 2007 2010 2013
Aumund Belt Elevator Population from 1995
AUMUND...
Expert in Conveying Equipment…
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Shaft center of up to 175 m
Capacity up to 1,650 mt/h
Permanent temp. up to 130 °C
Short term peaks up to 150 °C
Bucket width up to 1,600 mm
Belt strength up to 3,500 N/mm
AUMUND BWG Performance
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Labyrinth Seal
Forged chains with reduced bearing pressure and pre-lubrication to ensure high surface finish for reduced pin/bush wear and extended chain life
Sophisticated Forged and Sealed
Elevator Chains
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Three Point Contact Friction Drive
Segmented tyre rim replaceable with minimum dismantling and downtime
AUMUND Central Chain Solution
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Replacement of drive hub, shaft, bearings and drive ring
AUMUND Central Chain Solution
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Elevators. Clinker Transport. Feeders.
...AUMUND...
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 %
Structure and casing retained along with existing hood, not pretty but functional...
Case Study – Elevator Upgrade
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Converting an existing deep bucket conveyor to the standard AUMUND BZB specification retaining the existing supporting steelwork and galleries
Upgrading of a
Steep Inclined Bucket Conveyor
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Elevators. Clinker Transport. Feeders.
...AUMUND...
The drive head including shaft, bearings, and segmented sprockets configured to suit the existing steelwork and supports
New Head Shaft and Sprockets
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New bucket strands pre-assembled in manageable sections before installation and jointing on the new rails and guides
New Conveyor Buckets and Chains
by AUMUND
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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
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Elevators. Clinker Transport. Feeders.
...AUMUND...
Original Conveyor…
Type – Deep Bucket Conveyor
Centres Length – 89.14 m
Handling Rate – 220 t.p.h.
Upgrade to AUMUND Design…
Type – BZB 250 – 1200/350/5
Handling Rate – 272 t.p.h.
Cost Saving – 20 %
Improved performance and reliability by AUMUND
Case Study – Bucket Conveyor Upgrade
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Professional Solutions
for Bulk Materials Handling
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The AUMUND Group
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The AUMUND Group
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Inspection
Training
Consulting
PREMAS®
PREventive MAintenance Services
AUMUND PREMAS K.Gruene
by AUMUND
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(Kette Rexnord)
Why Preventive Maintenance?
What do you think
happend here ???
Only one bucket
was assembled wrongly !!!
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waited too long ….
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Advantage "Use until failure" – this concept means a low-cost effort for the servicing work …. until a machine failure occurs
Disadvantage Higher cost due to unforeseeable downtimes Higher manpower cost Higher cost due to production losses
Maintenance Strategies Reactive. Preventive. Condition Based.
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Maintenance Strategies Reactive. Preventive. Condition Based.
Advantage • Fixed maintenance intervals reduce machine downtimes • In contrast to reactive maintenance, a high cost saving can be reached • Maintenance can be planned and carried out in times of low sales • Reduction of production losses
Disadvantage • Higher cost for spare parts, as components featuring a residual service
time possibly have to be replaced
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Maintenance Strategies Reactive. Preventive. Condition Based.
Advantage • The permanent monitoring detects damage of components already at an
early stage • Maintenance work is carried out as required only and can be planned in
due time • Versus preventive maintenance an additional cost saving is possible.
This cuts down the costs for machine and process outages • The costs for manpower and spare parts are reduced further
Disadvantage • The investment expenditure for conventional monitoring systems such as
thermography and vibration analysis can be very high
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Considering the costs – value ratio The best strategy for conveying equipment is a combination of Preventive Maintenance and Condition Based Maintenance performing regular professional inspections of the equipment to identify the actual status of wear parts
AUMUND PREMAS K.Gruene
Maintenance Strategies - Conclusion
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AUMUND PREMAS K.Gruene
• Professional assessment of the machine condition
• Failure and wear analysis based on:
Function tests. Visual checks. Wear measures.
• Time scheduling depending on machine downtime
• Qualified and certified PREMAS® Inspectors
• Well structured, reliable and detailed reports
• Avoiding unforeseen stops of production
• Avoiding mechanical damage out of crashes in the conveying lines
• Higher operational availability and efficiency
• Minimized spare part stock-keeping
Added Value of PREMAS® Inspection. Training. Consulting.
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Parts
storage and
handling
Shipping
within an
agreed time
frame
Tailored
parts package
with fixed
costs
Field Service
Supervision
etc.
Fixed Field
Service Rates
On duty
within an
agreed time
Equipment
Inspection,
Training and
Consulting
Wear
estimates,
maintenance
and repair
proposals
Parts
identification
and
forecasting PREMAS®
Parts and Logistics
Field Support
Parts and
Services just
in time
AUMUND Lifetime Service Package
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AUMUND Worldwide
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AUMUND PREMAS K.Gruene May 2014
AUMUND PREMAS®
THE TEAM YOU CAN COUNT ON
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PREMAS®
THANK YOU FOR YOUR ATTENTION