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Pipe Conveyors Provide Operational Gains, Minimal Disruption, No Material Loss

April23,2015 0 1

1 2 3 4 5 SchwenkZementKGisreplacingitsolddragchainconveyorlinewithamodernpipeconveyorfromBeumerGroup.Requiringa
solutionthatwouldtransportalternativefuelssuchascrushedplasticmaterial,textiles,andpaperfromthewarehousetothe
feedingsystemoftheoveninitscementplantinBernburg,Germany,thisfullyclosedconveyingsystemmakestransportingbulk
materialmoreenvironmentallyfriendlyandenergyefficient.Maintenancecostsarealsoconsiderablylowerandthesystemcan
beoptimallyadaptedtotheambientconditions.
Schwenk'sproductdiversityandproductioncapacitymakethecementplantinBernburgoneofthelargestandmostefficient
buildingmaterialplantsinGermany.TheproductionofcementalongtheriverSaalehasarichhistoryduetotheprevalenceof
highqualitydepositsoflimestoneinthisarea.Theplanthasbeeninexistencesince1960.Schwenktookovertheplantin1990
andtoredowntheexistingsystemstobuildanentirelynewplant.Today,Schwenksproductportfolioincludesawiderangeof
efficient,specializedcementmarkedbyconsistentlyhighquality.Thecompanyproducestheidealproductusingmodernmixing
technology,asrequiredfortunnel,road,andwellconstruction,aswellasforgeothermalandenvironmentengineering.
OnetopicofgreatimportancetotheSchwenkplantissustainableproduction.Productionofcementhasalwaysbeenoneofthe
mostenergyintensiveoperations.ThisiswhySchwenkminimizestheuseofprimaryfuelssuchascoalandoilandfocuses
increasinglyonsubstitutefuels.Thesesubstitutefuelsaremainlyamixtureofhighcalorificwastematerials,comprisedmostlyof
plasticandpackagingresiduesandtextiles.Theyareprocessedtohighgradefuelswithdefinedproductparametersinexternal
Thepipeconveyoriscustomizedtofit processingplants.
perfectlyintothelocalfeaturesofthe
environment. HeatIntensiveProcesses
Forthemanufacturingofcement,limestoneisquarried,crushed,andhomogenizedwithadditionalrawmaterials.Beltconveyors
thentransportthecrushedmaterialwithothermaterialsfromtheblendingbedtotheplant.Itisgroundtothenecessarygrainsize
intherawmillsandthendried.Therawmealisthenhomogenizedandtemporarilystoredinlargesilos.ToobtainPortlandcementclinker,acoarseintermediateproduct,the
rawmealisfirsttransportedintothecyclonepreheater,thenintothecalcinator,bothpoweredbyalternativefuels.Thelimestoneportionoftherawmealisdeacidifiedat
temperaturesofover950C.Thematerialthenmovesintotherotarykilnwhereitisburnedattemperaturesofapproximately1450C.
Upuntilnow,Schwenkreliedonadragchainconveyorlinefortransportingthefuelsfromthestorehousetothefeedingsystemsofitsmainburner.Thebaffleplateson
thesemechanicalcontinuousconveyorsaremountedtoanendlesschain,transportingthebulkmaterialinatrough."Wehadbeenusingthissystemformorethan10years.
Thismeantthatwehadtoputmoreandmoremaintenanceworkintoit,"saysDirkFabian,productionmanageratSchwenkinBernburg.
Anotherproblemwasthatafterfurtherdevelopmentofthedosingtechnology,thedragchainconveyorwasnolongerabletotransportenoughbulkmaterial,withadensity
ofonly0.2tn/cum,totheweighfeeders(andthustothemainburner)."Wewerelookingforanalternativesolutionthatwouldbeecologicalaswellaslowinmaintenance,"
explainedDirkFabian.Inaddition,thenewconveyorhadtobeoptimallyadaptedtothecurvedroutingintheplant.

ComprehensiveExpertise,OptimumSupport
Forthebuildingmaterialmanufacturer,BeumerGroupwastheirfirstchoicesupplieroftheoptimalconveyingtechnology.Schwenkhasalongstandingandclosepartnership
withBeumerasaninternationallyoperatingsystemsupplier.BeumerhasprovidedSchwenkPutztechnikGmbH&Co.KG,headquarteredinUlminsouthernGermany,with
severalBeumerpaletpachighcapacitylayerpelletizers,equippedwiththenewlydevelopedtwinbeltturningdevice.Beumerhasbundleditscomprehensiveexpertiseinthe
buildingmaterialindustryandestablisheddifferentCentersofCompetence,inordertoofferoptimalsupportforglobalbuildingmaterialmanufacturersbyofferingsingle
sourcesolutions.The"pipeconveyor"segmentisonesuchCenterofCompetence.Thesecentersareinchargeofworldwideprojectmanagementandsales.Theycollect
andprocesstheexpertisefromtheindividuallocalgroupcompaniesandpassitontotheglobalGroupexpertsineachrespectivefield.

HighLevelofEnvironmentalProtection,LowLevelofMaintenance
"TogetherwiththemanagementteaminBernburg,wedevelopedasolutionthatistailoredexactlytomatchSchwenk'srequirements",saysMichalMikulec,managingdirector
atBeumerGroupCzechRepublica.s.andsupervisorforthisproject.Ourfirstideawastocombineanewdragchainconveyorwithseveralopenbeltconveyors,butitwas
quicklyabandoned.Itbecameapparentthatapipeconveyorwasthebestsolutionofferingenvironmentalprotectionandlowmaintenance.Itscloseddesignprotectsthe
environmentfromtransportedgoodsfallingdown.Anotheradvantageisthelackofdustdevelopmentontherunningline."
Theseconveyorsoffermanyotheradvantages.Theyareabletonavigatelongdistancesandtightcurveradii.Duetotheirabilitytonegotiatecurves,considerablyless
transfertowersarerequiredcomparedtootherbeltconveyors.Thisresultsinsubstantialcostsavingsforthecustomeranddeliveryofasystemcustomizedforindividual
routing.BeumerGroupsuppliedandinstalledasystemwithadiameterof200mmandalengthof230m.Itconveysupto15tonsofmaterialperhour.Beumerwasalso
responsibleforthedesignofthesystemandtheentiresteelstructure.
DurableconveyorbeltsguaranteeingtensilestrengthareusedintheSchwenksolution."TofindtheidealbeltversionforSchwenk,wecalculatedthetractiveforcesaswell
astheforcesthatoccurduringaccelerationanddecelerationalwaysconsideringthenetweightofthebeltandthetransporteditem,"saidMikulec.
Theengineersalsoprecalculatedthebeltpositionsindifferentcurveradiifortheemptyandloadedbelt.Anothersystemadvantageisthereducednoiseemissionofthepipe
conveyors."Specialidlers,aswellaslownoisebearingsandelectricmotors,workveryquietly.Thisimprovesthequalityofouremployees'daytodayworkenvironmentand
ensuresthepeoplelivingneartheplantarenotdisturbed,"saidFabian.

TroubleFreeOperation
Cranespickupthetreatedsubstitutefuelsinthestorehouseandunloadthemintothedischargebunkerwiththedischargesystem.Fromhere,thechainbeltconveyor
continuallytransportsthematerialtothenewpipeconveyorthatthentransportsittotheweighfeedersofthemainburner.
Beumerwasabletooptimallycustomizetheroutingoftheconveyortotheplant.Anotherrequirementmetbytheexperts:nosupportsunderneaththepipeconveyorthat
wouldotherwiseobstructvehicles.Thisiswhythetechniciansmountedthefirstsupportdirectlytothestorehouse.TheconveyortakeupsystemwasdesignedbyBeumeras
atakeuptower.Itislocatedrightnexttothefeedingstation.
IttookonlyeightmonthsfromthetimethecontractwasawardeduntilcommissioningofthenewsysteminFebruary2014."WehavebeenworkingwiththeBeumersystem
forseveralmonthsnow,"saidFabian."Weareverysatisfied.Itisveryrobustandwenolongerhaveanyfailures."

BeumerGroupisaninternationalmanufacturingleaderinintralogisticsinthefieldsofconveying,loading,palletizing,packaging,sortation,anddistributiontechnology.For
moreinformation,visitwww.beumergroup.com.

Forrelatedarticles,news,andequipmentreviews,visitourMechanicalConveyingEquipmentZone

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2/15/2017 PipeConveyorsProvideOperationalGains,MinimalDisruption,NoMaterialLoss|Powder/BulkSolids

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