10.00 Heinrich Höse, Aumund Fördertechnik GmbH

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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



Mega Cement Plant – 12,000 tons per day

Critical Choices in Concept and Components

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Holcim Ste. Genevieve

At over 12,000 tons per day actual clinker

capacity; this is the world’s largest kiln line



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

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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



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

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Railborne Intake Back-to-Back Feeders

Based on Tracked Vehicle chains and rollers with overlapping steel plates ensuring clean operation



Feeding of Secondary Crusher Limestone

BPB-S Apron Feeder with integral round link chain

scraper cleanup conveyor

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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



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

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Aumund BWZ Central Chain Bucket Elevator

...Proven...High

AvailabilityTotal

Reliability



Raw Meal Feed to Prehheater

Aumund Belt Bucket Elevators trusted with the Critical Paths to

Blending Silo and Preheater

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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)



Preheater and Kiln

Two String preheater with five stages and a single calciner.

Rotary Kiln: 6.6 x 93m

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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)



Pan Conveyors with Precision Laser Chains

...Legendry – Proven......Performance...

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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)



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

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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)



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

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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



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)

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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



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

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4 X CentrexTM Silo Extractors

CentrexTM pictured during erection. Typical design with

integrated Weigh Belt Feeder for Gypsum etc..



Clinker Dust Collecting and Transfer

Aumund type TKF drag chain conveyors for Clinker Dust fully sealed, spillage free and dust tight, multiple inlets & outlets

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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



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

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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



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.

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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..



Asia Cement Group – Jiangxi-Ya-Dong

An integrated cement plant on the Yangtze with four lines serviced by waterborne logistics

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An Enduring Relationship

Since 1982 Schade (Aumund Group) have supplied Stacker and Reclaimer equipment for the many cement plants

of Asia Cement Group



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

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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



Mobile Shiploader for Cong Thanh Cement

Fully Mobile Shiploader at Nghi Son Port for loading

larger ships to 30,000 DWT

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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



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

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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



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

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New Head Shaft and Sprockets

The drive head including shaft, bearings and

segmented sprockets configured to suit the existing

steelwork and supports



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

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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



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

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The Aumund Group - Fully Integrated Service

IntakeIntake

StockpilingStockpiling

ReclaimReclaim Vertical ElevatorVertical Elevator

FeedingFeeding

ConveyingConveying

Knowledgewith thePower

toPerform



Engineering and Design

Experience + Know-How = Performance

YourOne-Stop-Shop

forBulk Materials

Handling

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The Aumund Group

Established 1922

Headquarters in Rheinberg GermanyAumund Fördertechnik

1956 2011



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

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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



THANK YOU FOR LISTENING

10.00 Heinrich Höse, Aumund Fördertechnik GmbH

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Transcript of 10.00 Heinrich Höse, Aumund Fördertechnik GmbH