BV-P2103GB Pneumatic Conveying For The Cement and Gypsum Industries Sept 12
BV-P2103GB Pneumatic Conveying For The Cement and Gypsum Industries Sept 12
BV-P2103GB Pneumatic Conveying For The Cement and Gypsum Industries Sept 12
Acting locally to support your needs the Schenck Process Group is working where you are. With a global network of sites and competent partners, the name Schenck Process is synonymous throughout the world with process expertise and well-engineered measuring technology for industrial weighing, feeding, conveying, screening, automation and air ltration technology. Our key skills include planning processes, feeding bulk materials, controlling ows of material, recording ows of goods, weighing goods and automating transport processes. Members of the Schenck Process Group are:
Our key benets Signicant increases in productivity Environmental sustainability of the processes High system availability, reliability and performance Low operating costs and maintenance Greater Process control Cleaner and dust free working environment Cost savings through process efciencies Flexibility to integrate with existing and emerging technologies Comprehensive aftercare service and spares availability A wealth of experience to form close working relationships
The name Schenck Process is synonymous throughout the world with process expertise and well-engineered technology for the key processes of weighing, feeding, conveying, screening, automation and air ltration technology. Living up to our claim that we make processes work across the minerals industries. The combined product and process technologies from Schenck Process are able to handle the raw and processed materials in the Cement and Gypsum industries from delivery to despatch. Using Schenck Process pneumatic technologies the company can provide systems that are suitable for the main materials handling movements within a production plant. Schenck Process also delivers state of the art process injection solutions for these industries.
By using Dense Phase Pneumatic Conveying, for example, difcult materials that are abrasive or friable are transported by pushing the material along a pipe in a plug form at very low velocities. This means minimal wear on the pipe bends, and minimum damage to materials, providing minimum maintenance and long life of the installation. Efcient use of compressed air also gives low power consumption and running costs. Standard systems are available for material temperatures up to 450C, rates of over 300 t/h and for distances over 2 km, depending upon the material, all in a single pipeline but other specialised solutions outside these parameters can also be achieved.
Train Reception
Truck Scales
MoveMaster or TEDO Mechanical Conveying Dry Dense Transfer Phase Conveying Vessel
PortBulk
Fly Ash
Gypsum
Ground Slag
Cement OPC
Legend: Process step covered by the Schenck Process Group Unless stated otherwise, green lines indicate pneumatic conveying.
Handling ordinary Portland cement (OPC) and blend materials Schenck Process have provided many alternatives for production of CEM products to suit the clients existing plant. Blast Furnace Slag (BFS), pulverised Fly Ash (PFA), Desulphurised Gypsum (DSG) can be fed to the mill or blended from silos easily.
Pulverised Coal Stockyard Primary Fuel MULTICOR K Limestone Clay Silica Ferrous Sulphate Calcinator
Raw Meal MULTIDOS Weighfeeders Raw Coal Meal Mill Coal Dust Waste Heat Boiler Filters ESP Burner Rotary Kiln (Main Burner)
Coal Mill
Filter
Pulverised Coal
Pulverised Coal
Filters ESP
Coal
RotoFeed Injection
Clinker
Kiln ByPass Dust Clinker Classifier Filters MULTICOR S Mass Flow Unit Option 3 Mix after Mill Option 1 Mix in Mill Filled in Bulk Bags
Cement OPC
Cement
Train Reception
MoveMaster
25 kg
Bagging Plant
Legend: Process step covered by the Schenck Process Group Unless stated otherwise, green lines indicate pneumatic conveying.
Truck Scales Grout Line Mixer 25 kg Bagging Plant Mixed
Schenck Process have delivered complete handling solutions for new plants and process steps for upgrade projects. The pneumatic conveying equipment design and location is exible and can reduce plant footprint or thread through existing installations.
Crusher
Sizing Screen
Rock Breaker
Screen
DSG store
Crusher
MoveMaster
Mill Classifier
MoveMaster PreCalcined
Recycled Dense Filter Phase Conveying Dust Vessel
Additive System
Ground Precalcined
Pearlite
Guargum
Starch
HRA
Fiberglass
Kettle
Precalcined Plaster
Filter RTN Load Cells Micro silica Pearlite Waterrepel Bulk Loading Point
Additives Additives Additives
MULTIDOS Weighfeeder
Precalcined Plaster
Precalcined Plaster
Bad Batch
Calcined Plaster
Ground
Ground
Filter Tubed Stuco Tubed Stuco Tubed Stuco Post Clacine Stucco Post Clacine Stucco
Pigment
Sugar
Fibreglass
Plaster
Plaster
Plaster
Sizing Screen
Plaster
Plaster
MULTIDOS Weighfeeder
By using Dense Phase Pneumatic Conveying difcult materials that are abrasive or friable are transported by pushing the material along a pipe in a plug form at very low velocities. This means minimal wear on the pipe bends, and minimum damage to materials, providing minimum maintenance and long life of the installation. Efcient use of compressed air also gives low power consumption and running costs. Standard systems are available for material temperatures up to 450C, rates of over 300 t/h and for long distances over 2km, depending upon the material, all in a single pipeline but other specialised solutions outside of these parameters can be achieved using the technical expertise and experience of Schenck Process engineers.
Commonly Conveyed Products: Raw Meal Cement Sand Pulverised Coal/Granular Coal Ground Materials Limestone/Lime Additives Ferrous Sulphate Stucco/Plaster Pelletised & Granular Alternative Fuels Ground Blast Furnace Slag Filter Dusts Micro Silica Desulphurised Gypsum (DSG)
Dense Phase using Pressure Vessels The most energy efcient form of pneumatic conveying High throughputs achievable Long conveying distances achievable Minimum maintenance Low number of moving parts Low product degradation
The range of pumps for dense phase conveying are designed for different applications according to the material and the distances the material is to be conveyed. The range of dense phase pumps are: DensPhase pump simple system for low rates and short distances PD Pump more efcient system for ne particles CD Pump semi-continuous dense phase system TD Pump high capacity pump for long distances in a batch system for ne particles MPD Pump large multiple pickup systems for ne particles SD Pump suitable for sand conveying AV Vessel suitable for small, multiple pick up points for powders and granules Each pump can be tted with a number of optional extras such as high and low level probes, weighing, vent valves, internal coatings, vessel uidisation or outlet dome valves. Consultation with the client is used to specify the most ideal combination of controls for the dense phase pump that is suitable for the material and conveying distances required.
Injection Technology
For pneumatic conveying applications where an accurate steady controllable feed into a process is required, Schenck Process RotoFeed and RotoScrew injection technology provides the answer. Utilising the proven design of the Original Dome Valve and pressure vessel technology from the Schenck Process dense phase range, the addition of either a RotoFeed or RotoScrew acting as a volumetric metering feeder with a variable speed drive creates the injection system solution of choice. By incorporating weighing technology into the system a gravimetric version is created which can achieve accuracies of better than 1% and a turndown ratio of 10:1. Capable of injecting against back pressures such as in a chemical reactor, coal gasication process or blast furnace, or under a molten head of liquid metal such as in a copper bath smelter, or direct into a burner on a combustion process such as a cement kiln or ash furnace burner.
This technology is also suitable for multi-point injection of material and suitable for either batch or continuous injection.
Controllable Feed Provides a steady, controlled feed of material into a process. Adjustable Injection Rate The injection rate is adjustable and can be controlled to meet the needs of the process, 5:1 turndown is standard. Accurate Feed The injection rate is accurately controlled, by the RotoFeed/ RotoScrew to 2% by volume or 1% by weight. Injection against pressure The material can be injected into a pressurised environment. For Kiln Burner Fuel Injection Because of the ability to inject at higher pressures this enables longer injection distances to be possible with this technology
compared with traditional competing technologies. This offers the opportunity to reduce infrastructure, construction and operating costs. Integrated into Process Injection systems normally form an integrated part of a larger process plant. Wide range of materials RotoFeeds are used for ne uidisable materials through granulars to 10 mm. RotoScrew can feed cohesive or irregular and large materials as well as highly abrasive materials including: Pulverised coal Granular coal Coke Lime/Limestone
The highly innovative and well proven Original Dome Valve from Schenck Process is reputably the most effective fast closing, bulk material handling valve in the world. The Original Dome Valve was developed by Clyde Materials Handling in 1974 for use with pneumatic conveying systems and as a stand alone product. To date, more than 20,000 Original Dome Valves have been sold worldwide, for applications across a range of industries including: - food, pharmaceuticals, chemicals, plastics, minerals, power, iron and steel. The same simple design philosophy also eases the task of preventative routine maintenance and makes parts replacement a quick and simple task.
The seal automatically deates during opening and closing, thereby avoiding contact with the dome and eliminating unnecessary wear.
The seal automatically inates only when the dome is fully closed.
Features and benets include: Full bore unobstructed material ow Can cut through moving or static columns of material Wide range of valve sizes: 50mm (2) to 750mm (30) 10 bar design pressure as standard Forms pressure tight seal when closed Inatable seal leakage detection system Designs can be provided for pressures up to 35 bar (507 psi) Simple, fully proven design Can handle material temperatures from 20C to +480C (-4F to 896F) Long operating life Up to 1,000,000 cycles between major overhauls with most materials Suitable for vacuum applications Low maintenance Extremely quick seal replacement Fast operating function
Clyde Materials Handling Ltd was purchased by Schenck Process in 2011 and therefore the Original Dome Valve and Clyde Process Pneumatic Conveying and Injection systems are part of the range of Schenck Process technologies.
TestCentre
Perfect reliability through more than 40,000 tests with more than 10,000 different types of bulk material at the Schenck Process TestCentres.
Extensive test facilities include an impressive array of pneumatic conveying and pneumatic injection systems. Customers are invited to supply materials which can be tested using either dilute (lean), medium or dense phase technology in either positive or negative pressure congurations, in conjunction with a selection of pipe diameters, route congurations, transfer distance and throughputs. Most site conditions can be accurately replicated using full size systems, including transfer distances up to 500m. System efciencies and any material degradation can be fully monitored to ensure the best solutions are proposed. This also minimises the likelihood of overspend or delays during installation and commissioning.
Schenck Process has an extensive materials database covering over 10,000 samples where characteristics such as particle size distribution, shape, porosity, bulk density, temperature, moisture content, fragility and air retentiveness have been measured and the most suitable conveying method determined. This practical experience is invaluable in determining the most effective solution to a customers application and details of every new test is added to the database. This resource is also available to customers who independently need to establish the ow characteristics of a material or to help solve on-site problems with existing or competitors systems.
Individual Solutions for the Most Extreme Conditions. The harsher the environmental conditions, the more resilient the technical systems must be. This particularly applies to industries such as cement and gypsum production. Schenck Process Group offers these industries a wide range of reliable systems and sound application know-how.
FEEDING
FEEDING
FEEDING
MULTIDOS H Bulk Dosing Wide range of Schenck Process developed weighfeeders Feed rate up to 1,500 t/h Accuracy up to 0,25 % Mechatronic design Long experience with many important industrial materials
MULTICOR S Lime Feeders MULTICOR & MULTIDOS type Compact design, dust tight Accuracy 0.5% Easy plant integration Minimal wearing components
MULTICOR K Coal Dust Feeding Pulsation-free feeding High feeding constancy = high product quality and efcient kiln operation Feeding is unaffected by outside inuences Engineering, material discharge, feeding and measurement from a single source High-quality materials for all contact parts provide excellent wear resistance
FEEDING
CONVEYING
WEIGHING
MULTISTREAM G Solid Flow Meter Cost-effective, complete solution Dust-tight, robust construction Measuring and guide chute integrated into housing Available with integrated on-site evaluation electronics
Mechanical Conveying and MoveMaster Bulk Conveying Tube Belt Conveyor U Belt Conveyor Corrugated Belt Conveyor Smooth material handling Horizontal transport and elevating Maintenance optimised design For various bulk materials En-masse Chain Conveying
MULTIBELT Belt Weighing Precise mass ow measurement Standard and tailor-made design Accuracy up to 0,25 % Optional legal-for-trade execution
WEIGHING
WEIGHING
LOGISTICS AUTOMATION
MULTIRAIL LegalWeight Train Weighing Dynamic railway scale for all wagon types Legal-for-trade accuracy No foundation No rail gap Fully automatic operation Very quick installation Static/dynamic platform weighbridges also available
Truck Weighing Surface or pit mounted versions Optimised steel or concrete design Capacity up to more than 100 t Legal-for-trade accuracy Complete delivery, quick installation World wide references in all key industries
LOGiQ Loading Automation Logistics solution for bulk materials and cargo industry Automation of all loading procedures from ordering through to shipment Faster loading due to accurately dened processes Mass ow management of incoming and outgoing materials by truck, train and ship
Schenck Process is the global market leader of solutions in measuring and process technologies in industrial weighing, feeding, conveying, screening, automation and air ltration technology. Schenck Process develops, manufactures and markets a full range of solutions, products and turnkey systems on the basis of combining process engineering expertise, reliable components and eld-proven technology.
Schenck Process UK Ltd Carolina Court, Lakeside Doncaster, DN4 5RA, United Kingdom T +44 (0)1302 321 313 F +44 (0)1302 554 400 [email protected] www.schenckprocess.co.uk
BV-P 2103 GB
1000.08.12 All information is given without obligation. All specications are subject to change.