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W E C O N V E Y Q U A L I T Y
Conveying and Storing in the Cement Industry
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Contents
4 AUMUND Group Equipment in the Cement Industry
6 Clinker Transport
10 Conveying of raw meal, cement and additives
12 Transport of raw material, clinker, additives and cement
14 Hopper discharge and Crusher Feeding
16 Proportional feeding, Proportional Discharge
17 Silo and Hopper Discharge
19 Dust-Tight Transport
20 Material Reception and Transfer
21 Clinker Loading
22 Clinker Storage & Clinker Discharge
24 Conversions & Refurbishments
25 After Sales Service
26 Other AUMUND Group Equipment in the Cement Industry
• Highestqualitystandardsensuring reliability
• Efficiencyandprofitability
• Centralmanufacturewith intra-plant quality assuring systems
• Fieldassemblyandcommis-sioningwithhighlyqualifiedsupervisors
• Certificationaccording to DIN ISO 9001
• WorldwideAfter-Sales Services
Concept and Engineering
The guideline for the AUMUND concept is maximum customer benefit.
Manufacture, Assembly, Service
For the conveying and storagetechnology AUMUND offers aunique combination of:
• Adaptedtothecustomer’sspecificrequirements,alltransport processes are constantly optimised on the basis of innovations and the latesttechnicalknowhow.
• Offeredsolutionscombineeconomical and ecological aspects which will also complywithfuturedemands.
•Highsafetystandardsinall functions and under all conditions with worldwide proven technology, quality andreliability.
Company Headquarters in Rheinberg
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The AUMUND Group AUMUND Group products are successfully operating onallcontinents.
Thehighstandardsinthefieldsofconcept,engineering,manufacture and assembly are supported by a network ofworldwideofficesandrepresentations.
Hong Kong
P.R.China
India
DubaiU.A.E.
RussiaSwitzerland
France
Germany
Great Britain
BrazilUSA
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1. Limestoneintakeandtransferto stationary crusher (Samson® Feeder)
2. Storageandreclaimofshale/ clay (Portal Reclaimer)
3. Feedingpre-blendingsilos(Bucket Elevator)
4. Distributionoflimestoneandaggregates (En Masse Chain Conveyor)
5. Dischargeandreclaimoflimestone and aggregates (CENTREX®/RotaryDischargeMachine)
6. Proportionalfeedingofrawmill(Weigh Feeder)
7. Rawmillcirculation(BucketElevator)
8. Filterdustreclaim(EnMasseChain Conveyor)
9. Rawmealsilofeeding(BucketElevator)
10.Receptionandtransferofalternative fuels (Samson® Feeder)
11.Rawmealfeedingtopre-heater(Bucket Elevator)
12.Clinkerdustreclaim(EnMasseChain Conveyor)
13.Clinkertransportfromcoolertostorage (Pan Conveyor)
14.Automaticclinkerdischarge(MOLEX®)
15.Grabunloading(EcoHopper)
AUMUND Group Equipment in the Cement Industry
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16.Truckloadingofclinker(Telescopic Spout)
17.Clinkerintakeandtransfertoshiploader (Samson Feeder)
18.ClinkerloadingwithMobileShiploader
19.LinkConveyorwithmobile face crusher
20.Limestonecrusherreclaim(Arched Plate Conveyor)
21.Limestoneblendingbed(Stacker/Reclaimer)
22.Coal/petcokeunloadingandreclaim (Rotary Wagon Tipper)
23.Storageandreclaimofcoal/petcoke (Circular Stockyard)
24.Bucketelevatortocoalmill25.Proportionalfeedingofcoalmill
(En Masse Chain Conveyor)26.Coaldustreclaim(EnMasse
Chain Conveyor)27.Clinkerstorageinsteelplatesilo28.Gypsumstorageandreclaim
(CENTREX®/RotaryDischargeMachine)
29.Clinkertransfertomillhoppers(Pan Conveyor)
30.Dischargeandreclaimofclinkerand additives (Silo Discharge Gate/CENTREX®/RotaryDischarge Machine)
31.Distributionofclinkerandadditives (Pivoting Pan Conveyor)
32.Cementmillfeeding(BucketElevator)
33.Filterdustreclaim(EnMasseChain Conveyor)
34.Cementsilofeeding(BucketElevator)
AUMUND Group Equipment in the Cement Industry
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Deep-Drawn Pan Conveyor type KZBDeep-Drawn Pan Conveyors with transfer station
Pan Conveyor with Deep Drawn Pans type KZB
Deep-Drawn Pan Conveyor - Detail
• Inclinationupto30°• Qualityassuredand
cost-effective • Recognisedandproven
on all continents
When conveying hot, abrasive cement clinker, a trouble-free operation of the transport system is decisive for the availability ofthewholesystem.
AUMUND Deep-Drawn Pan Conveyors type KZB, stand out for reliability and long servicelife.
KZB – the economic conveying system for the transport of cement clinker incontinuousoperation.
• Capacitiesexceeding1,600t/h• Standardisedcomponents• Platewidthsfrom400to
2,400 mm• Stiffenedsideplates• Contactfreeoverlapping
of the plates• Chainbreakingloadsofupto3,900kN/chainstrand
Clinker Transport
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Silo feeding with steep-angle conveyor
• Inclinationupto45°
The standard Deep-Drawn Pan Conveyorsfittedwithbaffleplates allows for conveying at inclinationsupto45°.
The standard chain program allows for conveying heights up to 90 m.
Pan Conveyor with Deep Drawn PansandBafflestypeKZB-Q
PanConveyorwithbaffles
KZB-Q inclined at 45 degrees
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Pan Conveyor with Buckets type BZB
• Inclinationupto60°
AUMUND Bucket Apron Conveyors type BZB are designed for extreme inclinationsincementplants.Unfa-vourable space conditions and incli-nation angles up to 60° are regarded as preferred application conditions, espe cially in case of conversions in existingplants.Thenarrowbucket
spacingisidealforfine-grainedclinkerwithhighdustcontent.
• Capacitiesto600t/h• Smallestcurveradius10m• Standardisedcomponents• Chainbreakingloadsup to3,900kN/chainstrand
Feeding of steel plate silos
Bucket Apron Conveyor type BZB Detail
Feeding of mill hoppers
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Pivoting Pan Conveyor type SPB
• Feedingmultiplehoppersandsilos
Important AUMUND developments have turned the Pivoting Pan Conveyor type SPB intoanefficientinstrumentforautomizeddistribution.
If more than two silos are to be fed, the AUMUND Pivoting Pan Conveyor is the bestsolution.
• Automatedfeedingofclinkersilosandmill hoppers• Remote-controlled• Severalintermediatedischargepoints• Systemlengthof400mandmore• Simultaneousconveyingofdifferentbulk
materials in the upper and lower run• Lowmaintenance• Minimumenergyconsumption• Longservicelife
Feeding two silos in line
Mill hopper feeding
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• Highperformance
AUMUND Belt Bucket Elevators type BWG, with automatic parallel tensioning device are applied for the conveying of cement, raw meal orfine-grainedadditives.
For pre-heater feeding, lifts to 175 m and conveying capacities ofmorethan1,850m³/hhavebeen achieved with AUMUND beltbucketelevators.
• Conveyingheightsto175m• Conveyingcapacitiesofmore than1,850m³/h• Continuousreceiptanddis-
charge of conveying mate-rial by means of tight bucket sequence• Optimumdischargecondi-
tions• Continuousoperationwith low maintenance requirement
The steel reinforced belts fea-ture longitudinal cords with two layersoftransversecords.Thebelt ends are spliced with special clamp connections.
As a standard, the drive pulleys are equipped with exchangeable friction lining, thus enabling the exchange of the segments without openingthebelt.Aparalleltoothed rack guided tensioning device provides automatic belt tensioning and prevents off-trackrunning.
• Conveyingmaterialtemperatures up to 130 °C• Beltwithhightensilestrength• Inchingdriveformaintenance
purposes• Securebucketattachment
Drive pulley
BucketElevatorwithSteel-ReinforcedBelttype BWG
Conveying of Raw Meal, Cement and Additives
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Cement silo feeding
Pre-heater feeding Belt Bucket Elevators handling raw meal
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Bucket Elevator with Central Chain type BWZ
• Reducingvibrations• Preventingcrackformation• Longservicelife
High conveying capacities due to a tight bucket sequence and buckets up to 1,200 mm width are the characteristic features of the AUMUND Bucket Elevator type BWZwithforgedcentralchain.
The typical AUMUND bucket at-tachment reduces vibrations and thus prevents crack formation at bucketwallsandweldingseams.
The chain with lubricated labyrinth seals contributes to a long service life.
• Conveyingcapacitiesofmore than900m³/h• Conveyingheightsto90m• Longservicelivewithcontinuous
operation• Forgedcentralchainwithlargely
dimensioned joint surfaces
• Designedforoperationwith material temperature peaks up to 400 °C • Driveringandtensionwheel
in segments• Inchingdrivefor maintenance purposes
Bucket Elevator for silo feeding Central Chain
Transport of Raw Material, Clinker, Additives and Cement
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Double Bucket Elevator type BWZ-D
• Conveyingcapacitiesofmore than 1,800 m³/h
• Conveyingheightsover60m• Highoperationalreliability• Soliddesign
Higher kiln capacities and new grinding processes in the cement industry require Bucket Elevators with high conveying capacitiesandcenterdistances.
AUMUND Double Bucket Elevators type BWZ-D are the appropriate solution for these requirements and ideal as circulating Bucket Elevators in grinding plants.
Head of Double Bucket Elevator with double drive and two bucket strands
Silo feeding
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Arched Plate ConveyortypeBPBandBPB-S/SF
• Designstosuitconveyingofcohesivematerialsor heavy duty applications
For the transport of moist, sticky materials, such as clay, gypsum, anhydrite, puzzolana and marl the slightly arched plates of the Arched Plate Conveyor type BPB, allow a simple scraping off of cohesive materials.
Heavy plate conveyors type BPB-S or SF are installed forfeedingorreclaimofrunofminematerials.
The conveyors are equipped with forged chains and wear-resistantcomponents.Theplates,chainsandrollerdesignareconfiguredtosuittherelatedtaskandrequiredconveyingcapacity.
Loading and unloading station
Hopper discharge type BPB
Workshop assembly type BPB-SF
Heavy duty apron feeder type BPB-SF
Hopper Discharge and Crusher Feeding
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ArmouredChainConveyortypePKF
• Lowoverallheight• Adaptationtogivenhoppergeometries
The Armoured Chain Conveyor type PKF, is used as hopper discharge equipment for crushed limestone or for sticky raw materials, suchaschalk,gypsum,clayorcoal.
• Dischargecapacitiesof10toover1,200t/h• Overallwidthsfrom600upto2,600mm• Tractionforcesupto680kN/chainstrand• Twotofivestrandversionsdependingonthe
hopper width
• Adaptstogivenhoppergeometrieswhilethelow overall height also enables installation intoexistingplants.
Hopper discharge with Armoured Chain Conveyor
Armoured Chain Conveyor type PKF
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ApronWeighFeedertypeDPB• Proportionalfeeding• Proportionaldischarge
For proportional reclaim of bulk materials with poor flowpropertiessuchasclay,gypsum,marl,limestone,puzzolanaetc.theApronWeighFeederfeaturesarch-shaped plates especially designed for cohesive materials.
The Apron Weigh Feeder performs conveying and weighinginonestep.
For grained bulk materials such as clinker, slag sand and petcoke the Apron Weigh Feeder is equipped with deep-drawnpans.
For mill feeding the Apron Weigh Feeder is also available as completely enclosed and pressure-proof design.
Apron Weigh Feeder with arched plates Proportional feeding of additives
Mill feedingApron Weigh Feeder with deep drawn pans
Proportional Feeding, Proportional Discharge
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CENTREX®
type CTX-AFD/AV/IV• Trouble-freesilodischargeforcohesive
materials• Nosegregationorbridging On account of its compact and rigid design, the CENTREX® is an ideal solution for installation into or underneath existing silos or hoppers.Three basic alternatives are available within the CENTREX® system:
• CENTREX® with external drive and rotating inner cone type CTX-AFD• CENTREX® with external drive and stationary
inner cone type CTX-AV• CENTREX® with internal drive type CTX-IV
CENTREX® for discharge of natural gypsum and trass
Internal drive CENTREX® with internal drive
Silo and Hopper Discharge
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RotaryDischargeMachinetypeBEW
BEW-BL in block design BEW-FLinlowprofiledesign
BEW-K Rotating discharge machine
• Reliabledischarge
Rotary Discharge Machines ensure the reliable discharge of a wide variety of different additives or raw materials such as:
• Limestone,marl,clayorotherrawmaterials• NaturalandFGD-gypsum• Coal
The design alternatives of the discharge machine allow its adaptation to completely different applications: For the discharge from longitudinal hoppers or a line of silos,theblockorlowprofiledesignvariantisused,while the circular design is applied for the discharge from cylindrical silos.
Forthespecificcontrolofthereclaimcapacitytheblockorlowprofiledesigncanbeequippedwithaweigh feeder which comes fully integrated into the mobiledischargemachine.
The circular design guarantees a trouble-free reclaim of material from concrete or steel silos of up to 12 m diameter,offeringanadjustingrangeof1:10. • Firstin/Firstout• Simultaneousfeedinganddischarge• Proportionalreclaim
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Dust reclaim
“ENMASSE”ChainConveyortypeTKF• Especiallywear-resistantdesign• Ensuresauniformmaterialflow• Dusttight
Forconveying,distributing,andreclaimingcement,filterdusts,coalandadditivessuchasgypsum,anhydrite,sandorlimestone.
In especially wear-resistant design the Chain Conveyor is also usedtoconveycementclinker.
• Intermediatedischargethroughelectro-mechanically driven gates• Wear-resistantchainsforalongservicelife• Conveyingcapacityupto500t/h• Lengthupto50m• Shock-pressureproofdesignasanoption
For coal mill feeding applications, all Chain Conveyors come inadesignwhichisshock-pressureproofupto3.5baronastandardbasis.Additionally,suchChainConveyorsfeatureadouble-strandchain.Avariablespeeddrivewithfrequencyconverterensuresauniformmaterialflowandacontrolledfeedingcapacity.
Chain Conveyor in shock-pressure proof design for coal mill feeding
Dust-Tight Transport
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Samson®Feeder
Samson® - Transfer of additives
The ideal solution for the reception of all bulk materials in the cement industry such as cement clinker, coal and pet-coke, clay, limestone, gypsum rock, FGD gypsum, granulatedslag,alternativefuels.
Where materials are imported to cement plants by tipping or dump trucks and transferred to the next process step the Samson® Feeder offers an economical alternative to conventionalandexpensiveundergroundpitsandhoppers.
Surface installation eliminates costly permanent civil engineeringworksandallowsgreaterflexibilityinplantlayoutregardlessoflocalgroundconditions.
Since the Samson® is a single integrated machine it may be easily re-located to accommodate plant development.
The Samson® is available in different series designedforaspecificrangeofapplications.
Holding capacities up to 300 tons may be providedwithacontrolledratedischarge.
Samson® Feeder - for crusher feeding in a quarry
• Fasttruckdischarge• Nobridgingregardlessofmaterial
handling characteristics• Minimumdustgeneration• Easyaccessformaintenance• Flexibilityinlocationandrelocation• Reducedenergydemandandoperatingcost• Minimuminvestmentrisk
The Samson® concept
Material Reception and Transfer
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Telescopic Spout type TS
• Integraldustcontrol• Lowandheavydutyoperation
The AUMUND Telescopic Spout with integral dust control ensures the loading of clinker into trucks, barges or ships, offering an economic solution for lowandheavydutyoperation.
The heavy duty version of the telescopic spout is designed for rapidly successive loading cycles and high capacities of up to 700 t/h.Thissystemis usedinmorethan200installationsworldwide.
Applicationswithapproximatelyfiveloadingcyclesperday and loading capacities of 100 t/h to 150 t/h are the ideal field for the application of the low duty design.Duetothediminishedsegments,thesmallerhoist and the reduced dedusting volume, this system is the economical solution for installations requiring a low ormediumhandlingcapacity.
Ship loading Truck loading
Clinker Loading
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Concrete silo with steel roof
• Cylindricalsteelplatesilos• Specialdesignforextremelylargestoragevolumes• Concretesilowithsteelroof• Circularstoragehallwithsteelroof• Circularstoragehallwithconcretewall
and steel roof
To receive an optimum overall conveying and storage layout, early implementation of experienced layout engineers is recommended.
Silo Discharge gate type SAK
The design principle of the silo discharge gates prevents the free fall of the clinker onto the discharge conveyor and avoids dust generation (gravityprinciple).
The systematic alternating between the silo discharge gates ensures a uniform discharge of the clinker over the whole silo basis.
Clinker storage hall with concrete wall and steel roof
Gravity silo discharge
Clinker Storage
Clinker Discharge
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Automatic Clinker DischargetypeMOLEX®
• Successfullyoperating• Lowerinvestment• Loweroperatingand
maintenance costs
The MOLEX® is the residue-free discharge system successfully operating in several cementplants.
• 100%activestock• Availabilityofclinkerevenduringyearly
kiln shutdown• Blendingofoldandfreshclinker• Blendingofcoarseandfine-grained
clinker• Almostconsistentclinkermixtureformill
feeding
Lowerinvestmentand/oroperatingandmaintenance costs are the result of:
• Reductiontoonlyonereclaimtunnel• Lessconveyorsanddischargegates• Noresiduestocktoberemovedwith
loading shovels
Version with central column
Scraper chain drive
Covered stockpile with automatic discharge
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Conversions and Refurbishments
• Upgradingofexistingplantcomponents• Targetingincreasedefficiency• Higheroutput• Improvedavailability
With our expert team of engineers planning selective modernisation measures, we pay special attention to the upgrading of existing plant components,targetingincreasedefficiency, higheroutputratesandimprovedavailability.
Upgrading of your materials handling and storage equipment to state-of-the-art technology is achieved through a tailor-made refurbishment process under optimum utilisation of time and budget.
Most of the existing components are re-used in therefurbishmentprocesstosavecost.
Engineered conversions and refurbishments for increasedefficiencyandoutputareperformedonAUMUND equipment as well as on the equipment ofothermanufacturers.
Installation of new bucket strand
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After Sales Services
• CustomerProximityaroundtheWorldAt AUMUND, service does not end at the sale of the equipment.It’sthebeginningofalong-termpartnership.AUMUND offers you a full range of services – from commissioning to the delivery of quality spare and wear parts to customized preventive maintenance programs andequipmentupgrading.Thebenefitsforyou:Maximumequipmentefficiencyatloweroperatingcost.
• CommissioningandFieldService Today,presence“onthespot”isanabsolute“must”.Therefore, our commissioning and service engineers operate from support centers on all continents to guaranteeimmediateandcompetentsupport.
• SpareandWearPartsA comprehensive range of genuine spare parts is available for our entire product range from stocks inGermany,HongKongandtheUSA.Ourproductspecialistsprovideassistanceandrespondinstantly.
• RetrofitsAged and worn equipment? Capacity increase needed? Too high operating cost? AUMUND “just as new” retrofitsareeconomicalandtailor-madesolutionsforimprovingyourexistingequipmentatreasonablecost.
• PreventiveMaintenanceKnowing beforehand that service will be needed allows you to schedule downtime and save money with timely repairs.Repairsorretrofitscanbeaccuratelyanticipatedallowing for the downtime to be at the most convenient timesandatthelowestpossiblecost.
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Other AUMUND Group Equipmentin the Cement Industry
Stockyard Technology• Portal,bridge-typeor
cantilever reclaimers• Longitudinalstockyardsand
blending beds• Fixedandmobilestackers• Waggontippers• Circularstockyardsand
blending beds with portal, semi-portal, bridge-type or cantilever reclaimer
Bulk Material Handling• EcoHopper• MobileShiploaders• Stormajor® Boom Feeders• MobileLinkConveyors
Bridge Scraper Reclaimer for limestone
Mobile Shiploader with Samson® Feeder handling clinker for export
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Stacker & Bridge Scraper Reclaimer in circular storage for limestone
Cantilever Scraper Reclaimer for additive and corrective material
Unloading hoppers for clinker and additives
Stormajor® handling pet-coke
tHe AUMUnD GRoUP
GERMANY
AUMUNDFördertechnikGmbHSaalhofferStr.1747495 RheinbergPhone: +49 - 2843 - 72 0Fax: +49 - 2843 - 6 02 [email protected]
AUMUNDLogisticGmbHSaalhofferStr.1747495 RheinbergPhone: +49 - 2843 - 72 0Fax: +49 - 2843 - 7 24 [email protected]
SCHADELagertechnikGmbHBruchstraße 145883 GelsenkirchenPhone: +49 - 209 - 50 31 60Fax: +49 - 209 - 50 31 62 [email protected]
GREATBRITAIN
SAMSONMaterialsHandlingLtd.Gemini House Cambridgeshire Business Park, 1 Bartholomew`s WalkEly, Cambridgeshire CB7 4EAPhone: +44 - 1353 - 665 001Fax: +44 - 1353 - 666 [email protected]
INDIA
AUMUND Engineering PrivateLtd.2nd Floor, Lakshmi Neela Rite Choice Chambers · 9, Bazulla Road, T.NagarChennai-600017Phone: +91 - 44 - 4393 63 00Fax: +91 - 44 - 2815 60 [email protected]
HONGKONGSAR
AUMUNDAsia(H.K.)LimitedUnit3B&5,30/F. 148 Electric Road North Point Hong KongPhone: +852 - 3695 - 43 33Fax: +852 - 3695 - 43 [email protected]
DUBAI U.A.E.
AUMUNDFördertechnikGmbHRepresentativeOfficeP.O.Box35291Dubai, UAEPhone: +971 - 4 - [email protected]
THENETHERLANDSAUMUNDHoldingB.V.Wilhelminapark 405911 EE VenloPhone: +31 - 77 - 320 01 11Fax: +31 - 77 - 320 07 [email protected]
SWITZERLANDAUMUND AGArtherStr.36301 ZugPhone: +41 - 41 - 710 10 82Fax: +41 - 41 - 710 42 [email protected]
RUSSIAAUMUNDRepresentativeOfficeGerman-RussianHouse,Office44ul.MalajaPirogovskaja5119435Moscow/RussiaPhone: +7 - 495 - 287 90 02Fax: +7 - 495 - 287 90 [email protected]
SCHADERepresentativeOfficeGerman-RussianHouse,Office44ul.MalajaPirogovskaja5119435Moscow/RussiaPhone: +7 - 495 - 287 90 03Fax: +7 - 495 - 287 90 [email protected]
FRANCEAUMUNDFranceS.A.R.L.43, rue de Trévise · F 75009 ParisPhone: +33 - 1 - 42 46 72 72Fax: +33 - 1 - 42 46 72 [email protected]
BRAZILAUMUNDLtda.AvenidaEng.LuisCarlosBerrini 716-4.andar-conj.4104571-000-SãoPaulo/SPPhone: +55 - 11 - 3059 0160Fax: +55 - 11 - 3059 [email protected]
USAAUMUND Corporation1701 Barrett Lakes BlvdBarrett Lakes Center ISuite 450Kennesaw, GA 30144Phone: +1 - 770 - 226 - 95 78Fax: +1 - 770 - 953 - 48 [email protected]
P.R.CHINAAUMUND Machinery Trading (Beijing)Co.Ltd.Rm.7-8,22-F,EastOceanCentreNo.24JianguomenwaiAvenueChaoyang DistrictBeijing 100004Phone: +86-10-65155813/14Fax: +86 - 10 - 65 15 58 [email protected]
W E C O N V E Y Q U A L I T Y
AUMUND Headquarters in Rheinberg, Germany
Your partner for all requirements regarding material handlingandstorage.
We design, engineer, manufacture, erect and service reliableequipment.
Reputation and competence proven by more than10000installationsinover100countries.
GBTechnicaldatasubjecttochangewithoutnoticeA-GB-12/14-MA.©2014byAUMUNDHoldingB.V.Allrightsreserved.
AUMUNDFoerdertechnikGmbH·SaalhofferStr.17·47495Rheinberg(Germany) Tel.:+49(0)28 43-720·Fax:+49(0)28 43-6 02 70·[email protected]
www.aumund.com
