WE CONVEY QUALITY

The Cement
Industry
Cemtech
Dubai
2011

efficient and effective raw material

handling plus clinker and cement handling
in modern mammoth cement plants
Slide 1

Presented by Heinrich HOESE

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Mega Cement Plant 12,000 tons per day

Critical Choices in
Concept and Components

Presented by Heinrich HOESE

Slide 2

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Holcim Ste. Genevieve

At over 12,000 tons per
day actual clinker
capacity; this is the
worlds largest kiln line

Slide 3

Presented by Heinrich HOESE

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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
Presented by Heinrich HOESE

Slide 4

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Apron Weigh Feeders Limestone and Clay Bins

Load Cell Mounted Weigh Rail

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
Slide 5

Presented by Heinrich HOESE

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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
Presented by Heinrich HOESE

Slide 6

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Railborne Intake Back-to-Back Feeders

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

Slide 7

Presented by Heinrich HOESE

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Feeding of Secondary Crusher Limestone

BPB-S Apron Feeder with

integral round link chain
scraper cleanup conveyor
Presented by Heinrich HOESE

Slide 8

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Vertical Mills Basic Data

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

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

Slide 9

Presented by Heinrich HOESE

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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

Presented by Heinrich HOESE

Slide 10

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Aumund BWZ Central Chain Bucket Elevator

...Proven...
High
Availability
Total
Reliability
Slide 11

Presented by Heinrich HOESE

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Raw Meal Feed to Prehheater

Aumund Belt Bucket Elevators

trusted with the Critical Paths to
Blending Silo and Preheater
Presented by Heinrich HOESE

Slide 12

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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)
Slide 13

Presented by Heinrich HOESE

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Preheater and Kiln

Two String preheater with five

stages and a single calciner.
Rotary Kiln: 6.6 x 93m

Presented by Heinrich HOESE

Slide 14

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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)
Slide 15

Presented by Heinrich HOESE

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Pan Conveyors with Precision Laser Chains

...Legendry Proven...
...Performance...
Presented by Heinrich HOESE

Slide 16

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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)

Slide 17

Presented by Heinrich HOESE

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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
Presented by Heinrich HOESE

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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)

Slide 19

Presented by Heinrich HOESE

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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

Presented by Heinrich HOESE

Slide 20

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Clinker Distribution to Silos

Gypsum and other
Additives are metered
to the clinker stream
directly to the pan
conveyors on the
clinker burden
extracted from each
clinker silo
Four pairs of silos for
Gypsum and
Additives

Slide 21

Presented by Heinrich HOESE

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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)
Presented by Heinrich HOESE

Slide 22

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Clinker Transport Silo to Mill

Clinker
Silo
Gypsum
Additive
Silo

Type KZB-Q
Clinker
Transport

Weigh Belt
Conveyor
with Metal
Detector

Silo
Discharge
Gates
Weigh Belt
Feeder
Centrex
Silo
Discharger

Cement
Mill
Slide 23

Presented by Heinrich HOESE

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Additives Metered Direct to Pan Conveyor

Layer of Gypsum above the

Clinker Burden
A single pan conveyor takes
clinker from silo to mill onto
which Gypsum and other
additives are metered thus
eliminating the mill feed bins
Presented by Heinrich HOESE

Slide 24

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4 X CentrexTM Silo Extractors

CentrexTM pictured during

erection. Typical design with
integrated Weigh Belt
Feeder for Gypsum etc..
Slide 25

Presented by Heinrich HOESE

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Clinker Dust Collecting and Transfer

Aumund type TKF drag chain

conveyors for Clinker Dust fully
sealed, spillage free and dust
tight, multiple inlets & outlets
Presented by Heinrich HOESE

Slide 26

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Finished Cement Silo Elevation

Total 260,000 tons cement

storage capacity
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
Slide 27

Presented by Heinrich HOESE

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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 metres
That is in addition to the 4 units at the
raw meal silos and preheater

Presented by Heinrich HOESE

Slide 28

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Raw Material and Fuel Import Cement Export

Enclosed cement loading facility with
dust control down to the barge inlet

Approximately 75% of all material

movements are by bulk barge on the
Mississippi covering in total 19 states
Slide 29

Presented by Heinrich HOESE

WE CONVEY QUALITY

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 line
to break the 13,000 TPD barrier
Congratulations Holcim and Ste. Genevieve.
Presented by Heinrich HOESE

Slide 30

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Conch Tongling China, 10,000 t/d

Conch rely on Aumund BWG Elevators to
feed the Raw Meal to the Preheater

BWG Present Design Limits: Lift Height 175 metres..

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
Slide 31

Presented by Heinrich HOESE

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Asia Cement Group Jiangxi-Ya-Dong

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

Presented by Heinrich HOESE

Slide 32

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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
Slide 33

Presented by Heinrich HOESE

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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 Asia
Raw 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
Presented by Heinrich HOESE

Slide 34

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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
Slide 35

Presented by Heinrich HOESE

WE CONVEY QUALITY

Mobile Shiploader for Cong Thanh Cement

Fully Mobile Shiploader at
Nghi Son Port for loading
larger ships to 30,000 DWT

Presented by Heinrich HOESE

Slide 36

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Waterborne Logistics for Import and Export

Dust Controlled Grab
Discharge to Eco-Hopper

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 ??
Slide 37

Presented by Heinrich HOESE

WE CONVEY QUALITY

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

Economical
Less Disruption
Presented by Heinrich HOESE

Slide 38

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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..

New Chains, Buckets,

Wheels and Shafts
Structure and Casing
Retained

Comparison Cost to Direct Replacement

Cost Saving 30%.
Slide 39

Presented by Heinrich HOESE

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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
Presented by Heinrich HOESE

Slide 40

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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
Slide 41

Presented by Heinrich HOESE

WE CONVEY QUALITY

New Conveyor Buckets and Chains by Aumund

Robust rollers with large ball
bearings and labyrinth grease
seals for long life

Laser cut precision

conveyor chains for
maximum
Newreliability
bucket strands pre-

assembled in manageable
sections before installation
Press tool for chain pin
and jointing on the new rails
assembly with interference
andplates
guides
fit to chain side
Presented by Heinrich HOESE

Slide 42

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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
Slide 43

Presented by Heinrich HOESE

WE CONVEY QUALITY

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 1200/350/5
Handling Rate 272 t.p.h.

Improved
performance and
reliability with
Aumund

Comparison Cost to Direct Replacement

Cost Saving 20%.
Presented by Heinrich HOESE

Slide 44

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The Aumund Group - Fully Integrated Service

Intake

Feeding

Conveying
Stockpiling

Knowledge
with the

Power
to

Reclaim

Vertical Elevator

Perform
Slide 45

Presented by Heinrich HOESE

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Engineering and Design

Your
One-Stop-Shop
for
Bulk Materials
Handling

Experience + Know-How = Performance

Presented by Heinrich HOESE

Slide 46

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The Aumund Group

Headquarters in Rheinberg Germany

Aumund Frdertechnik

2011

1956
Established 1922

Slide 47

Presented by Heinrich HOESE

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Aumund International Sales and Service

Aumund USA
Atlanta, GA

B&W Mechanical Handling

England

AUMUND Frdertechnik
SCHADE Lagertechnik
LOUISE Frdertechnik
Germany.

Aumund Brazil
Sao Paulo

Aumund
Aumund Aumund
France Switzerland Middle
Paris
Zug
East
Presented by Heinrich HOESE

Aumund
India
Chennai

Aumund Aumund
Aumund
Asia
Russia
China
Beijing Hong Kong Moscow
Slide 48

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Aumund Group in the Cement Plant and Terminal

Feeding, Blending,
Conveying and
Imported
Recirculation in the
Raw Material Elevation to ClinkerClinker
Intake Export
Alternative
Rawand
Meal mill
Coal Fuel
and Ship
Storage and Silo storage and Handling
Intake
Pet Fuel
Cokecircuit
Raw Material
Loading
Blending Extraction and
andand
Handling
Intake
Intake and
Raw Meal
Blending
FeedingFeeding
and Storage
Elevation to the
Conveying in
Pre-Calciner Clinker
the Mine
Mill
Feeding
Recovery and
Clinker
Cement Handling
and
Transport
and
Additions
Elevation to
Storage
Intake StorageRecirculation
silo storage
and Blending

Aumund Group Products at every stage in the cement

process from mine to terminal (yellow)
Slide 49

Presented by Heinrich HOESE

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THANK YOU FOR LISTENING

Presented by Heinrich HOESE

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