BANDAS (Housekeeping Manual) PDF

Transport & Dedusting
Training
Objectives
Objectives
To find out the obstacles that do not allow for proper
evaluation of the Housekeeping Block
To propose solutions in order to overcome those obstacles
2
Holcim Group Support Transport & Dedusting Training
09.01.2006
Transport & Dedusting Training
Belt Conveyors
Part 1 – Design
Basics
Belt Conveyor Systems Part 1 – Content
Terminology
Elements
Belt stability
Belt alignment
Design guidelines
Most frequently failures
4
09.01.2006
Objectives
Point out main technology aspects about belt conveyors
systems
Inform about valid design guidelines
5
09.01.2006
Material Spillage Generation
6
09.01.2006
Terminology
Terminology of trough belt conveyor
7
09.01.2006
Elements
Idlers
Fig. 3: Return idler flat
Fig. 1: Carrying idler Fig. 2: Impact idler

(troughed)
Fig. 4: Return idler with rubber disc for
sticky material applications
Belt types
Fig. 2: Steel cord belt

Fig. 1: Fabric belt
(1) Steel cables
(1) Synthetic fabric layers (2) Tensile steel wire
(2) Shock absorbing rubber layers. (3) Layer of high grade rubber
(3) "top" and "bottom" abrasion and cut (4) Abrasion and cut resistant rubber covers
resistant rubber covers 8
09.01.2006
Elements
Pulley lagging
Common types
Fig. 1: Standard Steel Fig. 2: Pulley with replaceable Fig. 4: Pulley with vulcanized
Pulley lagging lagging
Fig. 3: Pulley with rubber

lagging
Very important to observe minimum pulley diameter (see

recommended pulley diameters on Transport & Dust
Collecting Manual page A1/19) 9
09.01.2006
Belt stability – Material feed point
Elimination of belt sag by providing adequate support
throughout the loading zone
Fig. 1: Belt support by impact idler
Fig. 2: Belt support by impact bar
Elimination of belt vibration at material feed point
Fig. 3: Wing type tail pulleys, Fig. 5: Spiral wrapped tail pulley
not recommended (As an alternative recommended
in sticky application)
Fig. 4: Not recommended wing type
pulley (belt vibration), feed chute too
close to tail pulley 10
09.01.2006
Belt Alignment Devices (1/2)
Carrying belt alignment devices
Recommended belt Should be avoided belt
alignment devices alignment devices
Fig. 3: Carrying side training idler
Fig. 1: Idler tilting approximately

every 30 m of conveyor length, Fig. 2: Control by belt
if after belt alignment procedure misalignment switches
the belt is still off-center running
Fig. 4: Multiple pivot belt tracking

system
11
09.01.2006
Belt Alignment Devices (2/2)
Return belt alignment devices Return belt alignment devi
Recommended return Should be avoided return
belt alignment devices belt alignment devices
Fig. 1: Return side training

idler
Fig. 4: Multiple pivot return

belt tracking system
Fig. 2: Raising
alternating return idler
Fig. 3: V-Return
idler 12
09.01.2006
Design Guidelines (1/5)
Belts shall be endlessly vulcanized
Trough angles α shall not be less than 30°
Belt speed:
The maximum belt speed plant internal shall not exceed
2.0 m/s
Conveyors handling dry fine material (i.e. cement) shall not
exceed 1.25 m/s
Belt speed for conveyors less than 50 meters in length
shall not exceed 1.5 m/s
Conveyors longer than 500 m (overland) can operate
faster than 2.0 m/s
Trough belt width shall not be less than 800 mm. For
special applications 650 mm belts may be used
13
09.01.2006
The minimum distance between the center of the tail
end pulley and the skirt arrangement shall be larger
than 2*belt width. As a minimum, the skirt should not
start until full troughing of belt has been achieved
Maximum conveyor slope:

Maximum Slope Raw Material, Clinker Cement Coal, Pet-
wet Slag Coke
All sections other

16° 10° 6° 15°
than loading point
At loading point 6° 0° 0° 5°
14
09.01.2006
Idlers:
Carrier and return idler shall be designed according to DIN
(15207-1 / 22107) or CEMA (Class C or greater)
Carrier and return idler diameter: 100 mm for 650 to 1000
mm belts, 127 mm for belts greater than 1000 mm
Carrier idler spacing shall not exceed 1250 mm for all belt
widths
High-density polyethylene impact bars at loading points
shall be used. Rubber protected impact idlers may be
used, with spacing of no more than 300 mm for all belt
widths
Return idler spacing shall not exceed 3000 mm for all belt
widths
For conveyors handling sticky materials, return idlers shall
be rubber disc rolls or anti-adhesive rubber tubes
15
09.01.2006
Pulleys:
All drive pulleys shall have rubber lagging
Tail and take up pulleys: rubber lined or spiral wrapped
wing pulleys. Wing type pulleys without spiral are not
acceptable
Belt tensioning stations:
For belt conveyors less than or equal to 50 m horizontal
center distance, screw tensioning shall be used
For belt conveyors over 50 m horizontal center distance,
vertical gravity or horizontal gravity shall be used
16
09.01.2006
Skirt plates and dust hood:
Skirt plates shall be made of wear resistant material and
dust hoods shall not extend less than 2 m from loading
point
Skirt plates shall be equipped with adjustable sealing
rubber stripes or pads and shall be of the quick release
type for easy adjustment
Covers:
Conveyors or parts thereof installed outside of buildings
shall be covered
For conveyors handling dry fine material (e.g. cement) the
lower edges of the covers must extend to 300 mm below
the return belt line
17
09.01.2006
The Most Common Design Failures
Transport system not suitable for specific application
(wrong system choice)
Plant layout not optimal
Incorrect designing / dimensioning of belt conveyors

Unsuitable design of the conveyor discharge or loading
chute
18
09.01.2006
Failures in Choosing Transport Systems
Material characteristic are not considered and result in:
Excessive wear
Material blockages
Material spillages and fugitive dust sources
Temperature impact (e.g. clinker transport)

High wear
Accelerated aging process of the belt
19
09.01.2006
Most Common Failures - Plant Layout
Equipment arrangement is not well studied. This results
in large number of belt conveyors (transfer points)
Feed to receiving belt is generally not in line or right
angle
Resulting in complex chute constructions and off-center
loading
Too small or too high material drop height
Optimal chute design is not possible
20
09.01.2006
Most Common Failures - Designing (1/2)
To narrow conveyor belts, therefore too narrow chute
openings
High belt speed
Too low through angle
Too small drive power (starting with full loading is not
possible)
Too small idlers diameter
Strong upward slope (conveyors)
Spillage and dust while loading material
Return flow
21
09.01.2006
Most Common Failures - Designing (2/2)
No calculation of conveyed material discharge trajectory
Belt tensioning station
Wrong placed
Unsuitable system
Too small vertical radius
The conveyor belt take off
22
09.01.2006
Belt Conveyors
Part 2 – Feed
and Discharge
Chutes
Objectives & Content
Objectives
To show influencing factors that should be considered prior
chute design
Inform about valid design guidelines

Transfer chutes design criteria
Most frequent failures
24
09.01.2006
Transfer Chutes have Six Missions
1. To feed the receiving conveyor in its direction of travel
2. To centralize the material load
3. To minimize impact on the receiving belt
4. To supply the stream of material at a speed equal to
the speed of the receiving conveyor
5. To return belt scrapings to the main material flow
6. To minimize the generation and release of dust
25
09.01.2006
Holcim-CTS Transfer Chutes Design Guidelines (1/2)
Chute design
The minimum valley angle shall correspond to the material
characteristics but shall not be less than 60°, expect for clinker,
where a minimum valley angle of 50° is acceptable
All chutes, covered skirt-boards and hoods shall be designed for
effective dust suppression and shall be provided with flanged
dust exhaust connections where required
Chute and chute support connections shall be flanged and bolted
(not welded) and shall be designed to facilitate the field erection
and future replacement of parts
Chutes shall be designed with removable top covers or large
access doors for replacement of the liner plates
26
09.01.2006
Holcim-CTS Transfer Chutes Design Guidelines (2/2)
Chute design
Chutes shall be constructed of a minimum 4 mm thick
plate. Accessible inspection doors shall be hinged and
shall be held in closed position by quick release
clamps
Chute lining
All chutes handling clinker or other abrasive material shall
be provided with rock boxes and wear lining (Ni-hard or
similar, approx. 20 mm thick)
Chutes handling sticky materials shall preferably be lined
with low coefficient of friction materials suitable for the
application (UHMW polyethylene, stainless steel etc.). As
an alternative, heated chutes may be foreseen
27
09.01.2006
Transfer Chute Design (1/3)
Coarse / sticky material
Impact
plates
Anti-sticking
lining
Hard metal
lining
Fig. 1: Chute design for coarse /

sticky material Impact
chain
Fig. 3: Chute design equipped

with impact chain
Fig. 2: Example skirt board sealing for
coarse wet material
28
09.01.2006
Fine bulk materials
Fig. 1: Feed chute with curved loading plate

for material speed-up Fig. 2: Example skirt board
sealing for fine dusty material
Fig. 4: Example skirt

board sealing
Fig. 3: Example cement

feed chute 29
09.01.2006
Coarse / abrasive material
Step chute
Material
centralization
Fig. 1: Belt conveyor feed chute for clinker
Fig. 2: Multiple rock boxes

inside the chute, (for
coarse/dry material)
30
09.01.2006
Most Frequent Failures – Feed of Material (1/4)
Loading in strong upward

slope
Off center loading
31
09.01.2006
Unsuitable chute design

Tall drop of the material
Material acceleration not in suitable direction
Unsuitable chute seals
32
09.01.2006
Too large skirt board with regard to

belt width
Chute seal on the entire conveyor
length
33
09.01.2006
Loading of material too close to the tail pulley
34
09.01.2006
Most Frequent Failures - Discharge Chute Design (1/3)
Discharge chute/bin too narrow
Spillage conveyors missing
Snap pulley
35
09.01.2006
Chute angle too flat

Problems with build ups and
blockages
Dropping parabola not

considered
High wear of chutes
36
09.01.2006
Unsuitable belt cleaning system

Spillage
Wear
Lack or inadequate inspection doors
37
09.01.2006
Belt Conveyors
Part 3 – Belt
Cleaner, Spillage
Handling
Objectives & Content
Objectives
Expose applied belt cleaning systems in our industry
Show methods to handle material spillages from transfer
chutes

Belt cleaner
- Technology
- Design criteria
Material spillage handling
- Spillage chute
- Spillage conveyor
39
09.01.2006
Belt Cleaner – Technology
Overview different basic methods of belt cleaning
Fig. 1: Result of a not sufficiently Fig. 2: Overview conveyor belt cleaner

performing belt cleaning device
Fig. 3: Belt turn over station design – Fig. 4: V-plow on return belt
Recommended for overland belt
conveyors
Fig. 5: V-plow for vertical gravity
tensioning station 40
09.01.2006
Belt Cleaner – Design Criteria
Minimum requirement for conveyor belt cleaning: dual
belt cleaning system, consisting of primary and
secondary belt cleaners
Primary
cleaner
Secondary
cleaner
Fig. 1: Correct position of the primary – Installed at Fig. 2: Segmented primary

three (3) o'clock position – and secondary belt cleaners scraper plates (plastic)
Fig. 3: Primary cleaner – keep contact area constant

41
09.01.2006
Secondary belt cleaners
Recommended types
Fig. 1: Spring loaded not segmented Fig. 2: Rotating secondary

secondary cleaner (hard metal) belt
Not recommended types
Fig. 3: Spring-loaded Fig. 4: Rotating brush – Not

segmented secondary cleaner recommended in the cement industry 42
09.01.2006
Belt Cleaner - Selection
43
09.01.2006
Inspection doors must be
provided in the transfer chute
Fig. 1:
in order to check belt cleaner Location of
condition inspection
doors for
maintenance
V-plow in front tail pulley and

above take-up pulley (if
applicable) must be installed to
avoid material between the
belt and pulleys Fig. 2:
V-plow for
vertical
gravity
tensioning
station
44
09.01.2006
Belt Cleaner – Improper Condition or Selection
Fig. 1: Primary cleaner - Improper type, wrong

placed and not in contact with the belt
Fig. 2: Correct type and
position for primary cleaner,
however lack of maintenance
Fig. 3: Improper secondary Fig. 4: Secondary cleaner

cleaner type and lack of unsuitable for sticky material
maintenance (not in contact application (accumulated
with the belt) material pushes the cleaner Fig. 5: Inadequate adjustment of
plates down) segmented cleaner (source of
damages in belt cover) 45
09.01.2006
Material Spillage Handling
Overview of different methods of material spillage
handling
Fig. 2: Spillage
chute (discharge
into separate
hopper)
Fig. 1: Example sufficiently
large discharge chute to feed
spillage into downstream
material flow
Fig. 3: Example spillage

conveyor
46
09.01.2006
Spillage Chute – Design Criteria
Whether possible, feed chute should be extended in a
way that the snap pulley is within it. Side wall should be
inclined beyond repose angle of conveyed material
When extension of feed chute is not feasible, then a
spillage chute (or spillage conveyor) should be
integrated
Fig. 2: Spillage chute at

discharge end of an apron
Fig. 1: Spillage chutes at discharge end of crushed limestone conveyor on top of clinker silo
belt conveyors 47
09.01.2006
Spillage Conveyor – Design Criteria
A scraper type spillage conveyor shall be installed at the
discharge end(s) of the conveyor, whether appropriate
spillage chute can not be installed
Chain speed of spillage conveyor not faster than
approx. 0.15 m/s (preferable not continuous operation)
If double round link chain is installed, the sprocket of the
drive should be designed as shown in the drawing,
including sprocket cleaners
Fig. 1: Spillage conveyor with

link chain
Fig. 3: The preferred design for
Fig. 2: If round link chain is used, tail sprocket includes
the preferred design of the head independent rotatable sprockets
sprocket as shown in the picture
48
09.01.2006
Spillage Conveyor – Design Criteria
The length of a spillage conveyor shall not exceed five
(5) meters
On apron/pan conveyors shall be included scraper-type
spillage conveyors to capture spillage and feed to
downstream equipment, as needed to ensure a spillage-
free operation. In any case, the provision for the future
installation of a spillage conveyor shall be made
Fig. 4: Spillage conveyor at apron conveyor feed point Fig. 5: Spillage conveyor at
apron conveyor discharge 49
09.01.2006
Transport Systems –
Mechanical & Pneumatic
(Exc. BC)
Content
Apron / pan conveyor
Bucket elevator
Pneumatic conveyors / air slides
51
09.01.2006
Apron / Pan Conveyor – Terminology
Different types of apron / pan conveyors
Steel Bucket Conveyor Deep Pan Conveyor Deep Pan Conveyor
with Baffles
Max. inclination approx. 45-50° Max. inclination approx. 28°
Max. inclination approx. 35-40°
Fig. 1: Example steel bucket

conveyor for clinker transport 52
09.01.2006
Apron / Pan Conveyor – Design Guidelines (1/3)
Drive design
Gear reducer, planetary gear box or hydraulic drive, shall
be directly coupled to the head shaft. V-belts and chain
drives shall not be used
Non-return stop for inclined arrangement must be
integrated
Chain and rollers
Sprockets shall be of segmented design with reversible
segments and the rollers shall fixed to the chain or aprons
be outboard mounted
Maximum speed for pan conveyors shall not be greater
than 0.4 m/s
53
09.01.2006
Aprons and pans
It shall be designed to minimize spillage from joints
between individual apron blades, overlapping design is
required
It shall be highly resistant against shocks, heat expansion
and deformations
Pan filling shall not exceed 85% of the manufacturer’s
theoretical loading for the slope used
Spillage Conveyors
The facility shall include scraper-type spillage conveyors to
capture spillage and feed to downstream equipment, as
needed to ensure a spillage-free operation. In any case,
the provision for the future installation of a spillage
conveyor shall be made
54
09.01.2006
Safety
Inclined conveyors greater than 30° and components
thereof, shall be safe from sliding down or falling off its
support structure by the installation of hold-down rails
Fig. 1: Example of
hold-down rails
55
09.01.2006
Bucket Elevator – Types
Types of bucket elevator
Fig. 3: Example
Belt bucket elevator round link chain
bucket elevator
Round link chain bucket elevator
Central chain bucket elevator
Fig. 1: Belt bucket

elevator
Fig. 2: Central chain bucket

elevator
Fig. 4: Bucket elevator Fig. 5: Double central

central chain chain bucket elevator 56
09.01.2006
Bucket Elevator – Elements
Belt bucket elevator
Fig. 2: Cage-type foot
pulley with deflector
cones
Fig. 1: Replaceable pulley lagging
Tensioning
Fig. 3: Automatic
tensioning device with
Fig. 4: Rubber bucket
parallel guide (for belt
elevator casing for conveying
and chain bucket
of sticky material (coal)
elevators 57
09.01.2006
Bucket Elevator – Design Guidelines (1/2)
Conveying Speed
Type of Material Filling Degree Maximum speed in m/s
Chain type Belt type
Round link central
Raw meal < 75 % 1.3 1.9 1.9
Cement < 75 % 1.3 1.9 1.9
Clinker < 85 % 1.0 1.6 --
Buckets
Buckets shall be provided with a hard faced edge for wear
protection
Buckets shall have air vent holes for aerated material
58
09.01.2006
Bucket Elevator – Design Guidelines (1/2)
Chain type
Highly wear resistant central chain design is preferred
Welded or forged link chains as well as “round link anchor
type chains” (calibrated link) are acceptable
Joining U-type shackles are not acceptable
Sprockets or traction wheels shall be designed with
reversible segments
Belt type
Belt shall be made of steel reinforced rubber
Belts shall be sufficiently heat resistant for the specific
application
Replacement of rubber lining segments on drive pulley
Self-cleaning cage type boot pulleys shall be provided
59
09.01.2006
Pneumatic Conveyors – Categories
Categories of pneumatic conveyors:
Pressure System – uses positive force to “push” material
from one place to another
Vacuum System – uses negative pressure to “pull” material

from one point to the next, (used in cement industry mainly
for clean-up work)
Air Gravity System – Air fluidizes the material and the force
of gravity “slides” it to its destination
60
09.01.2006
Pneumatic Conveyors – Systems
Overview of different types of pneumatic conveyors
Pressure Screw pump Air lift Airlock Jet feeder

vessel feeder
Conveying All non-adhesive Wide particle size Fluidized Coarse and All materials
characteristic materials distribution with fine materials fine materials,
shares low abrasion
Max. 125 400 900 60 5
throughput [t/h]
Max. conveying 3500 1000 120 vertical 250 75
distance [m]
Max. pressure 6 2.5 0.6 1 0.2
difference in
conveyor pipe
[bar]
61
09.01.2006
Pneumatic Conveyors – Screw Pump (1/4)
Terminology
(1) Feed hopper

(2) Pump screw
(3) Non-return flap
(4) Electric motor
(5) Coupling
(6) Shaft
(7) Air supply
(8) Conveying line
62
09.01.2006
Principle of operation Material Feed hopper
Air supply
Material forced against Material is mixed up

non-return flap with conveying air and
transported
Fig. 1: Screw pump 63

09.01.2006
General
The task of the screw pump is to introduce the material
flow into the conveying gas flow against the pressure of the
conveying line and at the same time seal the system
overpressure from the surroundings and upstream plant
sections
Basics of screw pump system
Conveying of bulk solid starts by the material entering a
feed hopper. A rotating screw transports the material from
the hopper to the mixing chamber
The purpose of the screw is to feed the bulk material
continuously from the non-pressurized section to the
pressurized section, i.e. the conveying line.
The filling of material in the screw forms a "material seal"
that prevents a reverse flow of conveying air
64
09.01.2006
A free-floating flapper valve (or “non-return flap"), located
in the discharge area of the pump, is a mechanical seal
that also assists in preventing the reverse flow of air from
the mixing chamber through the pump barrel
The bulk material drops into the pump discharge box
where the compressed air required for the conveying
process is injected via nozzles. At this point the bulk
material and the compressed air mingle and the mixture
flows into the conveying line
65
09.01.2006
Pneumatic Conveyors – Duct Elbows and Valves
Overview of different types of pipe elbows and valves
Fig. 1: Diverter pot Fig. 2: Long radius Fig. 3: Short radius

elbow elbow
Wear parts
Fig. 7: Easy replaceable wear
parts on diverter gate
Fig. 4: VORTEX elbow Fig. 5: Blind Tee elbow Fig. 6: Rubber pipe elbow
by Claudius Peters
Wear parts
66
09.01.2006
Pneumatic Conveyors – Air Slides
Function
1 (1) Casing (top section)
(2) Porous material
(3) Casing (bottom section)
(4) Throttle valve
(5) Piping
4 3 2 (6) Airslide blower with
intake filter
6 5
Fig. 1: Mechanical elements of an air slide transport system
Air slide design criteria (1/2):

Cloth shall be covered by metal screen, wire mesh or
similar at material feed points
Upper compartment shall be of high-top design to ensure
proper material flow and evacuation of conveying air
67
09.01.2006
Air slide design criteria (2/2):
Flanged dust air take-off hood to slow down air speed shall
be at the discharge end of the air slide conveyor
- Additional dedusting hoods for air slides longer than approx.
50m are acceptable
Clean-out ports on the air chamber shall be located ahead
of the discharge point and ahead of any distribution/turn
pots and diversion gates
A piping system with throttle valve on each inlet shall be
provided (air inlet lateral or from bottom with deflector
plates)
68
09.01.2006
Fan-Type Blowers design data:
The guide value for air quantity is 2.5 m3/m2 per minute
The air quantity may deviate, depending on the porosity of
the medium and bulk material characteristics
Guide values for air pressure are:
- Conveyor width < 500 mm 60 mbar
- Conveyor width > 500 mm 80 mbar
Slope for air slides (of polyester fabric membrane)
Type of Material Minimum Slope
Cement 6°
Cement separator grits 12°
Raw meal 5°
Raw meal separator grits 15°
Filter dust 8°
69
09.01.2006
Dust Collection
Part 1 – Design
Basic
Content
Technology of dust collecting systems
Design guidelines
Design features
Cleaning control
Examples
71
09.01.2006
Objectives
To point out and explain most important criteria in the
field of dust collector systems design
To provide basic concepts around dust collector
technology
To show examples, where design guidelines were
applied
72
09.01.2006
Technology – Terminology
Terminology of pulse-jet dust collector
1 Dust loaden air 11 Diaphragm pulse valve

2 Diffuser 12 Pulse control timer
3 Bag cage 13 Rotary valve
4 Clean air outlet (Plenum) 14 Differential pressure gauge
5 Tube sheet 15 Closing valve
6 Filter bag 16 Compressed air bin
7 Venturi 17 Regulation damper valve
8 Locking ring (or snap band fixation) 18 Fan
9 Blowpipe 19 Purge unit with hand reducer
and filter set
10 Header (compressed air tank)
73
09.01.2006
Technology – Cleaning Principles
Various cleaning principles used for bag filters
74
09.01.2006
Technology – Bag Fixation Systems
Types of filter bag fixations (jet-pulse)
Snap-
band
Filter bag
Fig. 1: Filter bag fixation by snap-band
Fig. 2: Filter bag fixation by mechanical clamp 75

09.01.2006
Filter Media (1/4) – Fabrics
Filter cloth fabrication
Needle felt
Woven felt
Differences of filter bags without and with membrane

treatment
Fig. 1: Filter bag without membrane Fig. 2: Filter bag with membrane 76
09.01.2006
Filter Media (2/4) – Fabrics and Trademarks
Fabric, Trademark Chemical DIN Tensile max. Operating Acide Alkali Resist. Abrasion Moist Heat Price Rating Density
Classification 60 001 strength Temperature [°C] Resist. Resist. Resist. [g/m2]
N/mm2 long time short time
Cotton Cellulose (CO) 410-670 70-90 120 5 3 2 3-4 $ 150-400

Natural
Fibers
Wool Keratin (protein) (WO) 120-230 90 120 3-4 4 3-4 3-4 $$ 400-600
Acrilan, AC/AC Polyacrylnitrile (PAN) 200-530 100-110 100-120 3 3-4 3-4 1 $$ 500-600
- copolymer
Dralon, Orlon, Zefran, Polyacrylnitrile (PAN) 200-530 110-120 120-140 2-3 3-4 3-4 1 $$ 500-600
Dolanit - homopolymer
Synthetic Polypropylene, Meraklon Polypropylene (PP) 260-640 90-100 100-120 1-2 1-2 1-2 1-2 $ 550
Organic
Trevira, Dacron, Terylene, Polyester (PES) 560-820 130-150 150-160 3-4 3-4 2 5 $ 400-600
Fibers
Tergal, Vestan, Kodel (dry)
Nylon, Perlon Polyamide (alipahtic) 370-850 90-110 100-120 4 2 1-2 3-4 $ 300
Nomex, Conex, Trol Polyamide (aromatic) PA 570-690 180-210 200-240 good in Excellent at 1-2 3-4 $$$$ 500-600
(Aramide) (AR) weak acids low temp.
Teflon Polytetra-Fluorethylene (PTFE) 380 260 280 1-2 1-2 3-4 1 $$$$$$$ 750-940
Ryton, PPS, Rastex, Polyphenylene- 1000-1200 180 max. 200 max. 1 1 2-3 $$$$$$ 500-800
Procon Sulfid (PPS) 5%O2 15% O2
P 84 Polyimid (PI) 850-900 240-260 280 1-2 1-2 4-5 $$$$$$ 550
Legend:
1: excellent 2: very good 3: good 4: fair 5: poor 77
09.01.2006
Filter Media (3/4) – Surface Treatment
78
09.01.2006
Filter Media (4/4) – Surface Treatment
79
09.01.2006
Design Guidelines (1/5) – General
Maximum 6 (8) dust sources to be connected to one
filter
The following maximum air to cloth ratios based on a
bag length of 4.5 m shall apply:
1.5 m3/(m2min) for general dedusting
1.2 m3/(m2min) for slag, coal, bypass, fly ash and clinker
dust
Can velocity (theoretically calculated raw gas velocity
between the filter bags in the area of the bag bottom)
valid independently of raw gas inlet design shall be
maximum 1.3 m/s
The hopper valley (corner) angles should not be less
than 55°
80
09.01.2006
Design Guidelines (2/5) – Fabrics
Filter cloth:
General application (dry gas) up to 120 °C (long time
operation), needle felt fabric made from high quality
Polyester fibers are used.
Application in drying/grinding (humid gas) up to 120 °C
(long time operation), Polyacrylnitrile or similar fiber cloth is
recommended.
Application for temperatures above 120 °C, Polyamide
(Nomex), Polyphenylene, Glass-fiber, Teflon/graphite
coated or similar.
Pleated filter bags and star bags shall not be used (except
for electrical room pressurization and only with engineer’s
approval)
81
09.01.2006
Design Guidelines (3/5) – Duct Work
Dedusting Ducts
Up- and downward sloping a minimum slope of:
- 60° for limestone, slag, cement

- 50° (45°) for clinker
- Horizontal ducts are not accepted
The maximum velocity in these runs shall be 18 m/s, for

slag/clinker 16 m/s
For fan discharge duct, the velocity preferably shall not
exceed 12 m/s
Minimum duct diameter shall be 133 mm (outside)
Velocity (v1) at dedusting hood entries shall
not exceed 1.5 m/s
Minimum duct and hood wall thickness
to be 3 mm (1/8”)
82
09.01.2006
Design Guidelines (4/5) – Duct Work
Recommended elbow 83
09.01.2006
Design Guidelines (1/5) – Venting Air Volumes
Recommended venting air volume
84
09.01.2006
Design Features (1/4) – Casing and Deflector
Raw gas inlet design (side inlet into dust collector)
Typical design Recommended Preferred deflector plate design
Raw gas inlet design (top inlet into dust collector)
85
09.01.2006
Design Features (2/4) – Hoppers
Problem solving for blocked dust collector hopper
∼ 700 ∼ 700
440
250
50
350 650 250
1250
Fig. 3: Example dimensioning of dust hopper and

screw
Fig. 1: Blockages may occur (sticky dust)
due to small opening of the dust hopper
discharge
Fig. 2: Possible solution, dust

hopper with vertical side walls 86
09.01.2006
Design Features (3/4) – General
Hooding for Belt conveyor Hooding for Airslide
Hooding for Bucket elevator head

Dust curtain
87
09.01.2006
Design Features (4/4) – Venting Hood
88
09.01.2006
Cleaning Control (1/2) – Cycle
Bag cleaning cycle guidelines:
The bag cleaning shall be controlled by timer and differential
pressure measurement across the bag filter
Cleaning pressure: max. 5.8 - 6.0 bar for polyester bags, max.
5.0 - 5.2 bar for polyester bags with membrane
Pulse duration: 0.1 sec
Pulse frequency: between two pulses 5 to 30 sec or more,
depending the differential pressure over tube sheet
Cycle time: each solenoid valve should pulse within 120 to 240
sec (max)
Differential pressure adjustment: lower set point 10 mbar, upper
set point 12.5 mbar
89
09.01.2006
Cleaning Control (1/2) – Sequence
Recommended cleaning sequence
Typical cleaning sequence Recommended cleaning sequence
Example of recommended cleaning sequence for a dust

collector with 17 bag-rows and 10 timer positions:
90
09.01.2006
Examples (1/3) – Drawing
Fig. 1: Example of properly designed

dedusting system for hot clinker (>150°C)
application
91
09.01.2006
Examples (2/3) – Installations
Dust Collectors
Packing Area
Proper designed ductwork, with

correct inclination and elbows
Proper designed dust collector

system with pre-separator chamber
due to hot clinker
Proper designed spillage collection
equipment below packer including
settling chamber for the main
venting duct
92
09.01.2006
Examples (3/3) – Installation
Dust confinement at crusher hopper by dust curtain
93
09.01.2006

BANDAS (Housekeeping Manual) PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BANDAS (Housekeeping Manual) PDF

Uploaded by

Copyright:

Available Formats

Transport & Dedusting

Fig. 3: Return idler flat

Fig. 1: Carrying idler Fig. 2: Impact idler

Fig. 2: Steel cord belt

Fig. 3: Pulley with rubber

 Very important to observe minimum pulley diameter (see

Fig. 1: Belt support by impact idler

Fig. 2: Belt support by impact bar

 Elimination of belt vibration at material feed point

Fig. 3: Carrying side training idler

Fig. 1: Idler tilting approximately

Fig. 4: Multiple pivot belt tracking

Fig. 1: Return side training

Fig. 4: Multiple pivot return

 Maximum conveyor slope:

All sections other

 Plant layout not optimal

 Incorrect designing / dimensioning of belt conveyors

 Material spillages and fugitive dust sources

 Temperature impact (e.g. clinker transport)

 Accelerated aging process of the belt

 Belt Conveyor Systems Part 2 – Content

Fig. 1: Chute design for coarse /

Fig. 3: Chute design equipped

Fig. 1: Feed chute with curved loading plate

Fig. 4: Example skirt

Fig. 3: Example cement

Fig. 1: Belt conveyor feed chute for clinker

Fig. 2: Multiple rock boxes

 Loading in strong upward

 Off center loading

 Unsuitable chute design

 Unsuitable chute seals

 Too large skirt board with regard to

 Loading of material too close to the tail pulley

 Discharge chute/bin too narrow

 Spillage conveyors missing

 Chute angle too flat

 Dropping parabola not

 Unsuitable belt cleaning system

 Lack or inadequate inspection doors

 Belt Conveyor Systems Part 3 – Content

Fig. 1: Result of a not sufficiently Fig. 2: Overview conveyor belt cleaner

Fig. 1: Correct position of the primary – Installed at Fig. 2: Segmented primary

Fig. 3: Primary cleaner – keep contact area constant

Fig. 1: Spring loaded not segmented Fig. 2: Rotating secondary

 Not recommended types

Fig. 3: Spring-loaded Fig. 4: Rotating brush – Not

 V-plow in front tail pulley and

Fig. 1: Primary cleaner - Improper type, wrong

Fig. 3: Improper secondary Fig. 4: Secondary cleaner

Fig. 3: Example spillage

Fig. 2: Spillage chute at

Fig. 1: Spillage conveyor with

Max. inclination approx. 45-50° Max. inclination approx. 28°

Max. inclination approx. 35-40°

Fig. 1: Example steel bucket

Fig. 1: Belt bucket

Fig. 2: Central chain bucket

Fig. 4: Bucket elevator Fig. 5: Double central

Fig. 1: Replaceable pulley lagging

 Vacuum System – uses negative pressure to “pull” material

Pressure Screw pump Air lift Airlock Jet feeder

Very important to observe minimum pulley diameter (see

Elimination of belt vibration at material feed point

Maximum conveyor slope:

Plant layout not optimal

Incorrect designing / dimensioning of belt conveyors

Material spillages and fugitive dust sources

Temperature impact (e.g. clinker transport)

Accelerated aging process of the belt

Belt Conveyor Systems Part 2 – Content

Loading in strong upward

Off center loading

Unsuitable chute design

Unsuitable chute seals

Too large skirt board with regard to

Loading of material too close to the tail pulley

Discharge chute/bin too narrow

Spillage conveyors missing

Chute angle too flat

Dropping parabola not

Unsuitable belt cleaning system

Lack or inadequate inspection doors

Belt Conveyor Systems Part 3 – Content

Not recommended types

V-plow in front tail pulley and

Vacuum System – uses negative pressure to “pull” material

Air slide design criteria (1/2):

Differences of filter bags without and with membrane

The maximum velocity in these runs shall be 18 m/s, for

Raw gas inlet design (top inlet into dust collector)

Example of recommended cleaning sequence for a dust