03-01-PODFA-DesignAndMaintenance-Blending Beds

Raw material stocking and preparation
Design and maintenance

Training PODFA
New Kiln 7 Dry Line Project - JSC Podilsky Cement / Ukraine
November 2010
Polysius
Raw material stocking and preparation - Design and maintenance

Training PODFA
November 2010
2 Polysius
Crushing, stockyards and mixing beds

Training PODFA
November 2010
3 Polysius
Crushing, stockyards and mixing beds
• Raw material preparation process
• Plant concepts
• Look over versions of equipment
• PODFA plant concept
• General function of mixing bed

• General design of mixing bed
• Detail design of mixing bed
• Documentation and maintenance

Training PODFA
November 2010
4 Polysius
Raw material preparation process
raw material preparation

Training PODFA
November 2010
5 Polysius
Goal of raw material preparation •Improvement of raw meal quality

•Raw meal which allows economical production
Side effect of raw material •Stockbuilding of raw material

preparation
•Raw meal which is always available
Stockpiles
Stockpiles (Stockyards) serve to pile up raw material for intermediate storing
MixingBeds
Mixing Beds serve additionally to homogenise and mix large quantities
• of separate bulk materials
• or variating analysis values of one single material

Training PODFA
November 2010
6 Polysius
Stockyards
Stockpiling Separation: quarry and production
One/(Two)-shift operation of quarry
compared to 24-h-operation of
production
Bridging of work-free days
Intermediate Storage Material supply in large quantities
... per ship
... per railway
Mixing Beds Additionally
Homogenisation Process requires uniform raw material
... in the chemism of one component
... in the composition of a mixture
Plant optimisation Direct mill feeding

 ... Saving of raw mill feeding hoppers
... and so prevention von handling problems
 ... shortening of conveying distances
Training PODFA
November 2010
7 Polysius
• Plant concepts
• Overview of versions of equipment
• PODFA plant concept

Training PODFA
November 2010
8 Polysius
Plant concepts
Circular mixing bed
Reclaiming
Stacking

Training PODFA
November 2010
9 Polysius
Plant concepts
Circular mixing bed
360°
End-Cone
Capacity
Life-Capacity Stacking Capacity
Reclaiming Angle Stacking Angle Dead Area

Training PODFA
November 2010
10 Polysius
Plant concepts
Longitudinal mixing bed
Reclaiming
Stacking
Stacking
Special design for

specific applications
Reclaiming

Training PODFA
November 2010
11 Polysius
Overview of versions of equipment
Circular mixing bed
existing of two parts
Stacker
controlled by crusher
Reclaimer
controlled by mill

Training PODFA
November 2010
12 Polysius
Circular mixing bed

Training PODFA
November 2010
13 Polysius
characteristic: ...
Stacker
Reclaimer
2 pile areas
each with
1 x life capacity
= 4 rails
= Extension possible

Training PODFA
November 2010
14 Polysius

Training PODFA
November 2010
15 Polysius
Portal reclaimer
Side reclaimer Stacker .... or tripper carriage, if roofed
Stacker
with Portal reclaimer with Side reclaimer

Training PODFA
November 2010
16 Polysius

Training PODFA
November 2010
17 Polysius
Longitudinal mixing bed - BEDESCHI

Training PODFA
November 2010
18 Polysius
PODFA plant concept
g
ushin
m cr
Tangential blending silo

loa
Raw m Raw mill

ill
and
feeding
Clay
hoppe
r
Circular mixing bed

Longitudinal clay store

Training PODFA
November 2010
19 Polysius
PODFA plant concept
Limestone - Mixing bed
Clay - Mixing bed

Training PODFA
November 2010
20 Polysius
PODFA plant concept
Why circular blending bed ?
 Blending effect
 Lower investment cost
 Lower demand of area

Training PODFA
November 2010
21 Polysius
PODFA plant concept
Blending effect
input value
output value
Circular bed
output value during

input value endcone reclaiming
output value
Longitudinal bed

Training PODFA
November 2010
22 Polysius
PODFA plant concept
Lower investment cost
Longitudinal mixing bed Circular mixing bed

Stacker Part of a Stacker
Bridge reclaimer Part of a bridge reclaimer
4 rails 1 central part for both machines
1 rail

Training PODFA
November 2010
23 Polysius
PODFA plant concept
Lower demand of area
70000
60000 Circular
mixing bed
50000
40000
life capacity
< 8000 m2 > 16000 m2
(t) 30000
20000
Longitudinal
10000
mixing bed
0
0 2000 4000 6000 8000 10000 12000 14000
space requirement (m2)

Training PODFA
November 2010
24 Polysius
• General function of mixing bed
• General design of mixing bed
• Detail design of mixing bed
• Documentation and maintenance

Training PODFA
November 2010
25 Polysius
General function of mixing bed

Training PODFA
November 2010
26 Polysius
pre- blending
blending
raw crusher pre- mixture
mixture grinding
grinding
raw crusher blending silo
silo
material blending recipe
recipe plant
plant
material
Input Output
... if selectiv
quarrying
Training PODFA
November 2010
27 Polysius
• Methods
– Windrow
Circular mixing bed
– Cone Shell
– ChevRon
– ChevCon

Training PODFA
November 2010
28 Polysius
Windrow
Stacking: Tripper car Reclaiming: Bucket reclaimer

Training PODFA
November 2010
29 Polysius
Cone Shell 10°
360°
1. Lowering stacker to min. height

and start material transport
2. Build up the initial cone to

max. height
3. Step sideways with steps size

acc. the material properties
360°
Training PODFA
November 2010
30 Polysius
ChevRon
Function of homogenisation only if

piles are fully built up
120°
Because always swivelling up and 120°
down 120° Each 120° one
transition zone
During building up no reclaiming of
Frequently major
neighbour pile
adjustments are
120° essential
Means:
only 1 of 3 piles active for reclaiming
Same size
than CHEVCON
Less capacity
Training PODFA
November 2010
31 Polysius
ChevCon
+ = ChevCon
ChevRon ConeShell
360°
1. Lowering stacker to min. height
and start material transport
2. Build up the initial cone to

max. height
3. Move sideways with up and down

moving stacker boom, following the
pile shape.
Training PODFA
November 2010
32 Polysius
Circular mixing bed
ChevRon ChevCon
120°
120°
120°
Main advantages of ChevCon compared to ChevRon Method

• better blending effect
• higher live capacity
• no abrupt chemical transitions

Training PODFA
November 2010
33 Polysius
Circular mixing bed
ChevRon ChevCon
Mixbed Mix bed out Mixbed Mix bed out

Material 1 Material 2 Material 1 Material 2
feed CHEVRON feed CHEVCON
200
max 53 333 208 126 205 max 53 333 203 123
200
190 min 36 98 70 101 195 min 36 98 72 114
190 Diff 17 235 131 9
180 Diff 17 235 139 25 185
180 average 44 181 118 120
170 average 44 181 120 120 175
s 3,4 44,3 24,9 5,4 170 s 3,4 44,1 23,9 1,7
160 165
160
150 155
150
140 145
140
value[LSF]feedaverage
130 135
value[LSF]
130
Value[LSF]
120 125 120
110 115 110
100 105 100
90 95 90
80 85 80
70 75 70
60 65 60
50 55 50
30 40 50 60 70 80 90 30 40 50 60 70 80 90
sample Nr.: sample Nr.:
LSF-mix CHEVRON_out mix-average LSF-mix CHEVCON_OUT

Training PODFA
November 2010
34 Polysius
Circular mixing bed
Attachments
Drives
Stacker Boom
Travelling Bogies
Slope Reclaiming System
Central Column
Bridge
Chain Scraper

Training PODFA
November 2010
35 Polysius
Circular mixing bed
(Material flow)
l De livery
i a
Mater
l S t acking
ia
Mater
Material Loosening
Material Tra Material Collecting

nsport to Pr
ocess

Training PODFA
November 2010
36 Polysius
General design of mixing bed
Central column
Independent Rotating Parts
Rotating Stacker (blue)
Rotating bridge reclaimer (green)
Fix located part of Central

Column (red)
Training PODFA
November 2010
37 Polysius
General design of mixing bed - the POLYSIUS solution
Rotating central column
Directly lead in cable to boom

Slipring unit
- smaller -
- protected by column
No cable trolley systems,
which is suspectable to trouble,
are necessary
Advantages
Central part of column is rotating
together with the bridge
Training PODFA
November 2010
38 Polysius
Central part of column is rotating

Framework Conveyor boom together with the bridge

Training PODFA
November 2010
39 Polysius
Second advantage of the rotating central column
Supposed
situation:
Reclaiming in operation Stacking interrupted

(public holidays)

Training PODFA
November 2010
40 Polysius
Second
Second advantage
advantage of
of the
the rotating
rotating central
central column
column
Plan view
Stacking interrupted, boom is stopped
Reclaimer is still in operation
The stacker boom keeps his

distance to the reclaimer
No stopping of reclaimer necessary
Complete material is able to be reclaimed
Boom will automatically be removed to the pile,

when stacking starts again
Training PODFA
November 2010
41 Polysius
Detail design of mixing bed Scraper Supports
Chain scraper system on Bridge reclaimers
Scraper Chain Guide
Scraper flights with

Chain with guide
guide roller
rollers
Scetch shows only the

priciple, the design may vary

Training PODFA
November 2010
42 Polysius
Detail design of mixing bed
All bearings
Chain scraper system
are sealed
by disks
Chain guide rollers
and ....
All roller bearings are
permanently
lubricated
... flight guide rollers additionally

completely
with antifriction bearings tight on the
outer side
Scetch shows only the priciple,
the design may vary
Training PODFA
November 2010
43 Polysius
Chain Material
Sideplate
C45 heat-treated to 800-900 N/cm2
Bolt + Sleeve
Depending on the type of chain
both C15; 0,6-0,8 mm deep

heat treatment to 58-60 HRC
or
both 16MnCr5; 0,6-0,8 mm
deep heat treatment to 58-60 HRC
Gap between bush and bolt
is 0,5 mm for normal bulk material
Scetch shows only the priciple,

the design may vary
Training PODFA
November 2010
44 Polysius
Chain with guide rollers
Advantage of a chain
with outside rollers :
When sprockets are in operation
not the rollers,
but the chain bushes will be forced.

Training PODFA
November 2010
45 Polysius
Ripping Teeth
as many as necessary,
but
max. one per flight,
to minimize the loads per flight
Side plates of the srapers

side by side in made of wear resistant material
the projection, (.... only cutting sides)
so that narrow loosening marks

will be caused.

Training PODFA
November 2010
46 Polysius
Stacker Boom
Central Column
Bridge
Chain Scraper
Tensioning Axle Drive Axle

Training PODFA
November 2010
47 Polysius
When
chain tensioning will
diminishes,
first,the chain rollers will hit
the guides inlets,
second, the flights will be tilt,

the rollers will be additionally strongly
loaded
and the power requirement will
increase

Training PODFA
November 2010
48 Polysius

Training PODFA
November 2010
49 Polysius
24

Training PODFA
November 2010
50 Polysius
Always to keep
24
The tensioning hydraulic
has to be set up suitably

Training PODFA
November 2010
51 Polysius
Slope reclaiming system

Training PODFA
November 2010
52 Polysius
• Slope reclaiming carriage

• Rake
• Adjusting rope
arrangement

Training PODFA
November 2010
53 Polysius

Training PODFA
November 2010
54 Polysius

Training PODFA
November 2010
55 Polysius

Training PODFA
November 2010
56 Polysius
Slope reclaiming system Common solution: Ripping teeth for loosening
Disadvantages:
Difficult to handle
Material will not flow down
Deep grooves occur
Finally: rake will touch
the pile
POLYSIUS solution
Bow Cutters instead
of teeth
The bow cutters undercut the surface

and let slay down large sized areas of the slope
Tight overlapped arrangement
Rake with Bow Cutters

Regularly only a little wear Have to be checked periodically In case they must be replaced
Training PODFA
November 2010
57 Polysius
Velocity controlling of the rake
Obligation of the slope reclaiming system:

- To loosen bulk material
- To fill the flights uniformly
Two systems:
Chain scraper 1 direction
Slope reclaimer 2 directions
Chain scraper and slope reclaimer same Chain Scraper and slope reclaimer in opposite
direction: direction:
- Sliding down material fills longer time the - Sliding down Material fills different flights
same flight - These flights are less filled than others
- These flights are more filled than others
Training PODFA
November 2010
58 Polysius
Velocity controlling of the rake
Obligation of the slope reclaiming system:

- To loosen bulk material
- To fill the flights uniformly
uniformly
Two possibilities to influence this:
- Variation of rake velocity Depending from location
- Variation of bridge velocity and direction of rake
Equal dispension of bulk material in front of moving flight strand

With adequate cutting depth for distribution of bulk material
Optimal adjustment of slope reclaiming system is the

secret of good mixing bed function
Training PODFA
November 2010
59 Polysius
Documentation and Maintenance
Mechanical part
• Technical data and safety
• Explanation of construction
• Short explanation of function
• Information acc. erection
• Information acc. maintance and

readjusting
• Attachements like spare parts supplier

documents and drawings
Electrical part will not be part of this presentation
Training PODFA
November 2010
60 Polysius
Training PODFA
November 2010
61 Polysius
Training PODFA
November 2010
62 Polysius

03-01-PODFA-DesignAndMaintenance-Blending Beds

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

03-01-PODFA-DesignAndMaintenance-Blending Beds

Uploaded by

Copyright:

Available Formats

Raw material stocking and preparation

Design and maintenance

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

• Raw material preparation process

• General function of mixing bed

Raw material stocking and preparation - Design and maintenance

raw material preparation

Raw material stocking and preparation - Design and maintenance

Goal of raw material preparation •Improvement of raw meal quality

Side effect of raw material •Stockbuilding of raw material

Raw material stocking and preparation - Design and maintenance

Plant optimisation Direct mill feeding

• Overview of versions of equipment

• PODFA plant concept

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Life-Capacity Stacking Capacity

Reclaiming Angle Stacking Angle Dead Area

Raw material stocking and preparation - Design and maintenance

Special design for

Raw material stocking and preparation - Design and maintenance

existing of two parts

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Side reclaimer Stacker .... or tripper carriage, if roofed

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Tangential blending silo

Raw m Raw mill

Circular mixing bed

Raw material stocking and preparation - Design and maintenance

Limestone - Mixing bed

Clay - Mixing bed

Raw material stocking and preparation - Design and maintenance

Why circular blending bed ?

 Lower investment cost

 Lower demand of area

Raw material stocking and preparation - Design and maintenance

output value during

Raw material stocking and preparation - Design and maintenance

Longitudinal mixing bed Circular mixing bed

Raw material stocking and preparation - Design and maintenance

space requirement (m2)

Raw material stocking and preparation - Design and maintenance

• General function of mixing bed

• General design of mixing bed

• Detail design of mixing bed

• Documentation and maintenance

Raw material stocking and preparation - Design and maintenance

Raw material stocking and preparation - Design and maintenance

Circular mixing bed

Raw material stocking and preparation - Design and maintenance

Stacking: Tripper car Reclaiming: Bucket reclaimer

Raw material stocking and preparation - Design and maintenance

1. Lowering stacker to min. height

2. Build up the initial cone to

3. Step sideways with steps size

Function of homogenisation only if

2. Build up the initial cone to