INTRODUCTION

Importance of cement
 CEMENT MANUFACTURING
PROCESS
 Mining
 Crushing
 Grinding
 Burning
 Cooling
 Cement grinding and Blending
 Packing and Despatching
 DIFFERENT TYPES OF
CONVEYING SYSTEMS
 Pneumatic conveying system
 Hydraulic conveying system
 Mechanical conveying system
 PNEUMATIC CONVEYING
SYSTEM
 Transmitters
 Hydraulic conveying system
 Uses liquid as carrier medium
 Energy input for this is small compared to
pneumatic conveying.
 Mechanical conveying system
 Bucket Elevator
 Screw Conveyor
 Drag Chain Conveyor
 Bucket Conveyor
 PRESENT FLYASH HANDLING
SYSTEM
 Wagons feed hoppers screw
conveyor bucket elevator air
slide transmitting hoppers
transmitters silo
 TRANSMITTERS
 Vent Valve
 Material inlet valve
 Air inlet valve
 Discharge valve
 Fly ash transmission
There are 4 phases in fly ash transmission
 filling

 fluidization

 transmission

 clean blowing
 DRAWBACKS OF PRESENT
CONVEYING SYSTEM
 High power consumption
 High maintenance cost
 Low working capacity
 Loss of material
 High pollution
 REPLACEMENT WITH
ANOTHER EQUIPMENT
 Pneumatic conveying system
-Transmitters with bulk tankers
 Mechanical conveying system
-Screw conveyors, belt conveyors, drag
chain conveyors for horizontal or inclined
transport of bulk materials.
 Bucket elevators for vertical transport of
materials.
 Bucket elevators
Bucket elevators:
Used for vertical transport of
material
Types :
-Belt bucket elevator
-Chain bucket elevators
 Advantages of belt bucket elevator
 Low power consumption
 Low maintenance cost
 Quieter running
 High capacity with same bucket size
 Reduced wear of drive mechanism
 Higher mechanical efficiency
 Proposed System
Proposed fly ash transport system
Proposed fly ash transport system flow

diagram
Functional details of the equipments
 Proposed fly ash transport system
Unloading hoppers Rotary air locks
Proposed drag chain conveyor
Belt bucket elevator air slide
Rotary screen silo
Functional details of equipments
 Unloading hoppers
 Rotary air locks
 Proposed drag chain conveyor
 Belt bucket elevator
 Air slide
 Rotary screen
 Unloading hoppers
 used to take the surge which occurs during the
unloading time and used to have a continuous
regulated flow of the material
 Rotary air locks
 Used to control the sudden flow or rushing of
the material and promotes the regulated
continuous flow.
 Proposed drag chain conveyor
 used to take the surge which occurs during the
unloading time and used to have a continuous
regulated flow of the material .
 Belt bucket elevator
 Used to transport the bulk materials vertically
to very high elevations
Bucket elevator contains,
 Head drum

 Tail drum

 Bucket strand
 Air slide
 Used to regulate the material flow from belt
bucket elevator to rotary screen.
 Rotary screen
 Used to separate the foreign particles from the
material.
 Cost estimation of the project
 Civil 2.25 Lacs
 Mechanical 59.40 Lacs
 Electrical 1.82 Lacs
 Instrumentation 0.50 Lacs
 Contingencies 3.08 Lacs
------------------
TOTAL 67.17 Lacs
-------------------
 MECHANICAL COST
ESTIMATION
 Drag chain conveyor 15.68 Lacs
 Belt bucket elevator 33.66 Lacs
 Air slide 1.57 Lacs
 Steel 6.48 Lacs
 Equipments erection 0.59 Lacs
 Structural fabrication 1.42 Lacs
------------------
TOTAL 59.40 Lacs
--------------------
 Present expenditure with existing
system
 Power consumption

283.7 KW x 22 H x 300 D x 0.8

=14,97,936 KWH x Rs 2.53 /-
= Rs.37,89,778.
 Stores and Spares : Rs 7,93,000 /-
 Total expenditure : Rs 45,82,778 /-
 Envisaged expenditure with
proposed System
 Power consumption

39.2 KW x 12 H x 300 D x 0.8

= 1,12,896 KWH x Rs.2.53
= Rs.2,85,627 /-
 Stores and Spares : Rs.2,00,000
 Total expenditure : Rs.4,85,627
 Anticipated net savings
 Anticipated net savings per annum
=Rs45.83 - Rs4.86lacs
=Rs40.97lacs

 Pay back period

 Comparison between the existing
and the proposed systems
EXISTING SYSTEM PROPOSED SYSTEM
 High power  Low power

consumption consumption
 High working hours  Less working hours

 High maintainence cost  Low maintainence cost

 Low working capacity  High working capacity

 High loss of material  Less loss of material