Complex system solutions for the bulk materials industry by BEUMER
The BEUMER Group uses its newly created Conveying & Loading Systems (CL Systems) division to develop and implement complex system solutions throughout the world for different industries, such as mining and the cement industry. The team is made up of experienced staff from the branches distributed around the world who work together on the projects and develops tailor-made solutions for the customers. This is demonstrated by three impressive completed projects.
In difficult environment cost-effective operation guaranteed
The operators for whom BEUMER has successfully commissioned conveying plants includes the TPI Polene Public Company Ltd. The third largest cement producer in Thailand uses this complex system solution to transport crushed limestone from the quarry to the blending bed.
Dr Echelmeyer, who has headed the Conveying and Loading Systems division in the BEUMER Group at its headquarters in Beckum since August 2015, says: “The challenge lay in the nature of the ground between the quarry and the cement plant. It was exceptionally demanding. We had to make allowances not only for numerous obstacles but also for a steep downhill section of the conveyor.” The team designed a complex, but above all cost-effective, integrated system comprising a total of 8 belt conveyors covering a distance of 6129 m. BEUMER also supplied a PLC plant control system, transfer stations, filter systems and foreign body collectors.
The system is designed for a conveying capacity of 2200 t/h. The key items in the limestone transport system are 2 downhill belt conveyors operating in the generator mode followed by a troughed belt conveyor with horizontal curves. The material passes from the crusher discharge belt the first two troughed belt conveyors. The material is then transferred to a long overland conveyor with a speed of 4.5 m/sec by an accelerator belt with a speed of 2.6 m/sec. 3 more conveyors finally transport the material to the blending bed.
One particular feature of the downhill conveyors is their power generation. With a total of 640 kW/h generated energy that is fed into the power grid they make a substantial contribution to the cost-effective operation of the overall system. “We have a great deal of experience with conveying systems that can negotiate horizontal and vertical curves and operate in the generator mode,” explained Dr Echelmeyer. During the development it was necessary, for example, to ensure safe and carefully controlled stopping of the large belt system to avoid problems during unavoidable events, such as a power failure.
BEUMER supplied 4 further belt systems with a total length of 989 m to deal with the discharge from the blending bed and supply the material to the raw mill feed hopper. The conveyors were all built and installed in only eleven months. The commissioning phase, lasting three months, was followed by performance tests. The team then handed over the entire plant to the customer. Dr Echelmeyer emphasized: “We supervised and monitored the installation and commissioning to ensure long-lasting, trouble-free, operation. This always forms part of our service.” The standard scope of supply also includes intensive training of the operating and maintenance personnel.
Complex and curved
Cong Thanh, the Vietnamese cement producer, also relies on the system solution expertise of the BEUMER Group for transporting crushed limestone from the quarry to the blending bed. The CL team discussed the various technical options intensively in a joint workshop held with the producer. Various routes were worked out and compared on the basis of the narrow terrain that was available. Dr Echelmeyer explained: “We have appropriate software for this, with which we can match satellite and aerial photographs with topographical data.” One conveyor section that drops steeply in some places with numerous obstacles in the terrain and seven road crossings was particularly challenging.
A total system consisting of 4 conveyors with a combined length of 3.5 km is now in use, BEUMER also supplied a PLC plant control system. The main component is an overland conveyor with 3 horizontal curves and a total drive rating of 600 kW. It is designed for a continuous conveying capacity of 2200 t/h. The heaped material is transported in trucks from the quarry face to the crusher. The limestone that has been pre-crushed to less than 100 mm is then transferred by discharge conveyors to an accelerator belt that feeds the long belt conveyor.
The troughed belt conveyor for downhill transport is 1 m wide, with a distance between centres of 3200 m, and drops 70 m. The conveying speed is 4.5 m/sec. The low operating costs are a special feature. Due to the downhill section the operation of the fully loaded conveyor is virtually energy-neutral. Its consumption during continuous operation is less than 200 kW, which means that not even 0.1 kW is required per tonne of transported material. “This, together with the low maintenance and repair costs, contributes substantially towards cost-effective operation,” states Dr Echelmeyer. After the installation and commissioning his team submitted the plant to a performance test that it passed successfully on all points.
Controlled loading through the middle of the rainforest
The CL Systems division of the BEUMER Group has also been very successful in Indonesia. The plant construction company Sinoma International Engineering Co. Ltd. was awarded the contract by the Indonesian end customer, Cemindo Gemilang, to supply a turn-key cement plant to Java. It should reach a daily clinker production of 10 000 t. Sinoma commissioned BEUMER with the design and supply of an overland conveyor between the quarry and the plant.
The challenges in this project were not only the demanding topographical routing but also the evergreen rainforest. Joint discussions were held between the BEUMER team, Sinoma and the end customer. The team worked various routes out and compared them. “The very narrow corridor of land in addition to the tropical climate required a complex and sophisticated design,” explained Dr Echelmeyer. Among other things his team designed a solution with tight horizontal curves that fitted optimally into the landscape.
The entire system now comprises 6 conveying plants with a total of length of 7.6 km. BEUMER also supplied acceleration and discharge conveyors and a PLC plant control system. The system is designed for a maximum continuous conveying capacity of 3000 t/h. The main component is a 7.4 km long overland conveyor. Upstream of this troughed belt conveyor is an intermediate hopper with a capacity of about 120 t. The material passes from this hopper via a variable-speed discharge conveyor to a downstream acceleration belt that feeds the overland conveyor. This controlled loading system ensures cost-effective operation of the plant, especially during the start-up phase. It also has a favourable effect in the dimensioning of drive components and the belt, and reduces the operating costs.
Dr Echelmeyer says: “The acceleration belt with a speed of 4 m/sec protects the belt of the overland conveyor and increases its service life.” For further protection there are also upstream units for collecting any iron and non-ferrous metals. The limestone is then transported to the blending bed on short troughed belt conveyors. The troughed belt conveyor has a width of 1200 mm and a distance between centres of 7381 m. One tail drive and two head drives are installed, each with a rating of 545 kW. The plant conveys the material at a speed of 5 m/sec and negotiates a height difference of minus 188 m.
The conveying system also runs past villages and for long sections passes through rainforest that deserves to be protected. The CL Systems team has taken numerous design measures to reduce the noise impact on people and animals. Dr Echelmeyer explained: “Among other things, we have used low noise idler rollers and appropriately dimensioned protective hoods at the drive station.” This means that the limestone passes through the rainforest in virtually silent mode. The construction time lasted only one year.
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