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Schade solves intake problem at Russian plant

World Cement,

Schade has developed a solution for the intake facility at the Kaluzhskiy Cement plant in Russia. Once completed in 2014, the modern plant will have a capacity of 3.5 million tpa. It is built to the Best Practice engineering and environmental standards to comply with European and World Bank standards.

Though limestone will be sourced from the local deposits throughout the Kaluga Oblast, other materials including bauxite, iron ore, gypsum and slag will be imported by rail and road. Schade designed the intake facility specifically for the plant’s unique requirements. Schade’s ‘Pivot-Frame’ system was chosen both for its flexibility in plant layout and its ability to combine the tippler with an automated wagon charger to move the wagons into and out of the tippler working zone. Using this design, the associated hopper can be placed beside the tippler, enabling road trucks to discharge to a common feeder.

The rail track routing to and from the tippler presented a potential problem, given the fact that the ground falls sharply away on the exit side. Schade engineers surveyed the site and realised that to level the track would require many thousands of tonnes of backfilling, so instead they devised a solution whereby wagons can enter and exit from the same side of the tippler location. The wagon traverser uses parallel track, which also enables the introduction of a second track hopper for bottom discharge wagons using a common conveying system. This work will be undertaken in phase 2 of the project.

Adapted from press release by Katherine Guenioui.

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