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Helping cement plants run at full capacity

Published by , Editorial Assistant
World Cement,

Cement manufacturers can employ a number of measures to prevent and eliminate material buildups and improve the overall flow of material throughout the production process. With an array of cement industry installations, in this article Standard Industrie International (SI) will explain how buildups and blockages can be addressed in various locations in a cement plant, improving both plant productivity and safety.

Material buildups in the cement production process often lead to reduced plant productivity and higher cleaning costs, as well as increased safety for maintenance staff. Such issues can be avoided by undertaking measures, including preventive solutions against blockages and buildups.

Since filing for its patent 1978, SI has sold more than 50 000 of its Airchoc® air cannon systems in 90 countries. The system can be applied to various locations in a cement plant.

Buildsup removal in the preheater tower and snowman at clinker cooler during operations.

Cement plant in Qatar

In a fast growing economy, Qatar is preparing for the 2022 World Cup and is building its new Doha metro and Hamad sea port. The demand for cement requires full capacity from the cement plant to match the deliveries of concrete. In this context, SI supplied its customer with a complete package of AIRCHOC 5 high temperature for both preheater and cooler lines. Air canons guarantee the smooth operation and running of the process without any stoppage due to buildup.

Declogging of hopper clay earth

Cement plant in Guatemala

The company delivered 49 AIRCHOC systems to its customer for the entire production line and cooler. The customer’s aim was to avoid the creation of clogging in cement production processes.

Safe cleaning

The development of wireless air cannons and silo cleaning solutions has improved safety and reduced operational costs, as they can be used without manual intervention at the locations where issues occur. Moreover, preventative action with such tools enables efficient material flow throughout the cement plant, thereby reducing or eliminating the costly shutdown of key equipment and improving plant productivity.

Cleaning industrialisation

The company also helps to avoid manual cleaning operations by sweeping or blowing. A cement plant can install centralised vacuum cleaning for different areas, such as palletising, packing, or truck loading.

To meet its clients’ industrial cleaning, pumping, and vacuuming requirements, SI offers a complete range of equipment and vehicles that combine safety and performance. From vacuum vehicles to mobile vacuum units, the company has designed solutions for various industrial vacuuming needs.

For example, a cement plant, with its bagging, tunnels, conveyor belts, cement grinding, and coal workshop, needed to be cleaned. The plant was already equipped with SI’s AIRCHOC WIRELESS. The cement producer turned to SI to supply several vacuum machines and purchase a UMA3000DMX. The UMA was the best solution to tackle the difficulties and constraints associated with a heavy vehicle. Powerful, mobile, and adaptable, the UMA is equipped with explosion vents. It can therefore vacuum coal and petroleum coke. The old equipment could not do it. SI was also responsible for installing a fixed pipe network in the bagging area. The nine suction inlets of the network made it possible to optimise the cleaning of three buildings.

Spillage and dust emission reduction

Optimising production tools means the reduction of atmospheric emissions, improved visibility and staff safety, reduced maintenance costs, etc. Regarding dust control in cement production, the advantages of using the LIFTUBE® in cement production include the following:

  • The LIFTUBE is a solution that optimises the sealing of various conveyor belts (smooth or cleats, rubber or PVC, vulcanised hot or cold).
  • It comes as a replacement to stations equipped with three rollers on conventional conveyors. These are standard 1 m modules that are scalable and easy to install on all or part of a new or existing conveyor, while keeping the belt, chassis, and motorisation of origin.
  • It is installed between the point of loading and unloading and is available in widths from 500 mm to 1400 mm, in high temperature, explosive food or self-extinguishing versions.
  • It avoids any contamination of the product transported in the outside environment. This seal-proof system enables the easy tilting of the glide boards and the central roller for easy and minimal maintenance.
  • Thanks to its pinch point protections the system significantly improves the working conditions of the operators.

These innovative and reliable solutions proposed by the design office of SI have been adopted by many plants where bulk is handled in various industries across the world.

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This article has been tagged under the following:

European cement news Cement news 2018