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Cement manufacturer Aalborg Portland A/S relies on the Pipe Conveyor of BEUMER Group: An economically convincing alternative

Published by , Assistant Editor
World Cement,

The manufacture of cement is particularly energy intensive. For an economical and sustainable operation, Aalborg Portland A/S therefore relies on alternative fuels and raw materials, in its Denmark lead plant, to ignite the calciner and the main burner. BEUMER Group supports the manufacturer with its AFR systems segment (alternative fuels and raw materials) and develops individual single-source solutions in order to efficiently convey, store and feed the differently composed materials. The core of these systems is represented by innovative Pipe Conveyors: The enclosed conveying systems ensure an environmentally safe, dust-free and low-energy transport of fuels and raw materials.

Figure 1. BEUMER Group supplied a single-source system to Aalborg Portland to feed the calciner and the main burner with alternative fuels and raw materials. The main component is given by the Pipe Conveyors. They are fed via screw conveyors.
Photo credits: BEUMER Group GmbH & Co. KG

Figure 2. The feeding station of the Pipe Conveyor to the calciner: in this regard, a take-up device has been installed at the rear.
Photo credits: BEUMER Group GmbH & Co. KG

In order to support producers of cement in the alternative fuels and raw materials field, BEUMER Group has set up a complete business segment dedicated to AFR systems. "Our know-how and our tailor-made systems permit us to offer an optimum support to our customers", says Tomas Hrala, Project Manager at BEUMER Group. "We have many years of good experience and we always consider customers' specifications". With this capability, the system provider is able to supply and install the whole chain from the acceptance and unloading of the delivery vehicle, up to the storing, conveying and feeding process of the solid alternative fuels for the specific user. The customer receives everything from one source, thus having a unique contact.

Figure 3. The two Pipe Conveyors: BEUMER Group realises different system solutions for the various bulk materials.
Photo credits: BEUMER Group GmbH & Co. KG

Figure 4. The Pipe Conveyor conveys the material directly to the rotary kiln. Curves can be easily realised during construction.
Photo credits: BEUMER Group GmbH & Co. KG

Pipe Conveyor as hub and pivot

"Due to the different grain sizes and the various compositions of these alternative fuels, it was necessary to develop an individual system solution for each line", explained Tomas Hrala. To enable the transport of the pre-processed fuels from the storehouse to the calciner and to the main burner, BEUMER Group supplied and installed respectively one Pipe Conveyor as the heart of these systems as well as the accompanying equipment. "This conveying technology is not only eco-friendly and requires low maintenance", describes Hrala. "Its enclosed type of construction protects the environment safely from material falling down and emissions. Another advantage is the lack of dust development on the running line". Due to its ability to navigate curves, considerably fewer transfer towers are required compared to other belt conveyors, allowing for a substantial cost savings to the customer. BEUMER Group can customise each system to the individual routing.

Figure 5. The penthouse is underneath the discharge station of the Pipe Conveyor of the calciner. The intermediate hopper with the activator and the two double discharge screw conveyors are positioned here. Photo credits: BEUMER Group GmbH & Co. KG

Figure 6. The weigh belt feeder with the rotary vane feeder including a blower conveys the material to the main burner through the pipes in a pneumatic way.
Photo credits: BEUMER Group GmbH & Co. KG

Efficient single-source system

The delivery of the oven-ready material is carried out in moving-floor trailers. The alternative fuels are unloaded and stored at the receiving station. Both lines receive the material/items transported by the moving floors modernised by BEUMER Group from the existing storehouse. All transport systems supplied and the accompanying equipment are intertwined to ensure steady fuel feeding. The Pipe Conveyor of the calciner has a diameter of 350 mm, a length of 135 m and can transport up to 50 t per hour to an intermediate hopper with a volume of 35 cubic m. This hopper is equipped with an activator and two double discharge screw conveyors, and distributes the material in two feeding and pneumatic conveying lines to both calciners. The two new pneumatic conveying lines to the calciner with rotary vane feeders and blowers were completely dimensioned and supplied by BEUMER Group.

BEUMER Group is an international leader in the manufacture of intralogistics systems for conveying, loading, palletising, packaging, sortation, and distribution. With 4500 employees worldwide, BEUMER Group has annual sales of about €950 million. BEUMER Group and its group companies and sales agencies provide their customers with high-quality system solutions and an extensive customer support network around the globe and across a wide range of industries, including bulk materials and piece goods, food/non-food, construction, mail order, post, and airport baggage handling. For more information, please visit:

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