Material Handling System in Cement Industry Submitted to Dr. Ariful Islam Associate professor Dept of IPE SUST
Submitted by : Bivek Bikram Adhikari Reg.No. 2007334051 Department of Industrial and production Engineering , Shahjalal University of Science and Technology, sylhet, Bangladesh .
Material handling system in cement industry. Objectives:
To study about material handling system in cement industry. To analyze the material handling equipment in cement industry.
ntroduction: I ntroduction: In the most general sense of the word, cement is a binder, a substance that sets and hardens independently, and can bind other materials together. Cement used in construction is characterized as hydraulic or non-hydraulic or non-hydraulic.. Hydraulic cements (e.g. Portland cement) harden because of hydration chemical reactions that occur independently of the admixture's water content; Non-hydraulic cements (e.g. lime and g ypsum plaster) must must be kept d ry in order to retain its strength. There are 31 cement industries in Bangladesh1. Material handling is one of the most important tasks in cement industry. Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and 2 disposal .
Material handling equipment: Material handling equipment (MHE) is used for the movement and storage of material within a facility or at a site. MHE can be classified into the following five major categories3: 1. Transport Equipment . Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyors, cranes, and industrial trucks. Material can also be transported manually using no equipment. 2. P ositioning ositioning Equipment . Equipment used to handle material at a single location so that it is in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment 3. U nit nit Load Formation Equipment . Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment. 4. S torage torage Equipment . Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required. 5. I dentification dentification and Control Equipment . Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manuall y with no specialized equipment.
1 2 3
http://www.bdyellowbook.com/catalog/Consultancy___Construction/ http://www.mhia.org/learning/glossary/m http://www.ise.ncsu.edu/kay/mhetax/index.htm
C ement ement production process: A cement production plant consists of the following three processes. 1. Raw material process 2. Clinker burning process &
3. Finish grinding process.
Material handling in cement industry:
Figure14: Material handling in cement industry
4
http://www.robs http://www.robson.co.uk/cement_conve on.co.uk/cement_conveyors/cement_conveyors yors/cement_conveyors.htm .htm
Figure1 shows the use of conve yor in cement industry .Following things are used for material handling in cement industry
Belt conveyor Air glide Elevator conveyor
00. Limestone Quarry and Crushing plant 01. Limestone Stockpile 02. Additives Hopper 03. Additives Storage 04. Raw Mill Building 05. Blending and Storage Silo 06. Preheater 07. Gas Conditioning Tower To wer and ESP 08. Kiln 09. Cooler 10. Deep Bucket Conveyor 11/12. Clinker/Gypsum Storage 13. Coal Mill Building 14. Cement Mill and Bag House 15. Cement Storage Silo 16. Packing & Dispatch 17. Central Control Room
Screw conveyor Silos
Belt Be lt
¡
¢
£
eyor:
A conveyor belt belt (or belt belt conveyor) consi consists of t o or more pull pulleys, eys, wit wit a conti continuous nuous loop of mat mat er ial - t e conveyor belt belt - t at rot rotates about about t em. One or bot bo t of t of t e pull pu lleys eys are powered, movi movi ng t e b elt and t e mat ma t er ial on t e b elt forward. The powered pull pulley ey is call called ed t he dr i ve pull pulley ey whil whilee t he unpowered pull pulley ey is call called ed the i dl er. ¥
¤
¥
¥
¥
¥
¥
¥
¥
¥
Figure: gure: belt belt conveyor Belt conveyor i conveyor is very si si mpl mpl e i n desi design and wi wi del del y used in many i ndust ndustr i es. B elt conveyor i conveyor is mostl mostly y used i n cement cement indust ndustry to convey raw mat mat er ial to gr i ndi nding machi machi ne. Af t er gr indi nding raw mat mat er ial it is conveyed by belt belt conveyor for mi mi ing process. Fi F inall nally y when cement cement clinker linker iis gr inded agai again f i nished cement cement is transferred for packagi packagi ng through belt belt conveyor. Al Also l ot of cement cement is transferred in belt belt conveyor i conveyor i n sil s ilos os af ter packagi packaging. B elt conveyer i conveyer is very basi basic mat mat er ial handli handling ng equi equi pment pmen t and used frequentl frequently y in cement cement plant an t. ¦
F igure : Belt conveyor
Ai r
g li li e conveyor: §
Air glide lide is a mat mat er ial handli handling ng equi equi pment pment useful useful for Bulk mat mat er ial handli handling ng process. Ai Ai r glide lide conveyors are desi desi gned to be robust robust and reli reliab ablle for harsh envi environment ronmen ts. The Ai Air glide li de B elt conveyor i conveyor is a devel devel opment opment of t of t he traditi raditiona onall t ype, but but inst nstead of carryi carryi ng idl ers it empl emp loys a cushi cushi on of air, bei bei ng the means of suppor ting ting t he loaded belt belt bet bet ween the feed and the discharge. Ai Air is in jec j ectt ed at regul regular i nt erval ervals along the "U" shaped bedpl bedplate t o the undersi undersi de of t of t he belt belt,, generati generating ng a low fr i ction tion suppor t cushi cushion. A small small blower unit unit suppli supp lies es the low-pressure f iltered ilt ered ai air t r to the pl p l enum, whi whi ch in most most inst nstances is suff i ci ent ent to suppl suppl y t he total belt belt lengt eng t h. In cement cement indust ndustry ai air gli glide de conveyer are us ed when additi additive ve mat mat er ials are suppli supp lied ed in a mi m i ture ¨
.
F igure5: Air gli glide de conveyor
5
http://www.robs http://www.robson.c on.co.uk/ce o.uk/ce ent _con _convey veyor orss/ ce ent _ rglide_c rglide_con onvey veyor orss.htm ©
©
levator E levator
conveyor:
Elevator conveyor is a precise solution to the vertical movement of dry and free flowing bulk materials for the Cement Industry. The Bucket Elevator is constructed using stainless steel or mild steel buckets attached to a belt or chain. Encased in a steel enclosure the elevated material is protected from the atmosphere, giving the Bucket Elevator the ability to be used internally or externally of buildings. In cement industry processing materials are uplifted vertically to feed in preheater. For a uplifting operation elevator conveyor are used in cement industry. As shown in fig:
6
Figure : Elevator conveyor
6
http://www.robs http://www.robson.co.uk/cement_conve on.co.uk/cement_conveyors/cement_elevator_ yors/cement_elevator_conveyor.ht conveyor.htm m
crew S crew
Figure: Screw Conveyor
C onveyor: onveyor:
Screw Conveyors have a variety of uses. Variations in the flight design allow Screw Conveyors to: y y y y
Convey Mix Feed Elevate\
With the bespoke construction of the screw conveyor it is possible to have multiple in feeds and a single out feed. In cement industry tons of material are processed the upper listed operation. When a semi liquid material is dried in a dryer obtained clinker is stored in a storage through screw conveyor.
ilos: S ilos: A silo is a structure for storing bulk materials. Silos are used in agriculture to store grain or fermented feed known as silage. Silos are more commonly used for bulk storage of grain, coal, cement, carbon black, woodchips, food products and sawdust. Three types of silos are in widespread use today - tower silos, bunker silos and bag silos. The cement storage silo is used for storing the finished product ± cement
Figure7: Silos
7
http://www.ecvv.com/product/1433105.html
Conclusion:
Material handling system is a basic component in cement Industry. Tons of bulk material are conveyed , uplifted, and stored in cement Industry so material handling equipment likeConveyor, like Conveyor, Elevator, S ilos ilos are the essential part of cement Industry. In this seminar we have defined a theoretical portion of material handling system in cement industry. We searched in internet for required information of our topics. Finally we decided to take a ³chhatak cement Industry ³as a case study in a second portion of this seminar.
