Pan Conveyors

W E

C O N V E Y

Q U A L I T Y

PAN CONVEYORS

W E

C O N V E Y

CONTENTS

2 Clinker Transport and Discharge 4 Deep-Drawn Pan Conveyor type KZB 6 Deep-Drawn Pan Conveyor type KZB-Q 250

8 Bucket Apron Conveyor type BZB 250

10 Pivoting Pan Conveyor type SPB 14 Silo Discharge 15 Reversible Conveyor 16 Components

Clinker dust reclaim (TKF HN)

17 Accessories 18 Conversions and Refurbishments

19 After-Sales Service

CLINKER TRANSPORT AND DISCHARGE • Proven technology • Patented plate design • Spillage free • Quality • Reliability • Long service life • Low maintenance

2

Reliable conveying equipment for hot, abrasive cement clinker is essential for economic operation in cement plants. Conveying systems forming the link in materials management are vital for the availability and productivity of the entire plant. To receive an optimum overall conveying and storage layout, early implementation of experienced layout engineers is recommend recommended. ed.

Q U A L I T Y

Clinker transport from cooler to storage (KZB)

Automatic clinker discharge (Mole)

3

W E

C O N V E Y

Deep-Drawn Pan Conveyor

Silo discharge conveyors

Spillage free design

Collecting chute

28° Feed chute

Cleaning scraper, C-shaped

Deep-Drawn Pan Conveyor under clinker cooler

Fines chute

Dust hood

Overload chute

Weather cover

Feeding and discharge - type KZB 250

DEEP DRAWN PAN CONVEYOR TYPE KZB 250 Reliable conveying equipment for hot, abrasive cement clinker is essential for economic operation in cement plants. Conveying systems forming the link in materials management are vital for the availability and thus the productivity of the entire plant. Experience has shown that even coolers of the latest design do not always ensure effective reduction of the clinker temperature. Red spots may occur occasionally. Plant operators who wish to be on the save side choose AUMUND pan conveyors for their reliability in conveying hot materials.

4

AUMUND Deep-Drawn Pan Conveyors type KZB 250 are well-known for low maintenance, tightness and a long service life. They are particularly suitable for applications with coolers. The material is directly discharged onto the Deep-Drawn Pan Conveyor arranged over the whole length of the cooler - a very economic solution as drag chains are not required.

• • • •

Slopes up to 28° Patented pan sealing Contact-free pan overlapping Suitable for hot material (up to 700° C)

AUMUND Deep-Drawn Pan Conveyors are equipped either with single-strand or double-strand chains. The single-strand types (central chains) are designed for a max. pan width of 800 mm and for low conveying capacities. Higher conveying capacities are handled with double chain strands provided for pan widths from 800 to 3,000 mm.

• Modular system • Electrical soft start • Variable-speed drives with frequency control • Standard chain sizes with breaking loads from 220 to 1,800 kN for each chain strand

Q U A L I T Y

The characteristic profile of the bottom plates provides high rigidity even with a pan width exceeding 2,000 mm. DeepDrawn Pan Conveyors may be designed with slopes matching the angle of repose of the conveyed material. Stiffeners pressed into the side walls of the pans as well as a special sealing edge increase the pan’s solidity and the dust-tight fitting between the pans. AUMUND attach particular importance to the design of feed chutes and dust hoods. Proper dimensioning of dedusting connections in the transfer areas considerably reduce the need for cleaning. Weather covers, chutes for collection of fines, distribution chutes and flat gates complete the product range. The pan conveyors are driven by bevel spur gears either foot mounted with flexible coupling between gearbox and drive shaft or shaft-mounted. For inclined conveying, the gear box is fitted with a back stop. A hydraulic coupling is installed between gear box and motor or, for soft start up of the motor, with a flexible coupling. Alternatively, the flexible coupling between motor and gearbox can be provided with a disc brake to stop the fully loaded conveyor in any given position if the back stop fails to work properly. Frequency converters adapt the conveying speed to the actual conveying capacity, thus minimizing wear and ensuring a longer service life of chains, rollers and rails.

Conveying capacity - Deep Drawn Pan Conveyor Type KZB 250 The capacities indicated correspond to a brimfull filling (water filling) =100 % Preferred sizes Conveyor section type KZB 250 Width mm

Theoretical conveying capacity m3 /h

Side wall P late thickness Conveyor speed m /s

0.10

Permissible

0.15

0.20

0.25

0.30

0.35

0.40

12

17

23

29

35

40

46

19

28

37

47

56

66

75

80 %

26

39

52

65

78

91

104

80 %

5

33

50

66

83

99

116

132

80 %

5

40

60

81

101

121

141

161

80 %

28

42

56

70

84

98

112

80 %

39

58

78

97

117

136

156

80 %

149

174

199

80 %

181

212

242

80 %

214

249

285

80 %

156

181

207

90 %

height mm

mm

400

100

5

400

150

5

400

200

5

400

250

400

300

600

150

5

600

200

5

600

250

5

50

75

99

124

600

300

5

60

91

121

151

600

350

5

71

107

143

178

800

200

5

52

78

104

130

800

250

5

66

99

132

166

199

232

265

90 %

800

300

5

81

121

161

202

242

282

232

90 %

800

350

5

95

143

190

238

285

333

380

90 %

800

400

5

109

164

219

274

328

383

438

90 %

1.000

200

5

65

97

130

162

194

227

259

100 %

1.000

250

5

83

124

166

207

248

290

331

100 %

1.000

300

5

101

151

202

252

302

353

403

100 %

1.000

350

5

119

178

238

297

356

416

475

100 %

1.000

400

5

137

205

274

342

410

479

547

100 %

1.200

200

5

78

117

156

194

233

272

311

100 %

1.200

250

5

99

149

199

248

298

348

397

100 %

1.200

300

5

121

181

242

302

363

423

484

100 %

1.200

350

5

143

214

285

356

428

499

570

100 %

1.200

400

5

164

246

328

410

492

575

657

100 %

1.400

250

5

116

174

232

290

348

406

464

100 %

1.400

300

5

141

212

282

353

423

494

564

100 %

1.400

350

5

166

249

333

416

499

582

665

100 %

1.400

400

5

192

287

383

479

575

670

766

100 %

1.400

450

5

217

325

433

542

650

759

867

100 %

1.600

250

6

132

199

265

331

397

464

530

110 %

1.600

300

6

161

242

323

403

484

564

645

110 %

1.600

350

6

190

285

380

475

570

665

760

110 %

1.600

400

6

219

328

438

547

657

766

876

110 %

1.600

450

6

248

372

495

619

743

867

991

110 %

1.800

250

6

149

224

298

373

447

522

596

110 %

1.800

300

6

181

272

363

454

544

635

726

110 %

1.800

350

6

214

321

428

535

642

748

855

110 %

1.800

400

6

246

369

492

616

739

862

985

110 %

1.800

450

6

279

418

557

697

836

975

1.115

110 %

2.000

250

6

166

248

331

414

497

580

662

120 %

2.000

300

6

202

302

403

504

605

706

806

120 %

2.000

350

6

238

356

475

594

713

832

950

120 %

2.000

400

6

274

410

547

684

821

958

1.094

120 %

2.000

450

6

310

464

619

774

929

1.084

1.238

120 %

2.200

250

6

182

273

364

455

546

638

729

120 %

2.200

300

6

222

333

444

554

665

776

887

120 %

2.200

350

6

261

392

523

653

784

915

1.045

120 %

2.200

400

6

301

451

602

752

903

1.053

1.204

120 %

2.200

450

6

341

511

681

851

1.022

1.192

1.362

120 %

2.400

250

6

199

298

397

497

596

696

795

120 %

2.400

300

6

242

363

484

605

726

847

968

120 %

2.400

350

6

285

428

570

713

855

998

1.140

120 %

2.400

400

6

328

492

657

821

985

1.149

1.313

120 %

2.400

450

6

372

557

743

929

1.115

1.300

1.486

120 %

filling degree

80 %

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W E

C O N V E Y

Clinker silo feeding type KZB-Q 250

Collecting chute Intermediate chute Feed chute

Fines chute Dust hood


Dust hood

Feed chute

Weather cover

Feeding and discharge - type KZB-Q 250

Deep-Drawn Pan Conveyor with baffles type KZB-Q 250

DEEP DRAWN PAN CONVEYOR TYPE KZB-Q 250 Standard Deep-Drawn Pan Conveyors with baffles are applied for inclination angles up to 40°. The basic concept of this economic inclined conveyor includes the use of standard elements like deep drawn pans, chains and rollers. The Deep-Drawn Pan Conveyor type KZB-Q 250 is designed for inclination angles between 28° and 40°. These slopes are still practicable for walkways in conveyor bridges. The AUMUND range of conveyor chains shown on page 9 is designed for lifts of more than 60 m. With an efficient plant layout, feeding of clinker silos can thus be performed with just one conveyor.

Standardized components reduce the variety of parts and constitute the AUMUND modular system: components such as sprockets, chains, rollers and rails of AUMUND pan conveyors are interchangeable to a large extent, an important asset for spare parts management. The deep-drawn pans are equipped with baffles for inclined conveying. These baffles are bolted to the bottom plate and hold in a loose fitting by cams which arepressed into the upper part of the side boards.The loose fitting allows the baffles to bend in case foreign bodies get onto the conveyor. Bent baffles will not affect proper functioning of the conveyor, they may be replaced at any time, for example during a regular stop of the system. Tightness of side walls

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Q U A L I T Y

As a standard, the rollers of AUMUND pan conveyors are separated from the traction element, the chain. This important design feature of AUMUND pan conveyors ensures that the chain selection is always made to suit the actual traction force, whereas the rollers are chosen in accordance with the weight of the pan conveyor itself and the conveyed material. The separation of traction elements and carrying elements simplifies maintenance and assembly. All rollers are fastened to their brackets by means of stub shafts, a simple but efficient and safe fixing means. Depending on the respective plate width, rollers are arranged at intervals of 500, 1,000 or 1,500 mm.

• Slopes up to 40° • Conveying capacities exceeding 750 t/h • Exchangeable baffles • Deep-drawn pans of solid design • Material temperatures up to 700° C

Conveying capacity - Deep Drawn Pan Conveyor with Baffles Type KZB-Q 250 The capacities indicated correspond to a brimfull filling (water filling) =100 % Preferred sizes Conveyor section type KZB-Q 250 Width

Theoretical conveying capacity m3 /h

Side wall P late thickness Conveyor speed m /s

mm

height mm

mm

400 400 400 400 600 600 600 600 800 800 800 800 800 1.000 1.000 1.000 1.000 1.000 1.200 1.200 1.200 1.200 1.200 1.400 1.400 1.400 1.400 1.400 1.600 1.600 1.600 1.600 1.800 1.800 1.800 1.800 2.000 2.000 2.000 2.000 2.200 2.200 2.200 2.200 2.400 2.400 2.400 2.400

250 300 350 400 250 300 350 400 250 300 350 400 450 250 300 350 400 450 250 300 350 400 450 250 300 350 400 450 300 350 400 450 300 350 400 450 300 350 400 450 300 350 400 450 300 350 400 450

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

0.10 33 40 48 55 50 60 71 82 66 81 95 109 124 83 101 119 137 155 99 121 143 164 186 116 141 166 192 217 161 190 219 248 181 214 246 279 202 238 274 310 222 261 301 341 242 285 328 372

0.15 50 60 71 82 75 91 107 123 99 121 143 164 186 124 151 178 205 232 149 181 214 246 279 174 212 249 287 325 242 285 328 372 272 321 369 418 302 356 410 464 333 392 451 511 363 428 492 557

Permissible

0.20 66 81 95 109 99 121 143 164 132 161 190 219 248 166 202 238 274 310 199 242 285 328 372 232 282 333 383 433 323 380 438 495 363 428 492 557 403 475 547 619 444 523 602 681 484 570 657 743

Reduced output factor Side wall height mm 250 300 350 400 450

35° 0.822 0.863 0.888 0.905 0.918

40° 0.701 0.769 0.812 0.841 0.863

0.30 99 121 143 164 149 181 214 246 199 242 285 328 372 248 302 356 410 464 298 363 428 492 557 348 423 499 575 650 484 570 657 743 544 642 739 836 605 713 821 929 665 784 903 1.022 726 855 985 1.115

30°

Reduced output factor up to angle of inclination of 30° 0.949 0.960 0.968 0.973 0.976

0.25 83 101 119 137 124 151 178 205 166 202 238 274 310 207 252 297 342 387 248 302 356 410 464 290 353 416 479 542 403 475 547 619 454 535 616 697 504 594 684 774 554 653 752 851 605 713 821 929

45° 0.589 0.682 0.741 0.782 0.811

0.35 116 141 166 192 174 212 249 287 232 282 333 383 433 290 353 416 479 542 348 423 499 575 650 406 494 582 670 759 564 665 766 867 635 748 862 975 706 832 958 1.084 776 915 1.053 1.192 847 998 1.145 1.300

0.40 132 161 190 219 199 242 285 328 265 323 380 438 495 331 403 475 547 619 397 484 570 657 743 464 564 665 766 867 645 760 876 991 726 855 985 1.115 806 950 1.094 1.238 887 1.045 1.204 1.362 968 1.140 1.313 1.486

filling degree

80 % 80 % 80 % 80 % 80 % 80 % 80 % 80 % 90 % 90 % 90 % 90 % 90 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 % 95 %

C o n v e y i n g d i r e c t i o n

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W E

Clinker silos 2 x 60,000 t

Bucket Apron Conveyor type BZB 250

C O N V E Y

Clinker transport with conveyor type BZB 250

Collecting chute Intermediate chute Fines chute

Feed chute

Feed chute

Dust hood


Clinker silo feeding with conveyor type BZB 250

Dust hood

Weather cover

Feeding and discharge - type BZB 250

BUCKET APRON CONVEYOR TYPE BZB 250 AUMUND Bucket Apron Conveyors type BZB 250 are the proper solution for clinker transport systems with up to 60° inclination. These conveyors with their narrow curve radius offer considerable advantages particularly for the modernization or conversion of existing plants where only restricted space is available. The modular system also applies for the AUMUND Bucket Apron Conveyor, ensuring interchangeability and combination of components like those used for the construction of Deep-Drawn Pan Conveyors. Standardized chains are used as well; merely the angular fishplates are modified

8

for the solid bucket fixing. The standard chain sizes are documented on page 9. The roller selection suits the bucket size and the load requirements. Standard roller diameters are diameters 108/140 and 160 mm.The standard roller spacing is 1,000 mm which means that one out of two buckets is fitted with a set of rollers. Same as the deep drawn pan conveyor, the Bucket Apron Conveyor features the proven roller brackets and stub shafts to fasten the rollers. An essential asset of AUMUND Bucket Apron Conveyors - the tight bucket arrangement - above all takes effect where very finegrained clinker with a high ratio of dust has to be conveyed. To

increase the buckets solidity and ensure safe operation, the bucket bottom is provided with a built-in stiffener. Depending on the individual plant requirements, the overlapping of the buckets is either forward or backward.

• • • •

Slopes up to 60° Lifts exceeding 60 m Minimum curve radius 8 m Tight bucket arrangement for fine-grained materials

Standard bucket sizes are available up to a width of 1,600 mm. When choosing the bucket size, it has to be considered that the actual conveying capacity is subject to a reduction factor defined by the angle of inclination.

Q U A L I T Y

The reduction factor is based upon the assumption that the material in the bucket will form an angle of repose of at least 25°. If feeding of the material is arranged in the inclined section only, a higher reduction must be accounted for as the factor will decrease gradually to a water filling level. In particular large buckets with a width of 1.200 mm and more require adequate design of the feed chutes. For a uniform bucket filling, feed chutes with saddles have proved to be a good solution, as they ensure even material distribution over the whole bucket width. Expert planning of the chute system is therefore considered to be a pre-requisite for trouble-free operation with only little dust generation. The take-up station standard provides for spring tensioning. In special cases counterweights are added where considerable chain elongations resulting from considerable temperature differences of the conveyed material have to be compensated. C-shaped cleaning scrapers arranged around the take-up station and recycling the collected fines, are used to minimize cleaning around the take-up station. Depending on the contents of fines in the conveyed material, the operating time of these cleaning scrapers can be adjusted by means of sequence control. For the drive station area, fines collecting chutes are the most suitable solution. Frequency controlled motors are provided to adapt the conveyor speed to varying conveying capacities. Monitoring of the bucket filling level or control of the drive unit form part of the equipment.

Conveying capacity - Bucket Apron Pan Conveyor Type BZB 250 The capacities indicated correspond to a filling of 100 % and a angle of repose of 25°. Preferred sizes Bucket Bucket

Sides wall height

mm

mm

Theoretical conveying capacity m 3 /h Conveyor speed m / s 0,10 0.15 0.20

0.25

0.30

0.35

400

200

24

35

47

59

71

83

400

250

30

45

59

74

89

104

600

200

35

53

71

89

106

124

600

250

44

67

89

111

133

156

600

300

53

80

107

134

160

187

800

200

47

71

95

118

142

165

800

250

59

89

119

148

178

207

800

300

71

107

143

178

214

249

800

350

83

125

167

208

250

291

800

400

95

143

191

238

286

334

1.000

300

89

134

178

223

267

312

1.000

350

104

156

208

260

312

364

1.000

400

119

179

238

298

357

417

1.200

350

125

187

250

312

375

437

1.200

400

143

214

286

357

429

500

1.400

350

146

219

291

364

437

510

1.400

400

167

250

334

417

500

584

1.600

350

167

250

333

416

500

583

1.600

400

191

286

381

476

572

667

Permissible filling degree 70-80 % of the theoretical conveying capacity

Reduced output factor Side wall height mm 250 300 350 400 450

Reduced output factor up to angle of inclination of 30° 0.949 0.960 0.968 0.973 0.976

35° 0.822 0.863 0.888 0.905 0.918

40° 0.701 0.769 0.812 0.841 0.863

45° 0.589 0.682 0.741 0.782 0.811

50° 0.589 0.682 0.741 0.782 0.811

55° 0.589 0.682 0.741 0.782 0.811

60° 0.589 0.682 0.741 0.782 0.811

Recommended inclination max. 45°

Link chains acc.to AUMUND standard for type KZB 250 KZB-Q 250 BZB 250 Chain pitch: 250 mm

Type

for conveyor type

breaking load KN

250 x 30/50 x 8

KZB

220

B

250 x 30/50 x 8

BZB

220

250 x 45/70 x 10

KZB

450

B

250 x 45/70 x 10

BZB

450

250 x 60/80 x 10

KZB

520

B

250 x 60/80 x 10

BZB

520

250 x 60/90 x 12

KZB

700

B

250 x 60/90 x 12

BZB

700

250 x 60/90 x 12 v

KZB

900

B

250 x 60/90 x 12 v

BZB

900

AU 625

KZB

1.200

AU 625 W

BZB

1.500

AU 725

KZB

1.800

AU 725 W

BZB

1.800

B B

Link surface pressure 50 N/mm2 max.

9

W E

C O N V E Y

Feed chute Upper run

Feed chute Lower run

Discharge station Upper run

Discharge station Lower run

Drive station

Overflow

Pivoting Pan Conveyor type SPB - operation principle

PIVOTING PAN CONVEYOR TYPE SPB Wherever feeding of more than two clinker silos or several mill hoppers in line is required, AUMUND Pivoting Pan Conveyors type SPB have proved a reliable solution. With its intermediate discharge stations placed at any given position, the Pivoting Pan Conveyor ensures multiple distribution of various materials with just one conveyor. A pan reversing system integrated into the drive and take-up station allows for simultaneous material conveying in the upper and lower run. The graphic shows the principle of the pan reversing system as well as specific feeding and discharge features. Depending

10

on given requirements, upper run feeding can be performed by a simple feed chute whilst a two-way chute feeds the lower run. All feed chutes are equipped with overflow systems for direct feeding of the silos or hoppers during periods when the Pivoting Pan Conveyor is not in operation. The overflow chutes` operation principle is illustrated by the examples for clinker silo and mill hopper feeding. Simultaneous conveying in the upper and lower run provides multiple solutions for material handling. For example, material discharged onto the upper run can subsequently be transferred

to the lower run through a discharge station located on the upper run. The material may then be distributed into clinker silos or mill hoppers through discharge stations on the lower run. Separate conveying on the upper as well as the lower run is another possibility. A hopper can thus be loaded with cement clinker by way of the lower run, whilst for example gypsum is conveyed on the upper run. These are just two out of many solutions available either for new plants or, in particular, for conversion or modernization in existing plants.

Q U A L I T Y

• Several intermediate discharge stations • Simultaneous conveying on the upper and lower run; even with different materials • PLC-controlled operation • Automatic feeding of clinker silos and mill hoppers • Center distances of 400 m and more

Take-up station

Standardized components and the variety of applications make the Pivoting Pan Conveyor a versatile and reliable system. The variety of applications and the related operations require perfect functioning of the individual components such as the discharge stations and the pan and chain arrangement. The conveying elements of the Pivoting Pan Conveyor consist of 1 m long pans equipped with rollers at one end and with a carrier axle at the other end. The carrier axle allowing the pan to perform the reversing movement is linked to both chain strands. The graphic demonstrates how the pans in the lower run are pulled by the carrier axle while being pushed in

the upper run. This arrangement enables the material discharge by lowering the rails in the discharge station and by turning the pans in the drive and take-up stations. With their slightly conical shape the pans overlap by approx. 70 mm. This pan arrangement with side boards of 150 or 200 mm forms a tight material carrying surface.

• Automated material distribution into silos or hoppers controlled by level sensors • Customized layout and planning • Low energy consumption


Turning of pans at drive station and take-up station

Clinker silo feeding with Pivoting Pan Conveyor type SPB

Mill hopper feeding

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W E

For intermediate discharge into either silos or hoppers, the discharge stations are of stationary design. Switching from one discharge station to the other is performed by a lever system lowering the corresponding rail and actuated by a gear motor.The rail points setting is controlled by limit switches. The position of the rollers is monitored at any given moment to prevent their collision with the rails during the switching operations. The whole system is PLC-controlled for smooth and safe operation. Feeding of long clinker storage halls requires continuous shifting of the discharge point. Mobile discharge carriages which can be moved to any given position above the hall are used with this particular application. A capstan drive actuates the movement of the discharge carriage. If moved while clinker is being conveyed, the clinker is continuously distributed over the whole travel length of the carriage. A slotted discharge opening in the storage hall roof is required over the carriage’s travel length. A roof-shaped rubber strip sealing minimizes dust emission through the slotted opening. Sensors fitted to the conveyor supports monitor the position of the discharge carriage. Level indicators control automatic shifting of the carriage as soon as a maximum filling level is reached inside the storage hall.

Conveying capacity - Pivoting Pan Conveyor Type SPB The conveying capacities indicated were determined according to the sketch (with an angle of 10°) and will apply for horizontal conveying. Preferred sizes Carrier plate Width

Theoretical conveying capacity m3/h Side wall height Plate thickness

mm

mm

400 400 600 600 800 800 1.000 1.000 1.200 1.200 1.400 1.400 1.600 1.600

150 250 150 250 150 250 150 250 150 250 150 250 150 250

5 5 5 5 5+6 5+6 5 5 6 6 6 6 6 6

Conveyor speed m /s

0.10 26 32 40 50 56 68 72 88 90 110 110 132 130 156

0.15 39 48 60 75 84 102 108 132 135 165 165 198 195 234

0.20 52 64 80 100 112 136 144 176 180 220 220 264 260 312

0.25 65 80 100 125 140 170 180 220 225 275 275 330 325 390

please refer to type KZB 250 (page 4).

Feeding of individual bins Drive station

Feeding - lower run

Feeding of individual bins Drive station

Take - up station

Feeding Upper run

Feeding of storage hall and storage bins Drive station

Take - up station

Feeding Upper run

Discharge carriage

Take - up station

Feeding of bin or storage silo Drive station

Feed chute with emergency overflow

Discharge station

Take - up station with forced discharged

Possible applications - Pivoting Pan Conveyor type SPB

12

0.30 78 96 120 150 168 204 216 264 270 330 330 396 390 468

Permissible filling degree

The Pivoting Pan Conveyor is designed for a multitude of applications.The examples shown provide information on technical modifications which have been repeatedly been carried out:

• Material feeding onto the lower run and distribution into different bins • Material feeding onto the upper run, discharge onto the lower run and subsequent distribution into bins

C O N V E Y

Q U A L I T Y

• Material feeding onto the upper run and discharge onto the lower run followed by either bin feeding or material distribution over a defined area with the discharge carriage • Material feeding onto the lower run and material distribution over a defined area of a clinker storage hall with the discharge carriage • Material feeding onto the upper run, discharge onto the lower run and, when required, material distribution with the discharge carriage • Material feeding onto the upper run and distribution into bins via discharge stations. At the same time conveying of a separate material loaded onto the lower run and distributed into a clinker storage hall with a discharge carriage

Feeding with Pivoting Pan Conveyor Feeding of storage hall and storage bins Drive station

Feeding - lower run

Storage bin feeding Drive station

Discharge carriage

Feeding Upper run

Discharge carriage

Feeding of storage hall and storage bins Drive station

Feeding Lower run 1

Feeding Lower run 2

Feeding Upper run Discharge carriage

Take - up station

Take - up station

Take - up station

Feeding of storage hall Drive station

Feed chute with emergency overflow

Direction of travel for mobile discharge carriage

Take - up station with forced discharged

Further combinations are possible including upper and lower run conveying as well as stationary and mobile design of the discharge stations. Our project department will be pleased to assist you in finding the appropriate layout for your particular needs. Most outdated clinker storage halls are equipped with overhead travelling cranes to either distribute clinker in the hall in continuous operation or to feed the mill hoppers. Also additives like gypsum and sand have to be conveyed to the respective mill hoppers. This application is best served with a Pivoting Pan Conveyor ensuring automated feeding of the mill hoppers and representing an economic and sensible project. The Pivoting Pan Conveyor and the discharge stations are controlled by material level sensors in the mill hoppers and ensure feeding on demand. This operation mode is efficient and minimizes dust generation in the clinker hall, thus providing improved working conditions for the crane driver and allowing to comply with environmental regulations.

Possible applications - Pivoting Pan Conveyor type SPB

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SILO DISCHARGE For clinker silo discharge with low dust emission, for proportional addition of lowburnt or foreign clinker AUMUND’s range of products includes gravity discharge systems operating in combination with the Deep-Drawn Pan Conveyor type KZB 250. The gravity discharge unit is designed to prevent the clinker from falling in an uncontrolled manner onto the pan conveyor. The material column on the pan conveyor is reclaimed with low speed thus minimizing the generation of dust and avoiding dust filters. The gravity discharge systems are provided with a shell valve which can either be operated manually or by means of a gear motor. As the height of the material layer on the pan conveyor is preset during commissioning, the discharge capacity and feeding onto the subsequent conveying equipment is maintained at a fixed rate. For maximum use of the stored volume, large clinker silos are equipped with a multitude of gravity discharge units. The motorized discharge units are actuated by remote control to allow for automatic change of the discharge points at regular intervals and uniform discharge of the stored material. For automatic operation the pan conveyor is fitted with an ultrasonic sensor ensuring switching from one silo discharge point to another if the material flow is insufficient. Combined with the Deep-Drawn Pan Conveyor, the silo discharge systems are used in direct feeding of the mill hoppers. The 20 m curve radius and the 28° inclination of the pan conveyor allow for a layout with a direct conveying line, thus avoiding additional transfer points.

• Conveying from clinker silo to mill hopper with minimised dust generation • No dust filters • Discharge capacities exceeding 750 t/h • More than 2,000 silo discharge systems in operation • Variable discharge capacity with frequency-controlled conveyor drive

Silo discharge with remote control

Silo discharge system with low-burnt clinker dosage and truck tipping station

Rod grate

Rod grate

Silo discharge

Deep drawn pan conveyor type KZB 250

Conveying direction

Conveying direction

Silo gravity discharge

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REVERSIBLE CONVEYOR For special plant constellations, alternate conveying into two directions is required. The appropriate solution for this application is the Deep-Drawn Pan Conveyor of special design: the reversible pan conveyor. By simply changing the travel direction, alternate feeding of two clinker silos is possible with just one conveyor.


This design developed by AUMUND is based on a divided deep-drawn pan and half a chain pitch, i.e. 125 mm. By alternating a troughshaped bottom plate with a cover plate to form the well-known deep-drawn pan with the 250 mm spacing, conveying is possible in both directions. The illustration demonstrates that the combination of one bottom plate and one cover plate each bolted onto the two corresponding chain links is guided around the sprocket as a rigid unit. Always one cover plate points in the requested conveying direction. This is achieved by defining the adequate center distance, which, for this reversible DeepDrawn Pan Conveyor, comes up to a multiple of 250 mm plus 125 mm. This asymmetrical center distance ensures that the adequate turning point of the chain articulation matches the given conveying direction. With this arrangement the overlapping cover plates always point in the chosen conveying direction. For the reversible Deep-Drawn Pan Conveyor, a horizontal arrangement is preferred. For larger center distances a drive unit can be installed for both sprockets.

Clinker silo feeding with reversible pan conveyor

Reversible pan conveyor - functional principle

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Drive shaft and tail axle

Runway with upper guideline Forged and hardened roller bodies

Deep pan

Roller

Roller bracket

Ball bearing

Securing ring

Grease nippel

Hexagon head screw with nut

Roller axle Cover

Intermediate washer

Washer

Grease chamber

Spacer ring

Labyrinth seal

Roller with sealing elements

Chain

COMPONENTS AUMUND pan conveyors feature standardized components wich have proved reliable in practical operation for a thousand times. With the concept of a modular system, components of different pan conveyor types are interchangeable, a major advantage for spare parts management. AUMUND pan conveyor tracks feature bogietype rails complying with DIN/EN 5901/5902. The rail size ranging from S14 to S30 is chosen in accordance with the pan conveyor size. In the curved area, the rollers are guided by upper guide-rails to prevent the conveying elements from being lifted off the rails. The standard curve radius for Deep-Drawn Pan Conveyors is 20 m whereas the curve radius for Bucket Apron Conveyors may be reduced to 8 m. The standard roller design for AUMUND pan conveyors features a tempered running surface and a sealing system preventing dust penetration.

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Multiple metal sealing, a labyrinth seal and a grease chamber form part of the system and provide efficient protection against dust penetration without the necessity of relubrication. AUMU ND rollers are fitted with stub shafts connected to the roller bracket by a simple hexagon head screw for quick and easy dismantling. The drive and tail shaft sprockets are equipped with exchangeable toothed segments allowing to replace the sprocket segments even with the conveyor strand closed. The sprockets feature a double tooth pitch and ensure meshing with the sprocket teeth only after each second turn. As a result, the service life of the segments is twice as long as with a single tooth pitch. The standard chains of AUMUN D pan conveyors are listed in the table on page 9.

Q U A L I T Y

ACCESSORIES

C-shaped cleaning scraper, tension station

Two-way distribution chute

Three-way distribution chute

In order to minimize cleaning especially at take-up and feeding stations, AUMUND cleaning scrapers ensure automatic recycling of spillage onto the conveyor. These scrapers are available as C-shaped scrapers for installation around the take-up station or as straight scrapers for installation underneath any given point of the conveyor. Operation of the scraper is controlled by a timer for intermittent operation actuating the gear motor on account of the actual amount of spillage. Cleaning may further be reduced by installing fines recycling chutes. Remote control of downstream conveying directions is performed with the AUMUN D two or threeway distribution chute. The chutes are fitted with shell gates actuated either by a gear motor or a hydraulic / pneumatic cylinder. Casing and shell gates are of wear-resistant design for a long service life. Motorized flat gates of sturdy design complete the range of accessory equipment for material distribution. If required, an automatic lubrication system may be provided for intermittent chain lubrication.

Chain lubrication system

Motor-operated flat gate

In addition, AUMUND offers maintenance trolleys with rack and pinion drive to be installed inside conveyor bridges for transportation of heavy tools, oil bins or equipment components to the top of high clinker silos. The maintenance trolleys are designed to suit any angle of inclination. The range of accessory equipment is completed by truck and ship loading systems with low dust generation and electronic control for easy loading operations.

Maintenance trolley

Truck loading station

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Retrofitting a heavy Apron Feeder

CONVERSIONS AND REFURBISHMENTS • • • •

Upgrading of existing plant components Targeting increased efficiency Higher output Improved higher availability

With our expert team of engineers planning selective modernisation measures we pay special attention to the upgrading of existing plant components, targeting increased efficiency, higher output rates and improved availability.

the feasibility and analysis of the bulk material’s properties and the technical specifications of the existing plant. Engineered conversions and refurbishments for increased efficiency and output are performed on AUMU ND equipment same as on equipment of other manufacturers.

Upgrading of your materials handling and storage equipment to state-of-the-art technology is achieved through a tailor-made refurbishment process under optimum utilization of time and budget . Most of the existing components are re-used in the refurbishment process to save costs. For each project, a system drawing showing how the new components fit into the existing geometry is generated after verification of Conversion of a Bucket Elevator

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AFTER-SALES SERVICE

THE AUMUND GROUP

• Supervises assembly and commissioning jobs • Proactive maintenance AUMU ND continues to place high emphasis on the service to the customer also after the successful completion of design, engineering, manufacture, delivery, assembly and commissioning.

Thus, after-sales service means for all companies of the AUM UND Group:

• Expert consulting in all aspects of the transport and storage technology • Modification and conversion concepts for a capacity increase or a modernization • Stockkeeping of spare parts • Maintenance and inspection services A team of well-experienced field engineers supervises assembly and commissioning jobs. An outstanding feature of the AUMU ND after-sales service is the proactive maintenance. Within the frame of a maintenance program, our partner company PREMA S offers field inspections and maintenance seminars for all products of the AUMUN D Group.

GERMANY

SWITZERLAND

AUM UN D-Fördere rbau GmbH & Co. KG

AUM UN D AG

Saalhoffer Str. 17 47495 Rheinberg Tel.: +49 - 28 43 - 72 0 Fax: +49 - 28 43 - 6 02 70 e-mail: [email protected] www.aumund.com AUM UN D Förder techni k GmbH

Saalhoffer Str. 17 47495 Rheinberg Tel.: +49 - 28 43 - 72 0 Fax: +49 - 28 43 - 6 02 70 e-mail: [email protected] www.aumund.com SCHADE Lagertechnik GmbH & Co.KG

Dorstener Straße 360 44653 Herne Tel .: + 49 - 23 25 - 58 74 0 Fax: +49 - 2325 - 58 74 74 e-mail: [email protected] www.schade-lagertechnik.com

Ober Altstadt 32a, P.O. Box 6301 Zug Tel.: +41 - 41 - 710 10 82 Fax: +41 - 41 - 710 42 02 e-mail: [email protected] PREMAS AG

Loewenstr. 55, P.O. Box 8023 Zürich Tel. +41 - 44 - 2 10 30 05 Fax +41 - 44 - 2 10 31 15 e-mail: [email protected] www.premas.ch

BRAZIL AUM UN D Ltd a.

Rua Haddock Lobo, 337 - 11. andar 01414-001 São Paulo, SP Tel.: +55 - 11 - 3059 0160 Fax: +55 - 11 - 3059 0161 e-mail: [email protected]

USA AUM UN D Cor poratio n

THE NETH ER LANDS AUM UN D Hol ding B .V.

Spoorstraat 42-52 5911 KJ Venlo Tel.: +31 - 77 - 351 98 75 Fax: +31 - 77 - 320 07 28 e-mail: [email protected]

GREAT BRITAIN B&W Mechanical Handling Ltd.

Lancaster Way Ely, Cambridgeshire CB6 3NP Tel.: +44 - 1353 - 665 001 Fax: +44 - 1353 - 666 734 e-mail: [email protected] www.bwmech.co.uk

2300 Windy Ridge Parkway Suite 150S Atlanta, GA 30339 Tel.: +1 - 770 - 226 - 95 78 / 80 Fax: +1 - 770 - 953 - 48 44 e-mail: [email protected]

INDIA AUM UN D Eng ineerin g Private Ltd.

2nd Floor, Lakshmi Neela Rite Choice Chambers . 9, Bazulla Road, T.Nagar Chennai - 600 017 Tel.: +91 - 44 - 2815 60 48 / 49 Fax: +91 - 44 - 2815 60 46 e-mail: [email protected]

HONG KONG SAR AUM UN D Asi a (H. K.) L td.

FRANCE AUM UN D France S.A.R. L. 53, Rue d’Hauteville . 75010 Paris

Tel.: +33 - 1 - 42 46 72 72 Fax: +33 - 1 - 42 46 72 74 e-mail: [email protected]

1301 Oxford House, Taikoo Place, 979 King's Road, Quarry Bay Hong Kong Tel.: +852 - 3695 - 43 33 Fax: +852 - 3695 - 43 11 e-mail: [email protected]

P.R. CHINA POLAND AUM UN D Polsk a Representative Office ul. Lektorska 34 G . 44-210 Rybnik

Tel.: +48 - 32 - 426 32 11 Fax: +48 - 32 - 426 32 01 e-mail: [email protected]

AUM UN D (C hina)

Room 909, East Ocean Center, No.24A, Jian Guo Men Wai Street, Chao Yang District . Beijing 100004 Tel.: +86 - 10 - 65 15 58 13 / 14 Fax: +86 - 10 - 65 15 58 15 e-mail: [email protected]

© 2006 by AUMUND Fördertechnik GmbH – All rights reserved. Neither this document nor any part of it may be reproduced or stored, processed, duplicated of circulated e.g. by using electronic systems in any form or by any means without the prior authorisation of AUMUND Fördertechnik GmbH. In case of infringements the infringing party will be obliged to compensate for all damages incurred.

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AUMU ND Headquarters in Rheinberg, Germany

Your partner for all requirements regarding material handling and storage. We design, engineer, manufacture, erect and service reliable equipment. Reputation and competence proven by more than 10.000 installations in over 100 countries.

www.aumund.com AU M U ND Foerdertechnik GmbH . Saalhoffer Str. 17 . 47495 Rheinberg ( Germany) Tel.: +49 (0)28 43-720 . Fax: +49(0)2843-60270 . e-mail: [email protected]

A M 6 0 / I I I 8 1 0 B G A e c i t o n t u o h t i w e g n a h c o t t c e j b u s a t a d l a c i n h c e T B G

Pan Conveyors

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