World Cement BMHR 2023

BMHR 2023

A SUPPLEMENT TO WORLD CEMENT

CONTENTS

how cement companies can realise their ideal facility by selecting the optimal storage system for their needs.

11 Supporting Silo Strength

Wen Peng and Zhu Xiaosheng, Henan SRON Silo Engineering Co., Ltd., delve into some of the details of a comparative analysis of structural design methods for large steel silos.

SILO CLEAN-OUT & REPAIR

15 Essential Elements For Eliminating Buildup

Jeff Shelton, Peter Klee, Connor Shelton, Steve Hildebrant, and Joel W. Hawbaker, Dracyon Corp., evaluate the primary factors that contribute to air cannon performance: nozzles and volume.

20 Paving The Way For A Sustainable Cement Industry

IGS offers insight into the ‘Good Neighbor Provision’ of the US Clean Air Act and discusses the role of air cannons in the maintenance of SCR systems.

27 Lessons In Lengthening Silo Lifespans Dennis Blauser, Marietta Silos, provides a series of examples to explain the proper protocols to follow when maintaining cement storage silos.

CONVEYING

31 Total Discharge: Clean Belt, Clear Chute Dan Marshall, Martin Engineering, offers recommendations on the best practices that can help operators avoid common inefficiencies at their discharge zone.

ON THE COVER

cement loading and the latest systems designed to

43 Charging Ahead With Cement Truck Electrification

Max Tschurtschenthaler, ABB, explains how replacing diesel haul and dispatch trucks with battery electric fleets, in partnership with a trusted technology provider, can help cement manufacturers decarbonise production and protect their licence to operate.

47 Navigating The Logistics Landscape

Reiner Bachthaler, Axians IAS, discusses the next step in logistics for the bulk material industry: tailored software and mobile apps for enhanced efficiency.

52 Conquering Complexity

Kyle Langley, Vortex, identifies some crucial considerations for the loading of dry bulk solids and highlights how automation can help overcome key challenges.

CRUSHING, SIZING & SCREENING

57 Clever Ways To Cut Aggregate Crushing Costs

Michael Metson, Komatsu, walks through five top tips that operators can implement to reduce the costs of crushing aggregates.

61 The Road Less Travelled

Duncan High, Haver & Boecker Niagara, explains how moving from traditional screening systems to advanced technologies improves both productivity and profits.

BMHR 2023

Dracyon Corp is a new company with years of experience in providing the cement industry with solutions to buildup problems. Now they are providing technological innovations to improve cleaning and reliability for air cannons. Dracyon has also established strategic partnerships to expand the use of air cannons as a SCR buildup solution for cement applications. Dracyon is making it possible and profitable for the cement industry to meet its ever-increasing environmental regulations. Find out more about how Dracyon can help you in their cover story on pg 15.

SMART LOGISTIC SOLUTIONS FOR THE BULK GOODS INDUSTRY

Software Suite for the central logistic workflow:

From order creation, order and transport planning to shipment and delivery

Portals and apps for customer, haulier and internal logistics

Automated solutions in the Yard:

FOREWORD

Managing Editor: James Little james.little@palladianpublications.com

Senior Editor: Elizabeth Corner elizabeth.corner@palladianpublications.com

Editor: David Bizley david.bizley@palladianpublications.com

Assistant Editor: Sol Klappholz sol.klappholz@palladianpublications.com

Contributing Editor: Paul Maxwell-Cook

Production: Kate Wilkerson kate.wilkerson@palladianpublications.com

Sales Director: Rod Hardy rod.hardy@palladianpublications.com

Sales Manager: Ian Lewis ian.lewis@palladianpublications.com

Sales Executive: Riccardo Saunders riccardo.saunders@palladianpublications.com

Events Manager: Louise Cameron louise.cameron@palladianpublications.com

Digital Events Coordinator: Merili Jurivete merili.jurivete@palladianpublications.com

Digital Administrator: Leah Jones leah.jones@palladianpublications.com

Administration Manager: Laura White laura.white@palladianpublications.com

Reprints reprints@worldcement.com

DAVID BIZLEY, EDITOR

Hello dear readers, and welcome to the 2023 edition of World Cement’s Bulk Materials Handling Review (BMHR).

For those who’ve not previously encountered BMHR before, this special issue of World Cement focuses on that often underappreciated aspect of cement manufacture: materials handling. Whilst stories about new kiln or mill installations often grab the headlines, none of these high profile projects would work without the materials handling equipment covered in this issue. Indeed, materials handling equipment can be regarded as the veins and arteries of the cement plant, delivering vital resources all the way from the quarry through the various production processes and out to dispatch.

The technical content in this year’s issue of BMHR begins with a review of storage solutions. On pg 6, Dome Technology explains how cement plant operators can take advantage of new technology to enable the construction of the optimal storage facility for their needs. Then on pg 11, Henan SRON Silo Engineering provides insights into structural design methods for large steel silos.

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Of course, all of these storage facilities require maintenance and, due to the nature of the materials involved, issues such as blockages and buildup can occur across a cement plant. Accordingly, the next article comes from Dracyon Corp. (pg 15) and discusses the primary factors to be considered when evaluating air cannon performance. This is followed up with an article from IGS (pg 20) on the use of air cannons in the maintenance of SCR systems. Marietta Silos (pg 27) then provides a series of examples to showcase effective silo maintenance.

On the topic of conveying, this issue features an article from Martin Engineering (pg 31), which highlights the role of modern belt cleaning techniques and technologies in reducing injuries, labour costs, and OPEX.

We then move on to an extended review covering the challenges surrounding loading, unloading, dispatch and logistics. Kicking off this section is a piece from PSCL (pg 39) that highlights the risk of fraud and theft faced by plant operators and explains how new loading systems can make these problems a thing of the past. On pg 43, ABB explains how cement manufacturers can make significant steps towards decarbonisation and protect their license to operate by converting dispatch fleets to electric vehicles. This is followed up by an article from Axians IAS (pg 47), which reviews the next steps in bulk materials logistics: tailored software and mobile apps. Then on pg 52, Vortex discusses the importance of automation in overcoming key loading challenges.

Following this is a feature discussing the challenges surrounding the handling and treatment of aggregates. Komatsu (pg 57) provides some top tips to operators looking to reduce their crushing costs, and closing the issue is a piece from Haver & Boecker Niagara (pg 61) explaining how advanced screening systems can improve both productivity and profits.

All of this means we have another content-packed issue of BMHR for you to enjoy – happy reading.

10 – 13 MARCH 2024

Hotel Cascais Miragem Health & Spa, Lisbon, Portugal

Join cement industry professionals from around the world at EnviroTech 2024, World Cement’s first in-person conference and exhibition.

Featuring a 2.5 day expert-led conference agenda, Q&A sessions, panel discussions, a full exhibition, and multiple networking events, EnviroTech offers you the opportunity to engage with industry leaders and gain actionable insights into how your company can play a role in the decarbonisation process.

For more details and registration: www.worldcement.com/envirotech2024

For sponsorship opportunities please contact:

Director

Lewis Sales Manager

PROJECT NEWS

BulkTEQ and IBAU HAMBURG: a collaborative breakthrough in bulk material handling

BulkTEQ, an engineering company, offers a novel approach to weighing equipment. It manufactures and sells various products such as weigh belt feeders; belt scales; loss-in-weight feeders; weighing bins; bag filling stations; and train, wagon, and truck loading systems. The company also has expertise in analysing onsite situations and technical client requirements.

The collaboration between BulkTEQ and IBAU HAMBURG has enabled a significant leap forward in cement loading procedures, focusing on three key objectives: boosting shipping capacity, decreasing human errors, and moving away from traditional truck scales.

At the core of this achievement lies BulkTEQ’s 100 t weighing bin, featuring cutting-edge Hottinger Brüel & Kjær (HBK) load cells. Seamlessly integrated into IBAU HAMBURG’s equipment for aeration, aspiration, and cement loading, this innovation aligns with BulkTEQ’s commitment to technical precision and functionality.

A notable feature of this innovation lies in the intricate synergy among three key components: the upper-level Loading Automation System (LAS), IBAU HAMBURG’s Silo control system, and the loading module control system. Based on BulkTEQ’s signal sequence for loading and weighing procedure, emergence control, these systems coordinate the loading trucks procedure, achieving not only consistency and precision but also streamlining the loading process and optimising the operation.

This unified approach represents a pivotal departure from traditional manual loading methods and has led to the successful commissioning of 20 cement loading modules. The close cooperation between BulkTEQ’s in-house engineers and IBAU HAMBURG’s engineers allowed all supervising installation and commissioning work to be completed within a remarkably short timeframe of one week for one loading module.

Andriy Lukash, Director of BulkTEQ, captures the project’s essence, stating: “We knew we could create something not just functional but innovative.” This sentiment resonates throughout the project’s execution, with a solution that elevates efficiency while significantly curbing the potential for human errors.

The loading module control system, BulkTEQ’s building on Siemens’ PLC and weighing module, along with its accompanying software, extends its capabilities beyond cement dosing. It influences the weighing bin loading and unloading stages, according to the established procedure. The system also has the ability to use electronic keys for truck loading tasks and data storage, further reducing the human factor.

The solution’s impact on productivity is evident, with the loading of a 24 t cement truck now taking just 5 – 7 min. with 10 – 40 kg weighing precision, in comparison with truck scale weighing.

Dr. Dimitri Weiss, Senior Sales Manager at IBAU HAMBURG, enthused: “The collaboration with BulkTEQ showcased the power of collective ingenuity. Our shared goal of driving progress and sustainability in the industry found its realisation in this project.”

The collaboration between BulkTEQ and IBAU HAMBURG has not only achieved its key objectives of boosting shipping capacity, optimising dosing, and removing the human factor, but it has also set a positive example provided a valuable contribution in the industry.”

The new solution enables a 24 t cement truck to be loaded in just 5 – 7 min.

One on-the-job highlight for Dome Technology’s Sales Manager Lane Roberts is when companies share their storage wish lists.

Often the ideal facility seems unattainable, but technology and engineering are now making features and capabilities possible that cement companies could only imagine five years ago.

Serious storage capacity at a reasonable price falls into that category. For at least two years, companies buying cement for their own use have been scrambling to navigate product shortages, and ready-mix companies without ample storage are not always able to provide customers what they need. This poses a problem when contractors have been guaranteed material for meeting their own deadlines. And the problem becomes pricier

Delivering the dome wish list

Rebecca Long Pyper, Dome Technology, explains how cement companies can realise their ideal facility by selecting the optimal storage system for their needs.

when contractors pass on the cost of delays to ready-mix suppliers.

The result? More ready-mix teams are building DomeSilos and purchasing extra product in the off season when prices are lower. Greater storage capacity makes buying in bulk an option, and the more product purchased at one time, the greater the savings. Companies capitalise on this by storing the increased product and benefit from a buffer when business picks up again.

Maximised storage gives companies flexibility. DomeSilos are an optimal structure for expensive portside property because they can be built tall on a small footprint. “The footprint is always something discussed because land is so expensive on those terminals,” Roberts said.

One of Dome Technology’s current projects includes three 7700 t Drive-Thru DomeSilos for a single customer. Straight out of the gate, these three will store three different products: white cement, grey Portland cement, and fly ash. But the domes can store a different product every time they are emptied, giving the

company a degree of nimbleness unmatched in other storage types.

Design-build benefits

Dome Technology utilises a design-build approach. It is a model that works well for cement companies and their timelines, and it is attractive to subcontractors and vendors who prefer complex and impressive projects.

Design-build streamlines projects because Dome Technology’s team handles engineering, construction, and all related systems at the design level.

Because a single team provides the whole project, costs go down, and change orders are easier to communicate. The final product is a turnkey facility more likely to run seamlessly because every element was planned with the others in mind.

Dome-storage benefits

Storage is often one of the largest components in any new facility, and a dome is built with an unlimited lifespan – its concrete shell and geometry boast unrivalled strength for the long term. Dome construction methods require no interior trusses, so the entire inside volume can be utilised for storage.

A dome’s maximised capacity is made possible by geometry: The double curvature of a dome lends itself to the ability to build up, rather than out, and the curve provides strength at all points of the structure, even at the apex. The entire interior can be used to contain product.

A dome’s strength and geometry also boast a tolerance for some differential settlement. Those qualities combined with geotechnical engineering and site analysis ensure proper foundation selection and performance.

All domes can provide ideal conditions for stored materials requiring a controlled environment. Monolithic concrete construction, coupled with a PVC fabric membrane surrounding the entire dome, prevents water and moisture entrance. The dome’s insulated nature reduces the heating and cooling of the walls and air inside, preventing condensation from forming on the interior. Polyurethane foam and concrete provide humidity control and moderate externally generated temperature fluctuations.

A dome differs from steel tanks and silos in key ways, including upfront and long-term cost savings. A dome has a longer life cycle than a steel tank, and compared to a silo of similar dimensions, a single dome stores more product. Every dome model is

The Drive-Thru DomeSilo allows companies to fill trucks or rail carriages directly from the storage structure.

A DomeSilo for Continental Cement in Buffalo, Iowa, USA, has a storage capacity of 125 000 t.

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adaptable, and integrating a variety of reclaim systems is always an option.

When capacity is king: three dome models

Three dome styles are popular with cement companies. The most common is the DomeSilo, a model that is taller than it is wide. What makes it unique is its storage capacity on sites with restricted space, allowing companies to stack product deeper on a smaller footprint and requiring less space. A DomeSilo allows for more storage than a silo with a comparable footprint; because the hemispherical geometry of a dome provides strength at all points of the structure, the entire interior can be used to contain product, right up to the apex.

The second dome model is the Drive-Thru DomeSilo, a model that allows companies to fill trucks or rail carriages directly from the storage structure and speed up the process of product reception to delivery. This system directly competes with bolted steel tanks and drive-through concrete silos but provides long-term advantages above and beyond these traditional models. The model has piqued the interest of ready-mix companies, who appreciate that the Drive-Thru DomeSilo can be quickly constructed and is price competitive. With a Drive-Thru, ready-mix companies can now buy 5000 – 15 000 t of cement – or more – with one or more truck/rail lanes.

Continental Cement Company was the first to adopt this model, and in 2018 a Drive-Thru was built at a recently acquired Continental Cement site in Memphis, Tennessee, USA. While the existing steel silo and adjacent scale had not been used for some time, complete upgrades of these assets along with a new dome, barge unloader and dock upgrades have allowed Continental Cement to become the leader in the Memphis market.

The company has been pleased with the efficiency of the overall system, said Area Supervisor Dustin Whited. “We can load trucks at the same time we can replenish our inventory via barge unloading – all of this while being basically dust free, which is important to our customers and to our community,” Whited said.

With dimensions of approximately 100 ft tall and 50 ft in diameter, this Drive-Thru can be supplied by barge from any one of Continental Cement’s plants. The engineering design of the new barge unloader allows discharge into either the Drive-Thru DomeSilo, storing 5000 t of cement, or the 3000 t traditional silo. New aeration of the existing silo allows for a much-increased truck-loading rate.

The Drive-Thru delivers 100% live reclaim from a fully aerated floor. Product flows through a truck spout for loading into truck and, potentially in the future, rail. An in-line lump crusher on the loadout stack-up ensures that lumps passed through the receiving system do not make it into trucks. The dome can receive 350 million tph from the barge unloader and load out at 320 million tph. According to Whited, the biggest advantage of this model is the ability to load directly from the floor of the dome.

The final dome model Dome Technology continues to build is the hemispherical dome, particularly at sites with a height restriction. These domes are essentially a sphere sliced in half. These structures are the original dome storage model and are also an economical solution.

Conclusion

The dome model sells itself thanks to the storage capacity it delivers, but commitment to handling each project as a joint effort makes a difference too.

“For more than four decades we’ve relied on a collaborative approach with companies – they’re in the driver seat, and we help navigate,” said Dome Technology CEO Bradley Bateman. “In every project the company works to include technology to maximise storage capacity and system performance with an economical solution.”

About the author

Rebecca Long Pyper has been a writer with Dome Technology for eight years. She holds a Master’s degree in Communication and a Master’s degree in Educational Leadership, and she previously taught college writing and worked as a Newspaper Section Editor.

Bridgesource, a division of Clyde Companies in Ogden, Utah, USA, opted for two identical DomeSilos.

Wen Peng and Zhu Xiaosheng, Henan SRON Silo Engineering Co., Ltd., delve into some of the details of a comparative analysis of structural design methods for large steel silos.

This article will use the finite element analysis of a large steel silo to demonstrate the stresses and deformation states of silo structures under a constant load, live load, storage material load, wind load, earthquake load, and other complex loads. The analysis looks at the performance of pure steel plate silo structures and that of two structures incorporating circumferential and longitudinal tendons into the steel plate design. The results of the analysis shows that the joint action of circumferential tendon and longitudinal tendon can significantly improve the strength, stiffness, and stability of the steel plate silo structure; significantly reduce the stress level on the silo; and reduce the

Supporting Silo

deformation of the silo under wind, earthquake, and other dynamic loads, so as to achieve both economical and safe performance.

Steel silos are widely used for the storage of various bulk materials. With the development of the industrial economy, there are more and more large and extra-large storage demand projects, and the design of large and extra-large steel silos is paid an increasing amount of attention. Unlike ordinary, smaller silos, large silos are far taller and store large amounts of material. They feature a complex design structure, and the influence of dynamic loads such as earthquakes and wind is obvious, and the safety of the equipment must be monitored closely.

Load action of steel silo

In the design, calculation, and actual operation of the steel silo, the following loads were considered:

f Permanent load: weight of the steel silo structure and fixed equipment.

f Live load: roof live load, silo roof deck live load, ash accumulation load, etc.

f Storage material load: lateral pressure of the storage material on the silo wall plate, vertical friction.

f Wind load.

f Earthquake action.

f Snow load.

While subject to various loads, the storage load has generally played a major role on silo performance. The main factor affecting the structural safety of the silo is the force exerted by the storage material which will form a large lateral pressure on the walls of the steel silo, if the wall is not strong enough, cracking, deformation, and other damage will occur. The steel silo must have sufficient strength and stiffness to ensure that the silo will not yield under the vertical friction from the stored material, structural self-weight, equipment loads, and other vertical forces linked to deformation, instability, and other damage.

Wind load produces uneven radial pressure on the surface of the silo wall, making the silo wall bend to produce vertical compressive stress, while the overall shear of the silo wall produces horizontal shear stress, all of which may cause damage to the silo wall, risking further instability.

Earthquake action, when an earthquake occurs, the silo storage material and other loads will produce a large dynamic load on the silo structure, as such the design of the silo structure must fully consider the joint action of earthquake load and other loads so that the silo structure can resist the above loads individually and simultaneously, ensuring the structural integrity of the silo in all conditions.

The live load, snow load, and wind pressure exerted on the silo roof require adequate strength and stiffness of the roof members.

The silo structure needs to have sufficient strength and stiffness to resist the loads and their combined effects without cracking, deformation, buckling, instability, or other damage.

The role of circumferential and vertical reinforcement bars in steel silos

Large steel silos are thin-walled structures and, with the end goal of withstanding the various dynamic and static loads that are associated with bulk storage, it is more cost-efficient

Figure 1. Circumferential tendons.

Figure 2. Vertical tendons.

to increase the circumferential and vertical tendons in the silo walls than it is to increase the thickness of the walls themselves.

Figures 3 and 4 show the nephogram diagrams of the von mises stress (equivalent force) and the deformation displacement diagrams for before and after the installation of vertical tendons.

According to the results of the finite element analysis, the von mises stress (equivalent force) cloud shows that, under the same working conditions, the maximum stress of the bin decreases from 355 MPa to 274 MPa after the installation of the circumferential and vertical tendons. Furthermore, the maximum stress of the bin is effectively reduced, and

the circumferential and vertical tendons can effectively enhance the strength of the silo while resisting load effects such as storage pressure and friction.

In addition to the strong resistance to the vertical friction of the storage material, the vertical tendons of the steel silo also have strong resistance to vertical loads such as wind to avoid deformation instability and damage of the steel silo under wind loads.

The deformation of the silo body is small, which means that the application of circumferential and vertical tendons has greatly improved the stiffness and stability of the steel plate silo body, indicating that this structure also has strong seismic resistance. After increasing the circumferential tendons and vertical tendons, the anti-deformation force of the silo body and the bearing capacity of the warehouse body were greatly improved.

Circumferential tendons, vertical tendons, and other sections are generally built using metal channel as its tensile, malleable, and shear properties are far better than those of steel plate, meaning it can enable savings in terms of materials without sacrificing safety.

Conclusion

Compared to the pure steel plate designs, adding circumferential tendons and vertical tendons to the silo body can significantly improve the strength, stiffness, and stability of the steel structure. The addition of circumferential and vertical stiffening ribs can significantly reduce the stress level on the steel silo, reducing the wind, earthquake, and other dynamic loads acting on the silo body. To achieve an economical, but also safe, project design the current practice has been tested for many years and is widely used in China and internationally.

Figure 4. Stress nephogram diagrams of unreinforced (left) and reinforced (right) steel silos under identical conditions.

Figure 3. Deformation displacement diagrams of unreinforced (left) and reinforced (right) steel silos under identical conditions.

Jeff

Shelton,

Peter

Klee,

Connor

Shelton,

Steve Hildebrant, and Joel W. Hawbaker, Dracyon Corp., evaluate the primary factors that contribute to air cannon performance: nozzles and volume.

It is time that technology caught up to the air cannon. The market has accepted underperformance and a lack of innovation for many years. Dracyon’s goal is to challenge various long-held assumptions regarding air cannon performance. Specifically, Dracyon challenges the belief that the most important factor in cleaning is peak force (Peak force is expressed by the following formula: area x pressure. It refers to the highest force an air cannon

will generate throughout the duration of the firing and lasts for a brief period of time). Rather, it is Dracyon’s belief that the most important factors in air cannon performance are 1) the nozzle used and 2) the volume of the air tank. For optimal performance, an air cannon needs to have enough power to break the bond of cohesion of the buildup and also have enough volume to then push the material out of the way. This means the keys to performance are the nozzle and the volume of the air tank.

Essential elements for eliminating build up

The nozzle is key because, regardless of the peak force of the air cannon, the power of the blast coming out of the nozzle is what matters. Once that bond is broken, then the remainder of the air is what actually moves the material, which is why volume is important.

In order to prove those statements, Dracyon performed a series of tests using an IGS 150 l air cannon, an IGS 300 l Big Blue air cannon, and a competitor’s 70 l air cannon. Each air cannon was fired against a 230 lb (104.33 kg)

sled that was allowed to move across a metal table. The sled was placed at various distances from the air cannon nozzles, ranging from 0.5 in. (1.27 cm) to 9 ft (2.74 m).

The first objective was to show the differences between the IGS High Velocity nozzle, the IGS 6 in. Monster nozzle, and a competitor’s 4 in. pipe fan jet nozzle. The second objective was to evaluate the air cannon performance based on the volume of the air tank. The third objective was to see the difference in performance made by air pressure, which is related to peak force.

In these tests, the air cannons were tested with different nozzles, with varying air pressures ranging from 60, 80, and to 100 psi. After each blast, the distance from the nozzle to the sled was measured.

Dracyon understands that many different factors impact cleaning and that these tests cannot account for all of them. These tests were specifically carried out to show the difference in cleaning performance produced by air cannons with different volumes as well as the various nozzles. In addition, this allowed the impact of air pressure and volume in cleaning applications to be measured.

Test results

Nozzle design

The first major factor in air cannon performance that Dracyon tested was the nozzle. The sled was placed at 3 ft and the IGS 150 l cannon was fired at 80 psi, the sled moved 34.5 in. using the High Velocity nozzle. When the same cannon was fitted with the fan jet designed nozzle and fired at the same pressure, the sled only moved 17.5 in., barely half the distance of the High Velocity nozzle. Similar results occurred regardless of the distance or air pressure parameters. The High Velocity nozzle clearly outperforms the fan jet nozzle, regardless of the air cannon used.

Increased volume

The second major factor, and the one that made the greatest difference in cleaning performance, was increased volume. When the sled was placed at 3 ft and the air cannon was fired at 80 psi, the fan jet nozzle at the competitor’s 70 l air cannon moved the sled 1.5 in. However, when using this same nozzle with the 150 l IGS air cannon, the sled moved 17.5 in. Here, using the same nozzle, the increased air volume from the IGS 150 l cannon led to a significant improvement in performance.

Air pressure

Lastly, the air pressure used also increased the movement of the sled. When using the fan jet nozzle at 80 psi, with the sled 3 ft from the nozzle, the sled moved 1.5 in. The same air cannon and nozzle at 100 psi moved the sled 5.5 in., also a significant increase. Air pressure matters, but not as much as the nozzle selection or the volume.

Summary

In existing 70 l air cannon installations, the cleaning area can be increased by simply

Competitor’s cannon vs IGS Big Blue Air Cannon.

Firing test against a 230 sled.

Chart showing air cannon test firing results.

Big Blue air cannon in action.

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replacing the fan jet designed nozzle with the IGS High Velocity Nozzle. Testing indicated a significant improvement at all psi test points. For even greater performance, the biggest factor was increasing the volume of the tank. The IGS 300 l Big Blue air cannon was able to move the sled off the table even with the sled starting 6 ft away. In addition, the 6 in. Monster nozzle, combined with the 300 l air cannon

moved the sled off the table at three different distances (1.5, 3, and 6 ft) and still moved it 97 in. (at 100 psi) when the sled started off 9 ft away.

Based on this testing, it is clear that nozzle selection and air tank volume are critical to cleaning and air cannon performance. Dracyon takes issue with the idea that the most important factor in cleaning is peak force. Increasing volume absolutely improves cleaning and the following statements can be made based on this testing.

f Peak force is not the most important factor in cleaning. High peak force is directly related to high pressure. A 4 in. cannon fired at 100 psi produces a force of 1256 lb. This force is reduced to 753.6 lb. when this same cannon is fired at 60 psi. When using a 100 psi nozzle blast from a 70 l air cannon with a fan jet nozzle, 5.5 in. of movement is achieved at 3 ft. Using this same fan jet nozzle with a 150 l IGS cannon with only a 60 psi blast, the sled moved 6 in. at 3 ft. The air cannon with 40% lower peak force out-performed the air cannon with a higher peak force. In other words, it delivered more energy to the sled.

f Air tank volume significantly increases cleaning, period. In every test performed, the air cannon with the largest air tank out-performed the air cannon with a smaller tank.

Table 2. Air cannon test data.

Pressure and volume make a difference.

IGS High velocity nozzle.

f As shown in this article and in the testing data in Tables 2 and 3, the choice of nozzle makes a drastic difference in cleaning performance.

f The two most important factors in maximising air cannon performance are nozzle selection/design and volume.

Based on this data, it is safe to say that with the increased cleaning ability of the higher volume tanks and better nozzles, air cannons will still perform better when placed farther

away from the applications. This is important because better placement of air cannons means they are better protected from extreme heat and blowback material, and they are easier to maintain. These factors lead to extended air cannon life without sacrificing the cleaning performance required. Extended life means higher efficiency and greater savings.

Notes

For full data set, use the following: https://dracyoncorp. com/air-cannon-test-data

Table 3. IGS 300 l Air Cannon Test data.

Nitrogen oxides (NOx) are harmful air pollutants that can have significant negative impacts on human health and the environment. NOx is formed during high-temperature combustion processes, such as those used in cement kilns, and contributes to the formation of ground-level ozone, which is a major component of smog.

Exposure to high levels of NOx can cause a range of health problems, including respiratory issues, cardiovascular disease, and lung cancer. NOx can also contribute to the formation of acid rain, which can damage ecosystems and harm aquatic life.

In addition to the health and environmental benefits, reducing NOx emissions from cement production is also becoming increasingly important from a regulatory perspective. Many countries have introduced stricter emissions standards for NOx, and failing to comply with these standards can result in significant fines and penalties for cement manufacturers.

Most recently, the ‘Good Neighbor Provision’ has set specific goals and targets for cement plants in 23 states in the US: Alabama, Arkansas, California, Illinois, Indiana, Kentucky, Louisiana, Maryland, Michigan, Minnesota, Mississippi, Missouri, Nevada, New Jersey, New York, Ohio, Oklahoma, Pennsylvania,

IGS offers insight into the ‘Good Neighbor Provision’ of the US Clean Air Act and discusses the role of air cannons in the maintenance of SCR systems.

Texas, Utah, Virginia, West Virginia, and Wisconsin.

The ‘Good Neighbor Provision’

The Good Neighbor Provision refers to a provision in the Clean Air Act (CAA) of the United States that requires states to address air pollution that crosses state boundaries and affects neighbouring states. The GNP aims to reduce NOx emissions from power plants and industrial facilities from upwind states that significantly hinder downwind states from attaining and maintaining the 2015 Ozone NAAQS. The provision applies to emissions of nitrogen oxides (NOx) and sulfur dioxide (SO 2 ) – which are pollutants that can contribute to the depletion of the ozone layer – and fine particulate matter.

Under the Good Neighbor Provision, each state is required to develop a State Implementation Plan (SIP) that includes measures to prevent significant contributions to air pollution in neighbouring states. If a state fails to develop an adequate SIP or fails to comply with the requirements of the SIP, the

Environmental Protection Agency (EPA) can issue a Federal Implementation Plan (FIP) to address the air pollution.

The Good Neighbor Provision has been instrumental in reducing the amount of air pollution that crosses state boundaries and contributes to poor air quality in neighbouring states. It has also led to the development of new technologies and strategies for reducing emissions of NOx and SO 2 from industrial sources, such as power plants and factories.

How does GNP affect cement companies?

In the context of the cement industry, the Good Neighbor Provision has an impact on all plants within the specified states of the provision. These companies must implement measures to reduce the emission of pollutants, such as particulate matter, nitrogen oxides, and sulfur dioxide, that could potentially affect air quality in neighbouring states.

The implementation of the Good Neighbor Provision will increase the cost of production for cement companies and bring new operational challenges, as they will likely need to invest in new NOx control and technologies to reduce emissions. Overall, the Good Neighbor Provision could have a significant impact on the cement industry by requiring companies to improve their environmental performance and reduce their impact on neighbouring communities.

The following are NOx limit changes in cement and concrete product manufacturing:

f Long wet: 4.0 lb/t

f Long dry: 3.0 lb/t

f Preheater: 3.8 lb/t

f Precalciner: 2.3 lb/t

f Preheater/precalciner: 2.8 lb/t

The benefits of using SCR to reduce NOx emissions in cement production

f High NOx reduction efficiency: SCR technology can achieve up to 90% NOx reduction efficiency.

f Can be used with high dust loads: The SCR process is not affected by the high dust loads typically found in cement production.

f Long catalyst life: SCR catalysts have a long life and can last up to five years.

f Low operating costs: SCR systems have low operating costs and require minimal maintenance.

f Can be retrofitted to existing plants: SCR systems can be retrofitted to existing cement plants, making it a cost-effective way to reduce NOx emissions.

SCR in the cement industry.

IGS CatFlow™ screen.

However, SCR systems require careful monitoring and maintenance to ensure optimal performance. The reductant injection rate and temperature must be carefully controlled to achieve maximum NOx reduction efficiency. Additionally, proper storage and handling of the reductant are critical to prevent ammonia leaks and ensure worker safety.

By implementing these methods, cement manufacturers can significantly reduce NOx emissions and contribute to a cleaner and healthier environment.

Maintaining SCR systems

Air cannons can be used in SCR systems to help maintain optimal performance by preventing the build up of ash and other particles on the catalyst surface. The air cannons are installed to clean the catalyst by re-entraining and redistributing ash to let the flue gas pass through.

The following are some benefits of using air cannons in SCR systems:

f Eliminates excessive pressure drop and maintains designed NOx removal rates.

f Improves system efficiency: A clean catalyst surface allows for optimal contact between the flue gas and the catalyst, resulting in higher NOx reduction efficiency.

f Low operating costs: Air cannons are relatively low-cost and require minimal maintenance.

f Easy to install: Air cannons can be easily installed in existing SCR systems with minimal disruption to the operation of the plant.

It is important to note that the air cannons must be maintained and operated efficiently. Improper use and failure to preserve the integrity of the cannons can render them ineffective and lead to excessive levels of buildup over time. Therefore, regular monitoring and adjustment of the air cannon settings are necessary to ensure optimal performance of the SCR system.

In addition, proper SCR maintenance means coupling the cannons with state-of-the-art CatFlow screens to ensure peak operational levels are maintained. The CatFlow screen captures the ash on its surface while the air cannon system sweeps it away, thus providing the best possible cleaning techniques to keep the SCR running at full capacity.

How to select the right air cannon for an SCR system?

It is important to consider several factors when selecting air cannons for an SCR system, including the specific requirements of the system, the characteristics of the dust or particulate matter being produced, and the operating conditions of the plant. Each brand or product may have its unique advantages and disadvantages, and it is important to focus on companies that have extensive experience with various applications. Plants can achieve up to 95% cleaning efficiency of their SCRs by leaning on this experience and partnering with an expert in the field of SCR optimisation.

Case study: US cement plant

As the cement industry faced mounting pressure to reduce emissions, a US cement plant proactively anticipated the implementation of Selective Catalytic Reduction (SCR) technology. Recognising the importance of SCR systems, this plant conducted a trial by installing SCRs in Europe and at their plant in the US. This case study focuses on the challenges

IGS Big Blue air cannon system.

IGS CatFlow screens and air cannon nozzles combine to re-entrain and redistribute ash evenly throughout the catalyst.

faced during the trial, the implementation of an innovative solution, and the subsequent success achieved by integrating IGS CatFlow™ screens and an air cannon cleaning system.

Trial challenges

During the initial phase of the trial, the cement plant encountered a significant hurdle in the form of extreme buildup on the SCR catalyst. This accumulation and pressure drop of the system severely limited the effectiveness of the SCR system, hindering its production capacity as well as its ability to reduce emissions. The buildup threatened to undermine the efficacy of the entire project, highlighting the urgent need for a solution to address this challenge.

Solution

To overcome the catalyst buildup issue, IGS offered a comprehensive SCR online cleaning system, including air cannons and CatFlow screens. The screens were strategically installed on the catalyst to prevent ash and other deposits from accumulating on the surface. These screens allowed the catalyst to function optimally while keeping it free from excessive buildup.

Additionally, an air cannon cleaning system was implemented to re-entrain and redistribute ash to allow the flue gas to naturally pull the ash through the system.

Successful implementation and results

The integration of the CatFlow screens and air cannon cleaning system proved to be a game-changer for this cement plant. The innovative solution effectively resolved the catalyst buildup issue, enabling the SCR system to reduce emissions. The screens prevented excessive accumulation, allowing the catalyst to operate at its peak efficiency. As a result, the plant witnessed a significant improvement in the performance of the SCR system.

Conclusion

This case study exemplifies the proactive approach taken by the cement industry to address environmental concerns through the adoption of SCR technology. The successful integration of CatFlow screens and an air cannon cleaning system provided a robust solution to the challenge of catalyst buildup. This cement plant’s positive experience showcases the importance of innovative solutions in optimising SCR performance, reducing emissions, and meeting regulatory requirements. This case study serves as an inspiration for other cement industry players to explore and implement effective solutions for emissions reductions and more sustainable operations.

EXPERIENCE THAT TOWERS ABOVE THE REST

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More than 35 years of tackling the most difficult silo cleanout projects in 30+ countries worldwide.

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Dennis Blauser, Marietta Silos, provides a series of examples to explain the proper protocols to follow when maintaining cement storage silos.

Regular inspection and cleaning are the most effective methods to ensure the integrity of concrete or steel silos. Operators must learn the best practices, safety records, case histories, deliverables, repair options, inspection programmes, and follow-up support in order to get the most out of their silos. The breakdown rate of silos

Lessons in lengthening silo lifespans

and bins is much more frequent than any other industrial machinery type. The causes of silo failures are often avoidable and can be quickly addressed if spotted early.

Depending on the severity, the harm caused may not be dangerous, and repairs can be carried out. However, in the worst cases, the destruction of the container, spoiling of the material inside, loss of the material, clean up, substitution costs, ecological damage, and even danger to life can occur.

A proactive inspection programme should be implemented to ensure the continued protection of personnel and guarantee that silos, concrete structures, and associated surfaces remain intact over time. The process of preventive maintenance for concrete silos is critical; postponing maintenance can result in expensive repairs and possibly deadly disasters.

The key to prolonging the life of any silo is to establish best practices for preventive maintenance through regular inspection.

f On average, it is recommended that concrete storage silos be inspected at least every two to five years or annually if the silo is used extensively.

f A comprehensive maintenance plan should be established to guarantee that the concrete and steel silos function properly and safely. The responsibility for following the programme lies in the hands of the owner, which includes keeping detailed inspection, maintenance, and safety records.

f Keeping track of inspection and maintenance records can help identify the cause of any structural issue that may arise. Silo issues can often be caught during an inspection and repaired before any major failure occurs.

Case study: repair

Market: Manufacturing

Material stored: Cement

Silo size: 27 ft diameter by 110 ft tall

Issue: Potential silo roof collapse.

During a regular inspection of the silo structure, it was discovered that a critical point of the structure, the beam pocket, was at risk of failure. The beam was sitting on a thick steel bearing plate.

However, the concrete beneath the plate had begun to spall, threatening the roof and all the equipment needed to operate the bulk storage system.

After a systematic assessment, a plan to restore the structural soundness of the beam trough was recommended.

f Initially, the roof beam was taken off the trough and its support plate to make way for repairs.

f Dirt and debris were carefully eliminated.

f Per the engineer’s specifications, structural steel was placed to preserve the rehabilitated beam pocket.

f Finally, a non-shrinking, high-strength mortar was used to patch the chipped area.

f After it had completely cured, the beam was put back on the support plate of the patched trough.

Regular examination of all machinery is necessary to minimise the possibility of malfunction in any production system, including silos.

f Proper silo roof design is essential.

f Although roofs are designed to support machinery, they are not designed to manage material.

f If a loading system fails or a silo is too full permitting bulk material to accumulate on

The silo beam pocket shown reveals a significant amount of spalling and concrete damage that increases the risk of collapse.

This interior photo viewed from the top down shows silo walls coated with hardened material before cleaning.

the roof, concealed damage can impact the entire structure.

In addition to inspection, Marietta Silos provides cost-effective repair solutions that range from silo upgrades to silo strengthening or silo and tank liners. All of these repairs are carried out to lengthen the life of the silo and ensure the safety of workers.

Upgrades to silos can be used to restore structural integrity to both the walls and the roof. High-strength post-tensioning strands can be placed around the perimeter wall to prevent vertical cracking or delamination.

The roof of a silo is vulnerable to damage from overfilling, explosions, and overloading, and requires regular maintenance to keep the structure sound and protect the contents inside. Corroded or damaged roof support beams can be particularly hazardous, and making replacements, repairs, or other modifications to the roof can extend the life of the silo.

Depending on the age, concrete stave silos may have corroded, broken, or missing hoops. Replacing worn-out hoops with new steel hoops is an effective solution to ensure stave silo functionality and storage capacity. Rehooping can extend the life of an aging stave silo and ensure its safe operation for years to come.

To fix sections of silos with structural issues, a mixture of sand, cement, and water defined as shotcrete-gunite, can be applied by an expert with an air pressure gun. This results in a concrete-like material impervious to weather and chemicals, and a material that bonds completely to clean concrete. Marietta Silos uses composite fibre reinforcements to reinforce existing concrete and masonry structures, such as resins with low conduction, chemical, and shock resistance, all without the need for heavy machinery. If the silo cannot be fixed conventionally, a liner made from concrete, steel, stainless steel, epoxy, PVC, or waterproof coatings can be installed, depending on need.

When repairs are impossible, the silo can be professionally dismantled to prevent damage to nearby silos. Once dismantled, other silo options that meet the customer’s requirements and material needs are available.

Case study: cleaning

Market: Cement industry

Material stored: Cement

Issue: The cement storage silo had not been cleaned since 2007 and experienced significant

material buildup in the hopper which restricted material flow.

A returning customer contracted USA Silo Service to service a cement storage silo that had not been serviced for 15 years. An inspection revealed a significant amount of material accumulation. The silo contained hot storage material that reacted with cool air blown in through air pads without dryers, forming condensation which moistened the cement and led to large amounts of a hardened substance accumulating on the walls. To break up these thick chunks, specialised machinery was necessary.

USA Silo Service outlined the consequences of leaving the material buildup on the roof and underside of the roof untreated. The silo owner approved the enhanced cleaning and roof coating to prevent any further cracks from appearing and to stop any interior buildup. This measure was taken to guarantee the longevity of the silo and to avert possible structural failure. The total amount of accumulated material removed from the silo walls totalled nearly 2500 t.

In addition to methods that clean a silo from the top down, a vacuum truck removes the remaining material from the bottom of the silo, which is either kept for reuse or properly disposed of. A vacuum truck can also be used in conjunction with one of the other cleaning methods by helping collect dislodged material to save or discard.

This case study illustrates how routine professional cleaning can increase the longevity of silos, preserve the materials held within them, help avoid costly maintenance and ultimately maintain a steady production process with minimal downtime. Furthermore, a properly maintained silo helps create a safe and secure workplace, reducing material accumulation inside the silo which could lead to a collapse, damaging adjacent buildings and equipment or causing injuries to personnel.

Conclusion

The use of concrete in silo design and construction offers many benefits, such as less maintenance to keep the structure functioning and secure. Nevertheless, concrete and steel can become damaged through regular use and environmental elements. Regular checkups can detect any troublesome areas and avoid the possibility of wall collapse, splitting, and weakening, which could result in harm or even fatalities in the workplace.

About the author

Dennis Blauser is the CEO of Marietta Group, which houses Marietta Silos, Marietta Inspection Services, and USA Silo Service. Marietta Group has spent over a century meeting the needs of industry professionals.

Total discharge: clean belt, clear chute

Dan Marshall, Martin Engineering, offers recommendations on the best practices that can help operators avoid common inefficiencies at their discharge zone.

Suggesting the ‘total discharge’ of cargo from a conveyor belt in any bulk handling application is enough to make operators and maintenance staff chuckle. In the dirty and punishing atmosphere of cement production, there are no absolutes. Spillage, carryback, chute clogging, and fugitive dust emissions obstruct walkways, foul rolling components, cause unscheduled downtime, and degrade air quality, but they do not have to. Manufacturers of innovative equipment solutions are always striving to improve workplace safety and production efficiency by eliminating as many of the causes of downtime as possible. Following the installation of modern belt cleaning technology, cement plant operators realise that the volume of material entering the transfer chute grows

exponentially, rather than piling around the discharge zone. This greater volume leads to blockages in the transfer chute followed by downtime to unclog it. However, designers can take a holistic approach and engineer an efficient discharge transfer point with components that work together. This approach strives to make equipment last between scheduled closures, improves safety by

minimising maintenance, and addresses the causes of inefficiency.

Signs of inefficiency at a discharge zone

The discharge zone starts at the last troughed idler before the conveyor belt flattens and encounters the head pulley. Cargo falls from the conveyor into a transfer ‘drop’ chute that can lead to several places including another conveyor, a storage silo/pile, a transport vehicle, etc. The primary cleaner is located after the discharge stream to clear any adhered material caused by the weight or characteristics of the cargo (moisture, cohesion, heat, etc.).

A secondary cleaner clears dust and fines from divots and cracks in the belt. Material cleared from the secondary cleaner is generally directed to a sloped surface connected to the transfer chute.

Obvious signs of discharge inefficiency are spillage, carryback, chute clogging, and dust. Alone, each can lead to a workplace safety violation, together they result in unscheduled downtime and increased operating costs. From an operational standpoint, three of the most expensive consequences are workplace injuries, belt damage from friction, and fouled equipment replacement.

Spillage and safety

Primary cleaners or ‘scrapers’ can fail in several ways, causing adhered coarse aggregate and caked fines to pass by the blade and spill around the discharge area. This fugitive material can build up quickly and encapsulate the belt, fouling rolling components and causing the belt to ride on top of the coarse pile, leading to serious belt damage and increased belt temperatures from friction.

Fugitive material spills into walkways, obstructs access for maintenance, and creates trip and fall hazards. When coarse grit fouls rollers it causes them to freeze, leading to friction and high-heat damage to the vulnerable return side of the belt, lowering the equipment’s life. To avoid belt fires and dust explosions, seized idlers/rollers should be maintained and changed right away, which makes clear access to the system imperative.

Cleaning spillages can be costly, divert staff from other essential duties, and become a workplace safety issue if workers are clearing material around a running belt (Figure 3). What may seem like a routine job in the beginning, clearing spillage by either shovelling it back into the cargo stream or into bins, requires more labour as time goes on and the problem worsens. Clearing material using machinery (front loaders, industrial vacuums, etc.) can

Figure 1. Discharge from the belt no longer needs to be a dirty and dusty process.

Figure 2. Sand spillage reaching up to the discharge point on a stacker conveyor.

Figure 3. The cost of cleanup and improved safety justify the expense of a well-designed discharge solution.

result in accidental contact with the stringer or supports, potentially leading to belt mistracking. Mistracking can be a major cause of spillage, not just along the belt path, but at the discharge point as well. The blade is centred on the head pulley, but if the belt is not, adhered material becomes spillage.

Recommendation

Install a belt tracker a distance of 3 – 4 times the width of the belt prior to the head pulley as the

trough angle flattens to ensure the belt hits the head pulley in the centre.

Over-/under-tensioning and/or extending blade changes for too long can also cause spillage. Over-tensioning causes rapid wear on the belt/splice and lower blade life. Under-tensioning allows material to pass without being removed. Allowing primary cleaners to wear excessively can result in pull-through, where the force of the belt causes the blade to face the opposite direction and, in some cases, break off.

Recommendation

Enter a service agreement with the blade manufacturer to regularly monitor, tension, and change the blades as needed. Consider installing a modern assembly that allows workers to slide units from the stringer for fast and easy one-person blade changes. There is also the option of using an innovative cleaner technology with 4 times the lifespan of the normal primary blade and needs no tensioning over the course the blade’s use (Figure 4).

Reducing carryback

Anything that clings onto the return side of the belt and travels with it is considered carryback, which seriously damages a system. Not only is it a major source of fugitive dust and fines, but it can migrate easily into return rollers and takeup pulleys, fouling the bearings, mechanical drives, and the face of the roller. The grit grinds down roller bearings and can lead to excessive friction heat, causing them to become misshapen and seize up.

Like spillage, carryback can migrate to the non-carrying underside of the belt. These chunks travel all the way to the tail pulley. The intense pressure between the pulley and the belt causes the hard, sharp mass to damage the vulnerable side of the belt and the pulley face, cycling over and over, delivering more damage as it does so. Along with shortening the life of the belt, dust and fines fill these blemishes and foul the pulley face.

When a roller or pulley face becomes fouled, it is caked with abrasive grit that degrades and damages the belting over time. In some cases, fouling causes slippage which can disrupt the smooth operation of the belt and promote mistracking.

Recommendation

If there is adequate space, install secondary and tertiary cleaners to ensure that the belt is totally clean on the return. To improve safety, consider units that allow a single worker to pull them away from the stringer for faster external servicing. Consider a diagonal or V-shaped plow placed underneath the loading zone right before the

Figure 4. Innovative new cleaner designs require less monitoring and no tensioning.

Figure 5. The V-plow diverts fugitive carryback to either side of the system, ensuring tail pulley health.

Figure 6. The direction of the cannon shot matches the stream trajectory to encourage constant flow.

tail pulley that rides on the underside of the belt removing any loose travelling material (Figure 5). For more effective cleaning and reduced friction damage, consider a plow with torsion arms rather than one held in place by chains. Install belt trackers or crown rollers along the upper and lower belt paths to ensure alignment.

Safely addressing bulk handling clogs

A clogged transfer chute or hopper is one of the most dangerous situations in bulk handling. Untrained and uncertified (enclosed chute entry certification) personnel should never enter a clogged chute or bin under any circumstances. A sudden discharge can be deadly as unknown

voids engulf and crush a worker. Material adhered vertically to the sides can loosen and send a sheet of debris falling on anyone occupying the vessel. Buildup points in chutes include:

f Rockboxes – Shelves, even if they are sloped, can experience buildup.

f Exit gates or doors – As these help to control flow, they are also prone to clogging.

f Sloped points – Under the secondary cleaner, chute grades, or located at choke points.

f Metal surface grain – The metal grain of chute plating should match the flow of cargo.

f Exposed surfaces – Surfaces where moisture can collect and cause buildup.

f Damaged surfaces – Surfaces that have scratching, denting, creasing, or divots.

Misguided practices for addressing buildup include banging on the sides of the hopper with a mallet or to loosen the obstruction by poking at it from below. In some operations, clogs are so frequent that spots for pounding are marked and mallets are left in the area for convenience. This is hazardous because it reduces the structural integrity of the vessel or chute, causing it to buckle. Ripple damage from pounding can create a situation where it is easier for material to build up, shortening periods between clogs and leading to more unscheduled downtime. Poking from below is even more dangerous, since a sudden discharge sends tons of material in a surge that will injure anyone in the vicinity and break the equipment below.

Recommendation

Air cannons strategically installed around the chute have nozzles pointed in the direction of the material flow. Powerful shots of air are distributed across the surface inside the vessel, dislodging material and preventing buildup. The air cannons are supported by vibration units that ensure gates and narrow spouts on hoppers and chutes retain proper flow before bridging starts. In many cases, vibration alone can handle most dry material flow but changes in humidity raising the stickiness of cargo and chute surfaces, along with fluctuations in production volumes, are much better handled by air cannons (Figure 6).

Discharge dust

Emissions at the discharge zone can be found billowing out of the chute against the direction of the cargo stream or exiting the sides and bottom as it loosens from the belt’s return side. Dust has become a highly regulated workplace and environmental concern which can lead to stiff fines and, potentially forced downtime if high volumes of respirable crystalline silica (RCS)

Figure 8. The roller is encapsulated by spillage at the discharge zone.

Figure 9. Cleaning the belt of dust and fines with a few telltale streaks on the belt denoting carryback.

Figure 7. Potential dust generated at discharge zone.

are detected. RCS is found in nearly every substance pulled from the earth, but is prevalent in limestone, coal, clay, etc. Regulators measure fugitive particulate matter (PM) at the size of <10 μ m in volumes of >50 μ g/m 3 over an 8 hour time-weighted average (TWA). This is the volume and size determined to cause serious chronic lung issues in workers and it does not just apply to RCS, this is the case with any PM.

Dust emissions returning from the chute can be caused by uncontrolled airflow at the exit point. The emissions can also be caused by hitting rock boxes meant to slow the flow of material or an unobstructed impact causing turbulence.

Dust from carryback permeates the area and spreads emissions down the entire length of the belt return. If the belt reaches into a tower or is exposed to the outdoors, this can cause dust to be carried long distances on air currents into nearby communities leading to possible violations.

Studies have shown that dust can be controlled by adequate cleaning at the discharge using levels 1 – 3. One is a primary cleaner, two a secondary cleaner, and level three a tertiary cleaner (Figure 7).

Recommendation

By reconfiguring the chute’s exit into a sloping scoop, material can be slowed and loaded onto the next belt in a controlled and centred manner with less turbulence. Air cannons installed along the chute are pointed with the material stream and can help direct air flow.

Case study: carryback in a Ukrainian cement plant

A cement plant located in Western Ukraine was experiencing extensive carryback on conveyors carrying slag. Due to the abrasive material’s particle shape and small size, it easily passed under the cleaner blade and remained on the return side of the belt, allowing it to drop along the belt path. Fugitive material built up on floors and encapsulated rolling components, causing excessive downtime for maintenance and cleaning (Figure 8).

After testing numerous primary and secondary cleaners from several suppliers, operators found none of the cleaners adequately cleaned the belt. Increased operational costs for labour and replacement parts inspired managers to seek alternatives.

Technicians from Martin Engineering Europe inspected the system and recommended the installation of a CleanScrape ® Cleaner.

Designed to be installed diagonally across the discharge pulley, the blade forms a three-dimensional curve with an extremely low

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contact pressure between belt and cleaner. The blade is comprised of a matrix of tungsten carbide scrapers and is tensioned against the belt by stringers, typically resulting in the removal of as much as 95% of difficult material. Engineered for belt widths up to 120 in. (up to 3000 mm), speeds up to 1500 fpm (7.5 m/s), and pulley diameters of up to 78 in. (2000 mm), the blade delivers double the life of most standard blades (Figure 9).

Following the installation, the results were immediately apparent. To fully clear the fines stuck in the cracks and divots of the belt, managers also installed a Martin ® SQC2S™ secondary cleaner for more complete cleaning. “Once we made the proper adjustments and finished the full installation, we are very happy with the result,” said an operator close to the project.

The company is now budgeting to equip several more belts with CleanScrape Cleaner blades.

Conclusion

Modern cement plants are changing and growing every day because the demand for raw and processed materials for construction and manufacturing keep rising.

Production increases can change throughput volumes and belt speeds, which have a direct effect on spillage, carryback, clogging, and dust.

Retroactively installing equipment that improves both safety and efficiency should be a priority for any operator. Although the initial capital investment might be slightly higher, the return on investment (ROI) and benefits are not just in fewer injuries, but reduced labour costs for maintenance, less equipment replacements, greater compliance, and a lower cost of operation overall.

About the author

Daniel Marshall received his Bachelor of Science degree in Mechanical Engineering from Northern Arizona University. With nearly 20 years at Martin Engineering, Dan has been instrumental in the development and promotion of multiple belt conveyor products. He is widely known for his work in dust suppression and considered a leading expert in this area. A prolific writer, Dan has published over two dozen articles covering various topics for the belt conveyor industry; he has presented at more than fifteen conferences and is sought after for his expertise and advice. He was also one of the principal authors of Martin’s FOUNDATIONS™ The Practical Resource for Cleaner, Safer, and More Productive Dust & Material Control, Fourth Edition, widely used as one of the main learning textbooks for conveyor operation and maintenance.

The cost of cement has been rising. Theft by fraud during loading has also been increasing, stealing from terminals, and depriving an already-overtaxed construction supply chain of a much-needed resource. That, in turn, completes the cycle and sends cement prices even higher.

Industry-wide, loading fraud is more prevalent than one would expect and automation systems are making it easier to prevent, but as the industry moves to adopt digitalisation,1 it is important to understand that companies deliver varying levels of effectiveness.

PSCL’s Cement Distribution Management (CDM) system is a fully-integrated control and monitoring solution for plants and terminals. Tied into site infrastructure and accounting systems via the ERP interface, operators know what trucks are where and what they are carrying in real-time, with built-in fraud and theft protection. This article will detail how criminals try to cheat the system and how PSCL’s CDM can stop them before they can begin.

Improper truck positioning Problem

A truck pulls onto the weigh scale. Ideally, it should be positioned completely on the scale to record an accurate weight.

A driver can drop an axle off the scale and record a lighter starting weight in a bid to overload his container with more product than is being paid for.

PSCL discusses the challenge of fraudulent cement loading and the latest systems designed to prevent it.

While this may result in ‘only’ a few hundred pounds of cement powder being stolen with each load, think of how many trucks go through a terminal in a day, each week, each month, for a year. As such this quickly becomes theft that easily runs into six and seven figures of lost revenue.

Schemes that lighten the initial weight benefit the driver by giving them more product than their employer is paying for. Conversely, increasing the initial weight benefits the terminal by recording more product than the truck receives. This is done by the truck pulling as far forward as they can while staying on the scale, then a second truck pulls forward, putting its front axle on the rear of the scale.

Solution

CDM combats positioning fraud in a number of simple ways. Improper positioning can easily be prevented with PSCL’s spout monitor – an alignment aid drivers use to line up the spout while pulling into the alley. This ensures the truck is in the correct spot for loading every time. For intentional positioning fraud, the system prevents this with configurable expected

rig weights. Rigs are associated with a driver’s access cards so the system will have basic data on what the truck/trailer should weigh unloaded and determine if the weights are not within the set threshold.

Scale tampering Problem

One of the most common methods of fraud is rigging the scale to give an inaccurate reading. This can be accomplished by the driver stepping off the scale during loading/check-in or wedging a crowbar to lift the pressure on the sensor to affect the scale reading, making the truck appear lighter. Due to the sensitive nature of scales even a moderate amount of pressure applied on the scale can result in fraudulent readings, affecting the weight recorded by thousands of pounds.

If unnoticed, this allows the driver to receive more material than is being paid for, resulting in a loss for the terminal. Additionally, if the truck is overloaded and an accident happens or the truck is reweighed during its travels, the terminal can be held liable for overloading a truck past the legal limit without the correct permits.

Solution

The CDM loading solution detects sudden decreases in weight. If the weight on the scale decreases or does not increase as fast as it should based on the current flow rate, the system will notify an attendant that there may be tampering with the scale. CDM stops the load and requires approval to continue loading, allowing time for the truck and scale to be inspected for foul play. When loading more than the legal limit in a jurisdiction where a permit is required, the overweight permit module ensures that only drivers with active permits can load past the legal limit.

Software overrides Problem

With some ticketing software systems, users are allowed to override the final gross and tare weights. This allows a dishonest user to overload trucks and then go back into the record and change the weights to make the truck legal on paper, generating a fraudulent bill of lading (BOL) in the process.

Adding weight to a scale with another truck’s front axle defrauds the purchaser who pays for more product than they receive.

Reducing weight on scale by having an axle off the scale allows the driver to receive more product than they are paying for.

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As with recording a lighter weight via scale tampering, this makes the terminal liable for the infraction if the truck is weighed and the BOL does not match. The terminal loses twice – first with the loss of product not paid for, and then being charged for allowing an overweight truck on a regulated road.

Solution

CDM combats this with the fact that it is integrated into the operator’s process controls. The scale and its output are automatically associated with the load, and it does not allow the manual entry of scale weights. Scale weights are automatically recorded by the system and added to the BOL, eliminating transcription errors and the opportunity to make fraudulent paperwork. It also makes CDM faster than other systems by being completely automated, allowing trucks to move on and off the site quicker, with greater safety and better accuracy.

Outright theft

Problem

Many loading solutions on the market are not integrated with process controls, instead relying on

APIs and third-party software that merely capture the scale weights before and after the load.

These ‘solutions’ leave the program open to being cheated. There is documented criminal activity where drivers were going back to sites after hours, manipulating the equipment’s physical controls independent of the ticketing system and were still able to load. This resulted in loading multiple rogue trucks every week – all of them off the books and without the terminal’s knowledge.

Another way criminals were able to cheat the system was by hiding fraudulent loads under contracts for a large company. This scam was not caught until years later when the terminal finally realised 20 trucks were being loaded every day for the client but only 18 were arriving at their intended destination.

Solution

With CDM the process controls are directly linked to the loading solution. By linking to the process controls every action taken using process controls is recorded. This works for all types of loading – attended or unattended – even when loading in manual mode or right from the HMI (Human Machine Interface). Every event and transaction is tracked and recorded. For example, the valve cannot be opened without an assigned contract, and alerts are sent to the organisation that fraud may be happening.

Without CDM’s integrated system the potential exists that fraud may not be caught at all, building a long-term weakness into a business active in a competitive market with tight margins. CDM’s real-time automation and integration into every process control and admin system gives plants and terminals a competitive edge over businesses only partially automated or worse – manually operated. PSCL’s advice for operators is to always know where their product is, who has loaded it, and where it is going. Customers will appreciate up-to-date process management and dispute-free accounting. With this system operators can get paid quicker and build rock-solid supplier/customer relationships, becoming the supplier of choice wherever CDM is implemented.

Notes

1. Digitalisation – moving existing processes into digital technologies, as opposed to digitisation – making analogue information digital.

A driver with a crowbar can lighten a truck’s initial weight allowing for extra product to be loaded.

Collusion between a driver and terminal staff can result in significant product theft in a manually-operated system.

Charging ahead

with cement truck electrification

Max Tschurtschenthaler, ABB, explains how replacing diesel haul and dispatch trucks with battery electric fleets, in partnership with a trusted technology provider, can help cement manufacturers decarbonise production and protect their licence to operate.

Cement manufacturing – like so many other hard-to-abate heavy industries that produce materials indispensable to the modern world – faces the twin

challenges of maintaining production levels to satisfy increased demand while simultaneously reducing carbon dioxide (CO2) emissions.

This is no small task. Production of cement is forecast to increase worldwide through 2050, yet the industry is responsible for approximately 7 – 8% of global CO2 emissions – even more than aviation.

The good news is that manufacturers have at their disposal a host of electrification, digitalisation and automation technologies that, when properly deployed in partnership with an experienced technology provider, are proven to limit energy usage and decarbonise the production process.

What is more, the potential to reduce the carbon footprint of cement production encompasses the entire value chain, from quarry to dispatch, and even includes hybrid and fully electric trucks used to transport limestone to refining facilities, as well as those that take the cement to construction sites.

This article will discuss how vehicle electrification in the cement sector compares with mining; how innovations such as rapid-charge batteries are being deployed to transition cement quarry and plant trucks from diesel to battery-electric power; and why ABB’s portfolio of solutions aimed at the cement industry is being expanded to include charging solutions aimed specifically at trucks within the industry, including goods-sized dispatch trucks.

Cement versus mining trucks

The main differences between mining and cement trucks have to do with size and the volume of the raw materials being carried. In mining, diesel trucks, often with a capacity of 100 t, account for the majority of direct emissions at a mine site (anywhere from 30 – 80%), mainly because they have to haul large quantities of ore in order to extract the few percent of grade required for milling and processing.

Electrifying these types of trucks means replacing the conventional fuel system with multiple battery units. This in turn reduces the vehicle’s holding capacity, meaning it can no longer carry the same tonnage, a significant problem, especially in a large fleet running on a 24/7 production cycle.

In the cement industry however, things are different; out of a ton of limestone

Cement manufacturers are seeking to electrify their limestone quarry trucks.

ABB has the technologies to help transition from diesel to battery electric.

mined, roughly 800 kg can be used (depending on the project), a much greater percentage. This equates to considerably less tonnage during production, and, subsequently, less need for the very large, emissions-heavy haul trucks seen in the mining industry. A small cement operation may operate less than ten vehicles, for example.

The biggest difference, however, is that cement operations typically also run many smaller dispatch trucks to transport the cement from the quarry; in fact, one ABB client recently noted that the industry covers more kilometres delivering goods to end customers year-to-year than Amazon does. This is where the largest potential lies in terms of vehicle electrification in the cement industry.

Less is more: electrifying cement dispatch trucks

Cement dispatch trucks typically have a range of 50 – 100 km per delivery; in other words, they travel 50 km, return to the cement plant, collect the next batch of product and then begin the next delivery.

This type of range can be covered by commercial battery trucks. Cement operators, especially in Europe and North America, are starting to recognise this and are looking to install the necessary charging infrastructure at their plants, so that trucks can charge ready for the next cycle while being loaded with the next product batch. In this way, they do not have to rely on external infrastructure. If dispatch is sub-contracted, the requirement for electric trucks can be built into the request for quote (RFQ), with the third-party supplier responsible for recharging at a highway station if the distance requires it.

ABB is already witnessing a new trend here, whereby cement operators are moving away from conventional diesel trucks in favour of larger fleets of smaller fully battery electric vehicles with a capacity of around 40 – 80 t. This ‘swarm fleet’ approach is something of a no-brainer; after all, battery electric vehicles can haul the same amount with smaller

batteries, have faster charging cycles, and are more efficient uphill, all of which equates to more tonnage carried and less CO2 emitted.

An increasing number of cement companies are therefore opting for smaller dumpsters and choosing to both electrify them and make the charging autonomous. There are also gains to be had in terms of maintenance; for example, smaller vehicles do not require tyres that cost several hundred thousand dollars, as is the case with large mine trucks.

Rapid charging innovation

ABB has developed ABB Ability™ eMine

FastCharge – set to be the fastest and only

fully automated charging system for mine trucks offering up to 600 kW of power – to make the process of charging vehicles at mine sites quicker and easier. ABB essentially deploys the same technology for cement fleets but with a smaller capacity (starting at around 150 kW) as the vehicle batteries are not as large.

The charging system consists of a powerhouse connected to the external power grid and a terminal module housing the automated connection device that attaches to the vehicle. When the truck is due to recharge its battery, it sends a signal to the collector pin alerting it that the vehicle is ready to charge. The pin knows which truck is arriving and automatically adjusts the height of the connection pin, so that by the time the truck arrives the pin is already elevated into the correct position. As soon as the charging cycle is completed the pin disconnects and the truck driver can continue their work.

ABB FastCharge is also vendor-agnostic, meaning its uses open automotive/industrial standards (OPPCharge and ISO15118 and IEC61851), so it is flexible enough to charge vehicles of all makes.

Rapid charging solutions are available, then, but it is fair to say that to a certain extent the vehicle OEMs are playing ‘catch-up’ when it comes to building compatible machines. This is changing, however, and ABB expects manufacturers in the next few years to begin supplying the market with trucks of all sizes that can take advantage of advancements in automated charging technology. So, what are the main advantages? Well, increasing the speed and efficiency of the power supply keeps vehicle downtime during charging to a minimum, meaning there is no loss of productivity.

The ability to pump a greater amount of energy into the vehicle battery in a shorter timeframe means haul truck fleets can be charged during existing working cycles as well as off-cycle. This enables cement operators to seamlessly integrate vehicle charging into their existing work order schedule; again, this maximises productivity and energy consumption, and reduces downtime.

Complete electrification solutions

As touched upon earlier in this article, ABB is seeing a real appetite from cement industry customers for battery electric vehicles as an ‘easy win’ solution that can help the industry reduce the carbon footprint of trucking, which currently stands at around 3 – 4% of total CO2 emissions.

ABB is collaborating closely with its eMobility business with a view to using their charging technology to develop their own solutions with one of the major truck OEMs on a cement plant project in Europe.

While other heavy industries are more risk averse when it comes to implementing new technology, the cement sector is traditionally more open to new innovations and ideas. Companies know they must be proactive when it comes to sustainability, and throughout the industry more and more companies are focusing their investments on reducing emissions to protect their license to operate.

ABB is committed to working with cement customers to help them achieve their decarbonisation goals. The company’s digital, electrification, and automation solutions cover complete cement plant electrification, integrated process control and optimisation services, and motor, and drive systems.

The partnership with Coolbrook is an example of this type of collaboration in action. The project combines Coolbrook’s RotoDynamic technology, which replaces the burning of fossil fuels in heavy industry with renewable electricity as the energy source, with ABB’s motors, power electronics, and process automation for increased efficiency. Scaling up RotoDynamic technology for use in industries such as cement has the potential to cut carbon emissions annually by up to 2.4 billion t.

The power to decarbonise

In conclusion, the cement industry is proactively looking for innovative solutions to the problem of greenhouse gas emissions from production, including from diesel vehicles, enabling companies to hit external and internal environmental targets and protect their licence to operate.

Switching truck fleets, particularly small dispatch trucks that deliver the end product from the mine to end users, from diesel fuel to battery electric power in partnership with a technology vendor such as ABB, is a compelling way to achieve these goals. After all, electrification and vehicle charging technology is already mature and it is proven to work, making it an ‘easy win’ for cement operators.

ABB is expanding its portfolio for the cement industry to include electric trucks and rapid charging infrastructure, facilitating the transition from polluting diesel engines to battery power, (ideally from renewable sources) and making a valuable contribution to the decarbonisation of heavy industry.

About the author

Max Tschurtschenthaler is the Global Business Unit Manager for Cement at ABB’s Process Industries Division. Prior to this, he was the Global Industry Lead for Cement at ABB. Max has more than 18 years’ experience in Engineering, Project Management, Sales and Business Development at ABB, in the field of electrification, automation, and digitalisation of cement plants.

Navigating the logistics landscape

Reiner Bachthaler, Axians IAS, discusses the next step in logistics for the bulk material industry: tailored software and mobile apps for enhanced efficiency.

In the context of the bulk material industry, where complex supply chains underpin operational success, the optimisation of logistics workflows emerges as a paramount consideration. As the industry faces challenges spanning inventory management, transport coordination, and real-time communication, the integration of advanced technologies has become imperative. This article delves into an extensive exploration of how to design a comprehensive toolkit for the nuanced demands of different roles in the logistics workflow like truck drivers or dispatchers, with a tailored combination of desktop software and mobile applications.

Challenges and demands

The traditional practices of manual processes, paper-based documentation, and limited adoption of desktop software have characterised logistics within the bulk material sector. However, the current landscape demands a more sophisticated approach, combining a blend of desktop software and mobile applications. This integration is crucial for solving the industry’s persistent challenges:

f Paperless workflow: The industry’s transition towards sustainability necessitates the abandonment of paper-based workflows in favour of digital alternatives.

f Transparency: Real-time visibility across the logistics chain is critical for timely decision-making and responsiveness to unforeseen disruptions.

f Data consistency: Ensuring coherence of data across all stages of the logistics process is essential to prevent errors and inefficiencies.

f Efficiency gains: Reducing manual interventions and streamlining processes can result in significant time and cost savings.

f Acceleration of processes: Timeliness is paramount in logistics; tools that speed up processing are invaluable.

f Skill shortage: With skilled logistics professionals in short supply, technology must bridge the gap by enhancing efficiency and reducing the need for extensive expertise.

Strategic utilisation of technology: dispelling ‘one-size-fits-all’ notions

As the industry contemplates the role of mobile apps, it is imperative to move beyond

a blanket approach. Rather, a nuanced differentiation and selection of tools suited to specific use cases and roles is crucial. Here are a few illustrative examples:

Ordering

Ordering processes can benefit from both desktop software and mobile apps, depending on the user role and environment. A site manager at a construction site needs a fast and mobile solution to order material flexibly with just a few clicks. This is a typical application for mobile apps, that can offer user-friendly interfaces, ensuring ease of use and intuitive navigation. While desktop software might be more suitable for roles requiring comprehensive data access, like a purchaser working in an office environment.

Dispatching and central order planning

For dispatching and central order planning, desktop-based software stands as the more pragmatic choice. The complexity of data handling for this use case requires the capabilities of desktop systems. While technology can aid these processes, direct communication through telephone remains vital for addressing nuanced concerns.

Unveiling complexities: handling delivery documents

Managing delivery documents is a complex task in the bulk material logistics industry. This process involves various stakeholders; including weighers; truck drivers; recipients (e.g. mixing plants or construction sites); and administrative units in producers, carriers, and customers.

Figure 1. VAS Cloud Logistics: central order planning.

Tapping into transformation: redefining delivery processes

At present, semi-digital or even paper-based workflows dominate the delivery process. A truck driver’s journey involves entry weighing, bill of loading creation, loading, exit weighing, delivery note creation, manual signatures, and the distribution of these notes across diverse departments. This intricate process underscores the need for optimisation.

Transformation at hand: tools in practice for delivery management

Preplanning of orders is crucial for an efficient delivery workflow, best suited for desktop apps due to the information required (though optional, it enhances predictability for producers and drivers).

When a freight order is preplanned, the most comfortable way of providing the related info to the truck driver is via a mobile app that can be used on a smartphone. A perfect example is the Axians’ Ticket App (Figure 2). The concept is well proven in many plants of leading material suppliers, showing the ability of mobile apps to increase the efficiency of the logistic workflow in the cement and other bulk goods industries.

At login, the app shows a complete list of all dedicated freight orders at a glance. Upon arrival at the plant for loading, the driver selects the freight order in the mobile app and scans the QR code at the entry terminal. There is no need to create a bill of loading. The app could even guide the driver to the correct loading station. Depending on plant automation, scanning the QR code may initiate automated loading.

After loading and weighing, all delivery details are automatically stored in the driver’s mobile app, optionally generating a PDF document as well.

Beyond the plant: simplify shipment and unloading with mobile driver apps

After finishing the loading process at the plant, the mobile driver app is also valuable for managing shipments and to recipients. When connected to telematics systems, it provides tracking for customers and dispatchers. The driver has access to all relevant information for the target location. At the recipient, the app can assign time stamps to dedicated process steps, thereby creating an electronic shipment record (e.g. waiting 20 min. for unloading caused by customer). Receiver confirmation is significantly facilitated as well through the app’s signature screen.

In a traditional paper-based workflow, the truck driver collects the signed delivery notes and at day’s end hands out these sheets to the accounting department, thereby requiring manual data entry in the accounting system. When the mobile app of the truck driver is online connected to the logistics

workflow system of the supplier, all shipment data can be collected automatically for further controlling and invoicing purposes with no need for manual data entry.

This example highlights the flexibility achieved through intelligent use of desktop software and mobile apps for various roles. In situations where most freight orders are unplanned and drivers arrive at the plant without prior notice, a mobile app still proves beneficial. The Ticket App from Axians enables easy freight order creation, predefining loading and shipment details.

A variation is when a truck driver should be completely disburdened from any login processes or selection from a list or from the task of creating of freight orders.

If a central logistic system or yard management system like Axians VAS Yard Management generates a freight order QR code, scanning it with the driver app provides all necessary info for the driver. It can be that easy.

This also shows the flexibility of the delivery workflow, that can be achieved with an intelligent combination of desktop software in the administration and mobile apps for roles like customers (purchaser) or truck drivers.

Summing up: a shift in efficiency

In conclusion, while mobile apps are not a cure-all, they significantly enhance specific logistics tasks like ordering, delivery, and shipment processes.

Integration across workflow areas, such as Axians’ central logistic workflow (VAS Cloud Logistics) aligned with a well proven logistic system at the plant (VAS Yard Management) and a powerful mobile app, is the key.

By embracing this approach, the bulk material industry can enhance efficiency, simplify processes, and adapt to the evolving landscape.

In conclusion, while mobile apps cannot solve every challenge, they significantly enhance specific logistics tasks like ordering, delivery, and shipment processes.

Integration across workflow areas is the key – this means online integration of all involved roles and data such as Axians’ central logistic workflow (VAS Cloud Logistics) aligned with a well proven logistic system at the plant (VAS Yard Management) and powerful mobile apps.

By embracing this approach, the bulk material industry can enhance efficiency, simplify processes, and adapt to the evolving landscape with confidence and trust to tackle current and future challenges.

About the author

Reiner Bachthaler has his roots in industrial software-based automisation projects and a long-term experience in software product management. He is a Senior Product Manager at Axians Industrial Applications GmbH.

Figure 2. Ticket App: order selection and processes at the plant.

Figure 3. Ticket App: Unloading proof of delivery.

Figure 4. Ticket App: Order selection with QR Scan&Go (no login required).

Kyle Langley, Vortex, identifies some crucial considerations for the loading of dry bulk solids and highlights how automation can help overcome key challenges.

oading dry bulk solids presents a complex set of challenges that industry professionals must tackle to ensure smooth and efficient operations. Key concerns such as labour, safety, environmental impact, and system efficiency play crucial roles in the loading process and can give rise to various issues if not properly addressed. For instance, the continued scarcity of labour makes innovation and automation critical to supporting ongoing demand, while overlooking safety measures may result in workplace accidents and potential damage to equipment. Environmental considerations, such as dust emissions and spillage, are vital

in maintaining compliance with regulations and protecting the surrounding ecosystem. Furthermore, optimising efficiency in the loading process ultimately impacts the bottom line, making it essential to adopt innovative technologies and strategies that streamline operations. By understanding and addressing these challenges, companies can deliver a high standard of performance, ensuring the successful handling and loading of dry bulk solid materials.

Labour and safety challenges

Loading dry bulk solids into trucks with hatches involves a combination of labour and personnel

safety challenges that must be effectively managed to ensure efficient and secure operations. A primary labour and safety concern is the coordination between spout operators and truck drivers, as miscommunication can lead to errors and potential accidents. Manual handling of the loading spout, alignment with the truck hatch, and monitoring material flow requires skilled labour and constant attention. In terms of safety, controlling dust emissions is crucial to protect workers’ respiratory health and maintain environmental compliance. Another safety challenge is preventing material spillage during loading, which can create slippery surfaces and increase the likelihood of accidents. Employing level-sensing devices and ensuring proper alignment can minimise spillage and enhance safety. By addressing these labour and safety challenges, companies can perfect the loading process for dry bulk solids while maintaining a safe work environment for their personnel.

Environmental challenges

Loading dry bulk solids also presents a range of environmental safety challenges that need careful consideration of design, safety standards, and loading processes. A primary concern is managing dust emissions, as excessive airborne particulates can lead to environmental compliance issues and pose health risks for operators. To address this issue, implementing efficient dust collection systems and using sealed loading spouts are essential steps in minimising fugitive dust emissions.

Material spillage during the loading process can also have an environmental impact, which can result in the contamination of the surrounding area and the waste of valuable resources.

Adhering to established safety standards and best practices is crucial in maintaining environmentally responsible operations. This includes regular equipment inspection, maintenance, and operator training on safe handling procedures and potential hazard identification.

Integrating innovative design elements and technologies, such as automated positioning systems and retractable spouts, can enhance the loading process’s environmental safety by reducing human error and improving operational efficiency. By addressing these environmental safety challenges, companies can contribute to a cleaner

Figure 1. Aero-Bin Bottoms.

Figure 2. Aero-Slide Gate Valves.

Figure 3. Aero-Slide Drum Valves.

and more sustainable future while loading dry bulk solids.

A new automated loading system

Introducing the Vortex Automated Loading System (VALS). A new Vortex solution designed to optimise loading operations for dry bulk solids. Combining the capabilities of Vortex loading equipment, this innovative system streamlines the loading process, minimises material spillage, effectively controls dust emissions, decreases direct labour costs, and enhances overall operational efficiency.

System overview

The primary purpose of VALS is to facilitate the efficient and precise loading of dry bulk materials into hatches on trucks. The system operates through the integration of a few core components: a Vortex camera and programmable logic controller (PLC) system, Vortex loading spouts, In-line filters, and positioners. These components work together to provide a clean, accurate, and reliable loading solution that meets the highest industry standards for safety and performance.

Automated loading

Automated loading fully automates the loading process by removing the labour typically used to locate the spout inside the truck through hatch finding technology using cameras and images to automatically seat the spout scavenger into the truck hatch. Once the truck driver has parked on the scale and positioned the hatch in the target area on the screen display, they are then able to remain in the truck while the automated loading system goes to work loading material into the truck.

Camera and PLC system

The Vortex Camera system along with a PLC locates the hatch and controls the Vortex positioner and loading spout to properly seat into the vessel hatch that the material is being loaded into. VALS enables more consistent load times as it is being controlled by the PLC instead of human interface. The PLC is programmed to load each container in a consistent manner. This ensures each time the system is triggered to load it goes through the same process without receiving any distractions (phone calls, etc.) that would typically be part of a manned operation.

Loading Spouts

Loading Spouts are designed to handle various types of dry bulk materials, offering

flexibility and adaptability to different loading applications. These spouts feature cone-in-cone stacking technology, enabling smooth extensions and retractions while maintaining material containment and dust control. The outer sleeve material options provide durability and resistance to wear, ensuring longer service life and reduced maintenance requirements.

In-line filters

In-line filters play a crucial role in controlling fugitive dust emissions during the loading process. These filters capture dust-laden air, separate the dust particles from the air, and reintroduce the filtered dust back into the load. The compact design of the Vortex In-line Filtration System allows for easy installation in limited spaces, while the vertical mounting of filter cartridges ensures optimal performance and extended service life.

Positioners

Positioners are essential components of the system, being able to automatically seat the spout into the open hatch, providing precise positioning of the loading spout above the truck hatch. The Vortex Dual-Axis Positioners allow for smooth and accurate movement along X and Y axes, enabling the system to achieve an

Figure 4. Aero-Slide Conveyors.

Figure 5. In-line filtration.

optimal alignment with the loading vessel. This feature significantly reduces material spillage and ensures a safe and efficient loading process.

Additional equipment

Aero-Troughs, Aero-Slides, Bin Bottoms, Shut off valves, and Flow Control valves are examples of equipment that are utilised in many load out operations. Though this equipment is not required for automated loading in a number of circumstances it can be programmed into the automated system functionality to further improve capabilities and efficiency.

System features VALS works in a variety of lighting and weather conditions and is capable of being integrated with most site-specific software. Vortex technical support is also available during installation and start-up. The system is able to eliminate the need for physical interaction between employees and equipment during the load out process thus decreasing the chance of safety-related incidents. Truck drivers can remain within their vehicles on the scale while VALS quickly goes to work loading the material.

Similarly, automation means it is no longer necessary for multiple employees to be present for material loadout. Labour availability and costs are no longer a concern with VALS and the reduction of employee involvement means fewer chances for human error and a more streamlined loading process.

Case study: cement manufacturer in Eastern Kansas

This cement producer in Kansas was familiar with Vortex because they had utilised their slide gates and diverters at other facilities. When they decided to create a new cement terminal in Eastern Kansas to expand their capacity and improve logistics, they partnered with a renowned engineering firm who contacted Vortex about providing an automated loading solution. Vortex set to work designing a 500 tph system that could deliver the required levels of efficiency and safety.

Equipment provided

f Aero-Flow Troughs

f Aero-Bin Bottoms (Figure 1)

f Aero-Slide Gate Valves (Figure 2)

f Aero-Slide Drum Valves (Figure 3)

f Aero-Slide Conveyors (Figure 4)

f In-line filtration (Figure 5)

f Dual Axis Positioner (Figure 6)

f Enclosed Loading Spout (Figure 7)

f Automated Loading System Package

Results

With the implementation of an automated loading system this customer has been experiencing average load times of less than 7 min. per truck. These loadout times have provided a new level of efficiency while also creating a safer work environment. This customer has been satisfied with the benefits that automated loading has brought to their process.

Figure 6. Dual Axis Positioner.

Figure 7. Enclosed Loading Spout.

Clever ways to cut aggregate crushing costs

Clever ways to cut aggregate crushing costs

Michael Metson, Komatsu, walks through five top tips that operators can implement to reduce the costs of crushing aggregates.

Crushing material at cement production plants is a challenging and complex process that can be costly, impacting the bottom line and potentially eroding profits. Without cost-effective crushing equipment, operators may suffer from expenditures that spiral out of control. Excessive energy consumption, material variability, inefficient size reduction, fines

generation, sticky and wet materials, large civil works, unplanned maintenance or downtime, and other aggregate crushing challenges can derail a plant’s profitability.

The good news is that crushing technology has evolved to become much more efficient in meeting these challenges, with new opportunities for cement producers to significantly lower their

total operating cost (TOC). Today’s innovative crushing technologies are more advanced and sophisticated, with machines that use less energy, do not require an expensive installation procedure, and can process different materials with less wear and tear and minimal fines generation.

By implementing the latest and greatest crushing and aggregate processing equipment at their plants, such as reclaim feeders, surface feeder breakers, and sizers, operators can lower their TOC in five ways – with the added benefit of greater productivity.

Achieving energy savings

Energy usage is a major expenditure in any cement plant, and crushing is the most energy-intensive function. A few facts:

f According to the US Department of Energy, the cost of energy (as part of the total production costs in the cement industry) is significant, typically at 20 – 40% of operational costs.

f Digging down further into the electric power consumption associated with crushing, roughly 60 – 70% of the total energy consumption is used for sizing down material.

f The average energy consumption for crushing is 2.5 kWh/t.

With such large expenditures, energy-efficient crushing technologies that can perform as well or better than traditional, less efficient equipment – i.e. cone, jaw, impact, or hammer crushers – can have a major financial impact. For instance, feeder breakers and sizers that exploit tensile strength crushing technology to break up material are much more energy-efficient than conventional equipment that crushes material using compression. Tensile strength crushing was pioneered in feeder breakers produced in the 1970s under the Stamler brand, with five thousand units sold globally to date, proving its merit and value.

Conventional equipment that utilises a compression crush and pushes material together – squeezing it to break it apart and size it down –requires a substantial amount of energy: “With a jaw or a cone crusher, you’re squeezing the rock until it reaches the point of maximum elasticity and fractures,” says Peter Janssen, Director, Crushing Product Strategy at Komatsu. “The amount of energy to compress the rock to the point of natural fracture can be phenomenal.”

Tensile strength crushing pulls the material apart with replaceable picks that drive into and split each piece with tension – a much more energy-efficient process. This is because the tensile strength of most minerals is less than 10% of its compressive strength. This makes

feeder breakers that use tensile strength crushing highly effective and energy-efficient in breaking down materials, particularly in cement applications.

“Any savings generated in this space would significantly impact the overall cost of any extraction and processing operation,” says Janssen.

Besides energy cost reduction, an added benefit of equipment that employs tensile strength crushing technology is less wear and tear on the machine, reducing downtime and maintenance costs. Tensile strength feeder breakers and sizers use replaceable picks that are simple and fast to replace with little downtime.

Reducing the cost of civil works for aggregate crushers

Large in-plant aggregate transport and crushing equipment requires extensive installation and civil efforts, translating into high equipment and labour costs. Conventional crushing equipment can be large and heavy, requiring a suitable foundation. The amount of work to create that foundation includes excavation, levelling, and the construction of concrete pads or structures to support the equipment.

Sizers require minimal civil works, are versatile in loading, and are easily moved. They feature a low, horizontal profile that operates without eccentric motion for the lowest installation height of any crusher arrangement available, minimising civil works and foundation costs.

Feeder breakers and reclaim feeders often do not require civil works with the added benefit of mobility. Operators can experience the flexibility of moving their feeder breaker quickly and easily. For instance, Komatsu feeder breakers feature three mounting options: a self-propelled crawler mount, a wheel mount easily relocated within operations with a firm floor, and a skid mount that allows the machine to be dragged into a new position by a dozer.

Improving crushing efficiency

Single-stage crushing involves sizing down large chunks into a manageable size to be transported and integrated into the cement mixing process. In two-stage crushing operations, it is possible that, without intermediary screening, undersized material could be subjected to an additional crushing passthrough with conventional crushing equipment – an inefficient, unnecessary, and energy-wasting process.

More advanced secondary sizers that use innovations like Komatsu’s matched velocity technology (MVT) only crush chunks of oversized materials. Pieces already at the optimum size or smaller simply pass through the rotating rollers with picks via gravity, falling into a hopper

or conveyor, reducing energy expenditure and maintenance costs, and without bypass arrangements.

“MVT sizers simply let materials that are already the right size pass through,” says Janssen. “They only crush the oversized stuff and fine material will pass through unhindered. The velocity of the scrolls is matched to gravity, and the idea is that the material is designed to flow through the middle of those rollers and not be agitated too much, making crushing much more efficient.”

There are other cost-cutting benefits of MVT. The optimal material flow of MVT technology minimises bottlenecks, reduces material spillage, and ensures a consistent feed to downstream processes. More consistent material flow also helps ensure accurate proportions of raw materials for the desired cement mix composition, which may reduce the need for costly rework or quality control measures.

Surface feeder breakers also offer similar benefits. For streamlined operation, feeder breakers combine the receiving, sizing, and conveying of mineral material into a single unit. The feeder breaker contributes to a lower TOC with a powerful rotary pick breaker that fractures material to near-uniform pieces with minimal fines generation. These pieces are then rationed onto the conveyor at a steady rate. Consistency in material size and discharge virtually eliminates spillage, reduces belt wear, increases belt life, decreases maintenance costs, and creates a cleaner operation. High crushing ratios help ensure operators can get the materials mined to the desired product size in fewer stages, making their crushing process more efficient and productive while reducing costs.

Reduce the need for heavy moving machines with reclaim feeders

Reclaim feeders are very efficient machines that can help reduce or even avoid the use of heavy moving equipment and the associated labour, fuel, and maintenance costs. They can streamline material handling processes, eliminating the need for manual material loading or wheel loaders, excavators, and dozers to extract material from stockpiles. Plants can reallocate those heavy machines and their associated labour to other parts of their production operations without requiring fleet resources on crushing equipment.

Reclaim feeders are very mobile too. They can be moved to where they are needed for continuous loading and can sit on a transfer or rehandle area. The hopper-less design allows material to be vertically discharged or pushed by dozers onto the integral drag conveyor.

“The nice thing about our reclaim feeder is that it sits on skids and can be towed or pushed into position with a dozer. It can be moved

incrementally to where it needs to be in an operation,” says Janssen.

Save costs associated with crushing wet, sticky material

Wet and sticky material is a nightmare for conventional cement crushing equipment.

Clogging of crushers decreases production and increases operating costs. Many cement plants struggle with clay, marl, other sticky materials and hard stones. Traditional hard rock jaw and gyratory crushers work well with hard material but can pack and clog with soft, sticky, or wet feed.

“You tend to find that jaw crushers do not like sticky material because they clog up and stall the whole process,” says Janssen. “Maintenance supervisors at cement plants hate digging wet and sticky materials out of a crusher when it has stalled. They need to manually remove loads of material before starting up again since conventional crushers rely on inertia through flywheels. Plus, the restart requires a lot of energy just to get things going again.”

This is why many operations in high-moisture environments, such as many equatorial regions, use surface feeder breakers and sizers that are designed to crush sticky and weathered materials with high water content efficiently, avoiding downtime and maintenance or repair costs.

These machines were originally created for underground tunnel environments where wet and sticky materials, such as clay, are common. The inherent design of this equipment makes them much more efficient with high-moisture material, helping to ensure that operations avoid costly downtime and achieve production goals.

Making the most of modern technology

Whether a cement plant has been operating for many years or the operation is fairly new, using the same conventional energy-sapping and inefficient crushing equipment still widely used in the industry is a missed opportunity to cut costs dramatically and bolster a plant’s bottom line. Today’s most versatile designs and innovative technology in reclaim feeders, surface feeder breakers, as well as primary and secondary sizers are available today to help optimise crushing efficiency.

It is also important to note that, while there are similarities in crushing processes and setups across the globe, every cement production plant has unique applications, layouts, and challenges. As plants look for cost efficiencies, they should work with their crushing equipment partner to ensure any solutions are application-driven and designed to optimise overall aggregate process flow.

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Duncan High, Haver & Boecker Niagara, explains how moving from traditional screening systems to advanced technologies improves both productivity and profits.

lobal demand for aggregates and mining materials is on the rise with the industry facing an expected growth of nearly 4.2 billion t over the next 15 years. That is a lot of

material, which means producers need efficient equipment to meet spec and turn a meaningful profit. Every ton of material must go over at least one vibrating screen, so ensuring the efficiency of equipment is critical to operational

success. The good news is that there are technologies available today that can help increase or improve screening productivity. Integrating cutting-edge systems like eccentric screening technology, state-of-the-art screen

media, and diagnostic tools can prevent blinding, pegging, carry-over, or contamination, improving screening performance, productivity and profits.

Heighten screening action

Vibrating screens that are engineered with a double eccentric shaft assembly create a constant stroke to maintain g-force during material surging. The double eccentric shaft design forces the screen body to follow the movement of the shaft. While the shaft travels up, the counterbalance weights move in the opposite direction and create a force equal to what is generated by the body. As a result, the forces cancel each other out and maintain a consistent positive stroke that handles material volume spikes without losing momentum.

One producer in western Canada quickly saw the benefits of switching to double eccentric screening technology when they replaced two horizontal vibrating screens with one double eccentrically-driven, four-bearing inclined vibrating screen. Changing their equipment helped to eliminate surging, blinding,

pegging, and material contamination challenges while increasing their production by 25%.

Reduce damaging vibrations

Vibrating screen technology does more than impact the screening action. It also affects the vibrating screen’s surroundings. The metal springs on a traditional concentric vibrating screen, for example, can be noisy to operate. This metal-to-metal, up-and-down or side-to-side movement can cause excessive noise and vibration. To resolve this problem, double eccentric technology makes use of shear rubber mounts that are strategically designed to minimise lateral movement. The rubber mounts reduce noise while maintaining smoother operation, even in extreme circumstances such as overloading, surging, and starting or stopping under load.

The use of eccentric technology virtually eliminates vibration in the structure – or chassis when used with portable equipment – which protects the integrity of the machine. This means producers can potentially use multiple eccentric vibrating screens in one structure, boosting productivity. Attempting to operate multiple concentric machines in a structure, however, could create vibrations damaging enough to not only cause a negative effect on the quality of production but also to open the door to safety risks and possible downtime.

A leading phosphate producer in North America – producing nearly 8 million tpy – increased their screening area by 60% by transitioning to double eccentric equipment. The mine incorporates a six-story screening plant to house multiple vibrating screens that run 24 hours a day, five days a week. Multi-story screen houses are common in the industry but can pose structural concerns due to the vibrating screens’ size, capacity, and force. Opting for double eccentric technology eliminated those concerns.

The loading rate at the facility increased by 50% for one-inch minus material and a 15% increase in overall load rates in the first year with the addition of eccentric screening technology.

Improve stratification

Combining the use of advanced eccentric screening technology with the best screen media for the application is a recipe for success. Specifically, polyurethane screen media can be a beneficial asset to any operation seeking to prevent blinding and pegging while improving material stratification and increasing wear life.

Polyurethane media offers the best combination of open area and wear life for both wet and dry applications. In particular, polyurethane screen media that is poured open cast can result in 1.5 to 2 times longer wear life than injection moulded products. Open cast polyurethane permanently hardens when cured to maintain its chemical properties and improve wear life.

A screen media company that offers a variety of screen media types can help evaluate how material moves through the three phases of screening – from layered to basic to sharp – to give recommendations on the best screen media for an application.

Producers can customise the screen deck by choosing screen media that maximises productivity for each phase by blending the best combination of open area and wear life.

Alternatively, injection-moulded screen media can soften when temperatures rise, resulting in shorter wear life. Polyurethane screen media also features tapered openings to reduce the risk of blinding and pegging.

The solution to improving material stratification lies in finding the ideal mix of screen media types to ensure all phases of screening work correctly. A screen media company that offers a variety of screen media types can help evaluate how material moves through the three phases of screening – from layered to basic to sharp – to give recommendations on the best screen media for an application. Producers can customise the screen deck by choosing screen media that maximises productivity for each phase by blending the best combination of open area and wear life.

Prevent equipment damage

A vibrating screen needs regular check-ups to run optimally. Vibration analysis and diagnostic systems designed by OEMs specifically for vibrating screens are reliable tools for maintaining continued efficiency and longevity of screening machines. To ensure the best productivity, operations can partner with an OEM that specialises not only in manufacturing equipment, but also offers additional diagnostic tools, product-specific knowledge, and years of engineering experience.

Utilising vibration analysis software, for example, allows mining and aggregates operations to monitor a vibrating screen’s performance in real time by detecting problems before they lead to diminished performance, decreased efficiency, and increased operating costs. The most robust systems incorporate eight wireless sensors that magnetically fasten to key areas of a vibrating screen and measure orbit, acceleration, deviations, and other important data points that indicate the condition of the machine. The sensors send real time information wirelessly to be analysed, ideally by an OEM-certified service technician who can provide a detailed summary and recommendations.

Some manufacturers use vibration analysis technology to offer impact testing – or a bump test – which ensures proper machine calibration and promotes efficient operation. Impact testing involves striking the machine at key points with a dead blow hammer while the machine is off. Vibration analysis sensors are placed at key locations on the vibrating screen while a technician tests the natural frequency of a machine. Based on the results, engineers can adjust machine parameters to avoid operating in resonance, which can diminish productivity, incur damage to vibrating screens, and pose safety risks. It is important to note that natural frequency can shift over time as components are repaired or replaced, so the impact test should be conducted regularly. By incorporating impact testing into an operation’s regular maintenance

routine, producers can ensure optimum screening performance and equipment reliability.

Another advanced diagnostic tool is condition monitoring, which is designed to monitor the health of vibrating screens using modern algorithms and artificial intelligence. The system utilises permanent sensors that monitor the equipment 24/7 to capture real time information and provide alerts via e-mail immediately upon the first sign of a potential problem. By constantly monitoring the accelerations of the vibrating screen, certain systems can even forecast the equipment’s dynamic condition in regular intervals of 48 hours, 5 days, and 4 weeks. With consistent use, condition monitoring software will accurately point out and predict critical issues and advise when to schedule maintenance, along with what to focus on during that planned downtime.

By using diagnostic programs to conduct regular analysis, and by engaging in predictive and preventive maintenance, operations will see minimised downtime through faster problem-solving, lower repair costs and increased peace of mind.

Increase profits through advanced technology

The development of the double eccentric screen and other screening technology provides operations with innovative and cost-effective ways to increase their profits and efficiency. By integrating the right equipment, screen media, and vibration analysis systems, producers can achieve more uptime, higher quality results, increased productivity, and greater profits.

About the author

Duncan High is the Processing Equipment Technology Manager at Haver & Boecker Niagara. He has more than 30 years of industry experience.

Utilising vibration analysis software, for example, allows mining and aggregates operations to monitor a vibrating screen’s performance in real time by detecting problems before they lead to diminished performance, decreased efficiency and increased operating costs.

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