HANDLING SOLUTIONS FROM SAMSON MATERIALS HANDLING
A quite comprehensive range of solutions for bulk materials has been developed by
SAMSON Materials Handling — another member of the
AUMUND Group — over a period of more than 40 years.
Flexibility, reliability, quality, safety and performance are at the
heart of its every product concept. Many uses of the company’s
machines are to be seen in the cement industry. For example,
the Samson® material feeder is the ideal solution for all raw
material and solid fuel intake from dumper trucks and rail cars.
Its surface installation simplifies the plant layout and reduces
project costs for both, the construction of new works and for
the development of an existing plant.
The mobile shiploader and Stormajor® boom feeder provided
by SAMSON offer the cement plant operator or trader a flexible
alternative to conventional fixed installations for the storage of
raw materials and export of cement clinker directly from truck
For clinker exports, the mobile shiploader receives material
either by dumper trucks or by loading shovel for discharge
directly to vessels up to Panamax size. Handling rates reach up
to 1,500tph. The option of full dust control measures can be
utilized to minimize environmental pollution.
The Stormajor® receives raw material and solid fuel for
stockpiling directly by dumper trucks. It combines the
performance of a fixed plant with the flexibility of complete
mobility. Performance and reliability are not impaired at all.
EXEMPLARY CASES FROM BRAZIL AND RUSSIA
Solutions from AUMUND companies are in high demand with
the BRIC states. So only five years after delivering a first bridge
scraper, SCHADE Lagertechnik delivered a circular column
equipped spreader to the Sobradinho plant of the Brazilian
cement producer Ciplan Cimento Planalto S/A. The machine
provides a flow rate of 1,800tph (max 2,000tph) and a 23-metre
beam as well as a belt width of 1,400 millimetres. Besides the
scope of delivery includes another SCHADE bridge scraper
equipped with a harrow covering the entire area of the
stockpile’s profile. The bridge scraper can be operated with a
flow rate of 700tph.
In Russia the customer OAO Mordovcement contracted
AUMUND for the construction of new process lines and for the
large-scale modernization of existing facilities. All in all, OAO
Mordovcement has purchased over 100 machines from
AUMUND over the years. SCHADE Lagertechnik last delivered
a storage system for additives designed as a covered rectangular
stockyard. The scope of delivery included a travelling tripper car
for material feeding to the stockpile, a cantilevered boom
reclaimer for material reclaim as well as feeding and discharging
conveyors. Further machines delivered to different facilities are
heavy duty apron feeders, rotary discharge machines as well as
different kinds of conveyors and bucket elevators.
CONVERSION AS AN ALTERNATIVE TO BUYING A NEW MACHINE
However, the installation of a new machine is not always the best
solution for the customer. The conversion and modernization of
existing equipment might be more in his best interest. A record
breaking conversion project was realized by AUMUND in India.
At the Himachal Pradesh plant of Ambuja Cement, one of the
largest and most modern cement works in India, a bucket
elevator had to be renovated, after continuously raising the raw
meal to the pre-heater tower 24/7 at a rate of 650tph.
Whilst the machine remained in service a detailed inspection
revealed that a replacement belt would soon be required. At 170
metres centre distance, this is the highest belt bucket elevator
installed in the world today and as such only a very few
companies possessed the know-how to deliver a competent
Originally, the machine was fitted with a steel cord belt of
width 1,450mm and tension rating of 3,500N/mm. AUMUND
decided to offer an alternative based on its own design concept
resulting in a belt width of 1,050mm and with a bucket size of
1,000mm at 430mm pitch.
In addition to the new belt the elevator will be fitted with
new drive pulley including friction linings and rubber bucket
mounting strips all to be supplied locally. The casings, inlet and
outlet plus the complete drive unit will remain unchanged.
The AUMUND belt concept is very different in that
continuous close pitch longitudinal ropes are employed. There is
no need for rope-free bucket mounting spaces. Additional wire
ropes are running laterally across the width of the belt adding
considerable lateral stiffness without significantly changing the
belt longitudinal flexibility. This cross-stabilized construction gives
improved directional stability and better tracking to the belt.
Using continuous wire ropes without rope free spaces at
close pitch both longitudinally and horizontally gives maximum
strength and stability. However, this technology does require the
bucket fixing to be punched through the belt and steel ropes
through and through. This is taken into account with the tension
calculation. The ruptured ropes can be ignored in the full belt
width tension rating.
To punch the necessary holes into the belt, AUMUND has developed a special punching machine design which provides
clean fixing holes accurately aligned relatively to the belt edge
and at precisely the correct pitch. The belt is held in a cassette
and is advanced automatically under the punching frame using a
precision encoder to measure the pitch. The belts are prepared
at the AUMUND works in Germany and shipped to site
worldwide to the exact required dimensions including a prepared
joint and the required clamping strips.
This illustrates the AUMUND conversion and refurbishment
service offered across the equipment range including belt and
chain elevators, pan and bucket conveyors plus plate feeders. A
converted machine can be supplied with all new moving parts by
AUMUND retaining often only the structural elements. This
results regularly in a substantially new machine with significant
cost reductions compared to outright replacement. With
minimum changes to the structural parts and chute works,
installation time is greatly reduced and machines may generally be
upgraded to the AUMUND standard during a scheduled outage.
Of course, once upgraded in this way the client can expect the
usual AUMUND dependability, access to service support and genuine AUMUND spare parts. Not only existing, life expired
machines can be revitalized and upgraded this way. At the same
time AUMUND can often tease out additional performance thus
opening the possibility of plant capacity improvement with
minimum new investment.
The three companies of the AUMUND Group are not only the
suppliers of a vast range of highly specialized machines for the
cement industry. They can also rely upon a multi-decade
experience and a staff of highly experienced engineers and
specialists to develop solutions for individual needs of customers
from the cement industry worldwide.
ABOUT THE AUMUND GROUP
The AUMUND Group is active worldwide. The conveying and
storage specialist has special expertise at its disposal when
dealing with bulk materials. With their high degree of
individuality, both its technically sophisticated as well as
innovative products have contributed to the AUMUND Group
today being a market leader in many areas of conveying and
storage technology. The manufacturing companies AUMUND
Fo¨rdertechnik GmbH (Rheinberg, Germany), SCHADE
Lagertechnik GmbH (Gelsenkirchen, Germany), SAMSON
Materials Handling Ltd. (Ely, England), as well as AUMUND
Logistic GmbH (Rheinberg, Germany) are consolidated under the
umbrella of the AUMUND Group. In conjunction with the
headquarters of the manufacturing companies, the global
conveying and storage technology business is spearheaded
through a total of ten locations in Asia, Europe, North and South