COMPLEX AND CURVED
Cong Thanh, the Vietnamese cement producer, also relies on the
system solution expertise of the BEUMER Group for
transporting crushed limestone from the quarry to the blending
bed. The CL team discussed the various technical options
intensively in a joint workshop held with the producer. Various
routes were worked out and compared on the basis of the
narrow terrain that was available. Echelmeyer explained that
“We have appropriate software for this, with which we can
match satellite and aerial photographs with topographical data.”
One conveyor section that drops steeply in some places with
numerous obstacles in the terrain and seven road crossings was
A total system consisting of four conveyors with a combined
length of 3.5km is now in use, BEUMER also supplied a PLC plant
control system. The main component is an overland conveyor
with three horizontal curves and a total drive rating of 600kW.
It is designed for a continuous conveying capacity of 2,200tph.
The heaped material is transported in trucks from the quarry
face to the crusher. The limestone that has been pre-crushed to
less than 100mm is then transferred by discharge conveyors to
an accelerator belt that feeds the long belt conveyor.
The troughed belt conveyor for downhill transport is one
meter wide, with a distance between centres of 3,200m, and
drops 70m. The conveying speed is 4.5m per second. The low
operating costs are a special feature. Due to the downhill
section the operation of the fully loaded conveyor is virtually
energy-neutral. Its consumption during continuous operation is
less than 200 kilowatts, which means that not even 0.1 kilowatt is
required per tonne of transported material. According to
Echelmeyer, “This, together with the low maintenance and repair
costs, contributes substantially towards cost-effective operation.”
After the installation and commissioning his team submitted the
plant to a performance test that it passed successfully on all
THROUGH THE MIDDLE OF THE RAINFOREST
The CL Systems division of the BEUMER Group has also been
very successful in Indonesia. The plant construction company
Sinoma International Engineering Co. Ltd. was awarded the
contract by the Indonesian end customer, Cemindo Gemilang, to
supply a turn-key cement plant to Java. It should reach a daily
clinker production of 10,000 tonnes. Sinoma commissioned
BEUMER with the design and supply of an overland conveyor
between the quarry and the plant.
The challenges in this project were not only the demanding
topographical routing but also the evergreen rainforest. Joint
discussions were held between the BEUMER team, Sinoma and
the end customer. The team worked various routes out and
compared them. “The very narrow corridor of land in addition
to the tropical climate required a complex and sophisticated
design” explained Echelmeyer. Among other things his team
designed a solution with tight horizontal curves that fitted
optimally into the landscape.
The entire system now comprises six conveying plants with a total of length of 7.6km. BEUMER also supplied acceleration and discharge conveyors and a PLC plant control system.
CONTROLLED LOADING ENSURED
The system is designed for a maximum continuous conveying capacity of 3,000tph. The main component is a 7.4km-long
overland conveyor. Upstream of this troughed belt conveyor is an intermediate hopper with a capacity of about 120 tonnes. The material passes from this hopper via a variable-speed discharge conveyor to a downstream acceleration belt that feeds the overland conveyor. This controlled loading system ensures cost-effective operation of the plant, especially during the start-up phase. It also has a favourable effect in the dimensioning of drive components and the belt, and reduces the operating costs.
According to Echelmeyer “The acceleration belt with a speed of 4m per second protects the belt of the overland conveyor and increases its service life.” For further protection there are also upstream units for collecting any iron and non-ferrous metals. The limestone is then transported to the blending bed on short troughed belt conveyors.
The troughed belt conveyor has a width of 1,200mm and a distance between centres of 7,381m. One tail drive and two head drives are installed, each with a rating of 545kW. The plant conveys the material at a speed of 5m/s and negotiates a height difference of minus 188m.
PROTECTION OF PEOPLE AND ANIMALS
The conveying system also runs past villages and for long sections passes through rainforest that deserves to be protected. The CL Systems team has taken numerous design measures to reduce the noise impact on people and animals. Echelmeyer explained that “Among other things, we have used low noise idler rollers and appropriately dimensioned protective hoods at the drive station.” This means that the limestone passes through the rainforest in virtually silent mode. The construction time lasted only one year.
The BEUMER Group is an international manufacturer of intralogistics systems for conveying, loading, palletizing, packaging, sortation and distribution. Together with Crisplant a/s and Enexco Teknologies India Limited, the BEUMER Group employs 4,000 people worldwide, and achieves an annual turnover of about €700 million. With its subsidiaries and sales agencies, the BEUMER Group serves customers around the globe, across a wide range of industries.