B3 CONVEYING B3.1 Comparative Power Consumption for Lift kwhyt100M Screw pump 1.20 Airlift 1.10 Dense phase pump 0.59 Bucket elevator 0.41 (Fujimoto; WC; 7/1993 pg 25) B3.2 Pneumatic Conveying Fuller Kinyon (FK) Pump. This is a pneumatic conveyor comprising a decreasing pitch screw which compresses a material seal inside a barrel section followed by injection of fluidising and conveying air. Power consumption is 0.8-1.5kWh/tonne per 100M combined for screw drive and compressor; screw speed is 750-1500rpm and air pressure 1-2.5kg/cm? (15-35psi). The original ‘H’ pump has a screw which is unsupported at the discharge end and requires constant material flow. The ‘M’ pump has a side discharge and a fully supported screw; the ‘Z- flap’ is a retrofit outboard bearing for ‘H’ pumps. Capacity to approxi- mately 500t/h is possible but the sizing of pneumatic conveying systems is complex depending principally upon line length and config- uration as discussed by Hunlich & Bogdanski (ZKG; 6/1997, pg 307). Design air volume is typically 0.012NM°/kg material. Air Lift (Aeropol). The air lift conveyor comprises a vertical cylindrical pressure vessel, with aeration pad at the bottom and conveying air noz- zle passing upwards through the centre of the pad. A rising pipe (con- veying line), open at the bottom, is situated just above the conveying air nozzle. Material is fed in near the top of the vessel and controlled by a level indicator; the material column overcomes the back pressure of the conveying line and material is forced into the rising air stream. An alle viator is fitted to the top of the rising pipe to separate carrying air from material. The quantity of material conveyed increases with vessel filling, height, and blower pressure is a surrogate for material flow rate. The conveying height is limited by, and is approximately 10 times, the ves- sel height. Design air volume is typically 0.048NM?/kg material. Cement Plant Operations Handbook * 229 SNIAJANODDe-aeration of pneumatically conveyed kiln feed. If not de-aerated, conveying air enters the preheater with the feed material and, if the kiln is ID fan limited, will de-rate kiln production. Approximately, the gas flow at the top of a preheater with 850kcal/kg and 5% excess oxygen is 1.53NM?/kg clinker. ‘An FK pump will deliver 0.012NM® x 1.6 = 0.019NM?/kg clinker or 1.25% of preheater exhaust. An Air Lift will deliver 0.048NM® x 1.6 = 0.077NM3/kg clinker or 5.0% of preheater exhaust. A separate dust collector to avoid injecting carrying air to the preheater may, therefore, be justified. B3.3 Bucket Elevator Power kW = k.CH/367 where C = load, tonneshour H = height, M k = coeft varying from 1.2 for fed buckets to 2.0 for nodular material with high scooping resistance B3.4 Belt Conveyor Power Calculation for belt conveyors is complicated by belt inclination and the number of rollers, scrapers, etc. (Labahn). The economics of long belt runs is described by Azan & Clot (ICR; 7/1990, pg 30) B3.5 Screw Conveyor Power kW = 2.25 (L + 9)(C/530) where L = length, M B3.6 Air-slide Air slides are inclined at 4-10° with aeration compartment lengths of up to 5M. Air pressure is typically 40cm HO, air volume is 2M?/M2?/min and power consumption approximately 0.01kW /t/10M (Labahn). Dust collection is required to maintain upper compartment under negative pressure. 230 * Cement Plant Operations HandbookB3.7 Drag Conveyor Power kW = (CL/220) +0.8 This is a simplistic equation for a horizontal drag using a theoretical loading; ie the maximum load before slip occurs within the material column. B3.8 Tube Belt Conveyor Relative to traditional troughed belt conveyors, tube conveyors shape the flat belt into a closed tube between loading and discharge points. Advantages are intrinsic protection from wind and rain and prevention of fugitive dust, together with ability to climb steeper gradients and turn tighter corners. There are variations of design (Bahke; ZKG; 3/1992, pg 121: ICR; 10/1997, pg 43), some of which involve special belting with cables embedded in reinforced edges. Installation cost and power consumption are comparable to troughed belts but maintenance is less. Tube conveyors up to 850mm diameter have been built carrying 2500t/H of material up to 400mm in size. B3.9 Sandwich Belt Conveyor Troughed belt conveyors are limited in elevating loads to angles of less than 15°. This limitation can be overcome by use of a sandwich belt or high-angle conveyor which allows conveying angles up to 90° (Dos Santos; WC Bulk Materials Handling Review; 1996, pg 34). B3.10 Magaldi Belt Conveyor Magaldi Corporation offer a line of conveyors for original installation or for retrofit to belt systems in which steel plates (for horizontal trans- port) or steel pans (for inclines) are fastened to steel mesh belt. The belt can run on an existing belt conveyor frame and can usually employ the same drive, Benefits include high temperature capability and much reduced risk of belt failure (Robino; BSH; 5/1991, pg 483). B3.11 Pneumatic Capsule Conveyor An innovative conveying system is Sumitomo's installation of a 3.2kM pneumatic capsule conveyor for limestone which is claimed to involve lower capital cost, lower maintenance and lower noise than a belt conveyor (ICR; 10/1994, pg 52). Cement Plant Operations Handbook * 231 SNIAJANODB3.12 Water Pump Power kW = QHi6.1e where H = head, M Q = flow, M¥/min e = pump efficiency (typically 0.6-0.9 for positive displacement pumps increasing with pump size) eee 232 * Cement Plant Operations Handbook.