Material Handling System in Cement Industry

Submitted to Dr. Ariful Islam Associate professor Dept of IPE SUST

Submitted by : Bivek Bikram Adhikari Reg.No. 2007334051 Department of Industrial and production Engineering , Shahjalal University of Science and Technology, sylhet, Bangladesh .

Material handling system in cement industry.

Objectives:
  To study about material handling system in cement industry. To analyze the material handling equipment in cement industry.

Introduction:
In the most general sense of the word, cement is a binder, a substance that sets and hardens independently, and can bind other materials together. Cement used in construction is characterized as hydraulic or non-hydraulic. Hydraulic cements (e.g. Portland cement) harden because of hydration chemical reactions that occur independently of the admixture's water content; Non-hydraulic cements (e.g. lime and gypsum plaster) must be kept dry in order to retain its strength. There are 31 cement industries in Bangladesh1. Material handling is one of the most important tasks in cement industry. Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal2 .

Material handling equipment:

Material handling equipment (MHE) is used for the movement and storage of material within a facility or at a site. MHE can be classified into the following five major categories3: 1. Transport Equipment. Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyors, cranes, and industrial trucks. Material can also be transported manually using no equipment. 2. Positioning Equipment. Equipment used to handle material at a single location so that it is in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment 3. Unit Load Formation Equipment. Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment. 4. Storage Equipment. Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required. 5. Identification and Control Equipment. Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment.

http://www.bdyellowbook.com/catalog/Consultancy___Construction/ http://www.mhia.org/learning/glossary/m 3 http://www.ise.ncsu.edu/kay/mhetax/index.htm

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Cement production process:

A cement production plant consists of the following three processes. 1. Raw material process 2. Clinker burning process & 3. Finish grinding process.

Material handling in cement industry:

Figure1 4: Material handling in cement industry

http://www.robson.co.uk/cement_conveyors/cement_conveyors.htm

Figure1 shows the use of conveyor in cement industry .Following things are used for material handling in cement industry

  

Belt conveyor Air glide Elevator conveyor

 

Screw conveyor Silos

00. Limestone Quarry and Crushing plant 01. Limestone Stockpile 02. Additives Hopper 03. Additives Storage 04. Raw Mill Building 05. Blending and Storage Silo 06. Preheater 07. Gas Conditioning Tower and ESP 08. Kiln 09. Cooler 10. Deep Bucket Conveyor 11/12. Clinker/Gypsum Storage 13. Coal Mill Building 14. Cement Mill and Bag House 15. Cement Storage Silo 16. Packing & Dispatch 17. Central Control Room

Belt

A conveyor belt (or belt conveyor) consists of t o or more pulleys, wit a continuous loop of material - t e conveyor belt - t at rotates about t em. One or bot of t e pulleys are powered, moving t e belt and t e material on t e belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler.

Figure: belt conveyor Belt conveyor is very simple in design and widely used in many industries. Belt conveyor is mostly used in cement industry to convey raw material to grinding machine. After grinding raw material it is conveyed by belt conveyor for mi ing process. Finally when cement clinker is grinded again finished cement is transferred for packaging through belt conveyor. Also lot of cement is transferred in belt conveyor in silos after packaging. Belt conveyer is very basic material handling equipment and used frequently in cement plant.

eyor:

Figure : Belt conveyor

Air gli e conveyor:

Air glide is a material handling equipment useful for Bulk material handling process. Air glide conveyors are designed to be robust and reliable for harsh environments. The Air glide Belt conveyor is a development of the traditional type, but instead of carrying idlers it employs a cushion of air, being the means of supporting the loaded belt between the feed and the discharge. Air is injected at regular intervals along the "U" shaped bedplate to the underside of the belt, generating a low friction support cushion. A small blower unit supplies the low-pressure filtered air to the plenum, which in most instances is sufficient to supply the total belt length. In cement industry air glide conveyer are used when additive materials are supplied in a mi ture

Figure5: Air glide conveyor

http://www.robson.co.uk/ce ent_conveyors/ce ent_ rglide_conveyors.htm



Elevator conveyor:
Elevator conveyor is a precise solution to the vertical movement of dry and free flowing bulk materials for the Cement Industry. The Bucket Elevator is constructed using stainless steel or mild steel buckets attached to a belt or chain. Encased in a steel enclosure the elevated material is protected from the atmosphere, giving the Bucket Elevator the ability to be used internally or externally of buildings. In cement industry processing materials are uplifted vertically to feed in preheater. For a uplifting operation elevator conveyor are used in cement industry. As shown in fig:

Figure6: Elevator conveyor

http://www.robson.co.uk/cement_conveyors/cement_elevator_conveyor.htm

Screw Conveyor:
Screw Conveyors have a variety of uses. Variations in the flight design allow Screw Conveyors to:
y y y y

Figure: Screw Conveyor

Convey Mix Feed Elevate\

With the bespoke construction of the screw conveyor it is possible to have multiple in feeds and a single out feed. In cement industry tons of material are processed the upper listed operation. When a semi liquid material is dried in a dryer obtained clinker is stored in a storage through screw conveyor.

Silos:
A silo is a structure for storing bulk materials. Silos are used in agriculture to store grain or fermented feed known as silage. Silos are more commonly used for bulk storage of grain, coal, cement, carbon black, woodchips, food products and sawdust. Three types of silos are in widespread use today - tower silos, bunker silos and bag silos. The cement storage silo is used for storing the finished product cement

Figure7: Silos
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http://www.ecvv.com/product/1433105.html

Conclusion:

Material handling system is a basic component in cement Industry. Tons of bulk material are conveyed , uplifted, and stored in cement Industry so material handling equipment like Conveyor, Elevator, Silos are the essential part of cement Industry. In this seminar we have defined a theoretical portion of material handling system in cement industry. We searched in internet for required information of our topics. Finally we decided to take a chhatak cement Industry as a case study in a second portion of this seminar.