Cement Americas

FALL 2017

Cement Americas provides comprehensive coverage of the North and South American cement markets from raw material extraction to delivery and tranportation to end user.

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www.cementamericas.com • Fall 2017 • CEMENT AMERICAS 23 FEATURE then elevated and discharged directly into the grinding mill, where it was reduced to a fine particle cement. No firing was required because the steel mill slag is a clinker. An additional installation for a cement plant in the south- eastern United States delivered various raw products to the storage bunkers that ultimately fed the kiln. A most interesting aspect of this installation was the long approach with multiple feed points. The blending of the products (limestone, gypsum, sand, iron ore, etc.) was achieved by a crane-mounted clamshell which stocks the materials above the respective apron feeders. This 90-degree angle arrangement also replaced a pre- vious system composed of a horizontal feed conveyor and bucket elevator, thus, once again, eliminating a transfer point and greatly reducing operating and main- tenance costs. The sandwich belt high-angle conveyor has also been used for the hot handling operations of a cement plant. Such a system replaced the typical arrangement of a long approach conveyor, linked to an elevating pan con- veyor, and handled a range of materials from hot and powdery clinker to gritty pozzolanic sand to sharp lumpy gypsum rock. This was not only more economical but provided a system where material flowed continuously, with no intermediate transfer, until discharge. Continuing to prove the versatility of the sandwich belt high angle conveyor, Dos Santos International commis- sioned a DSI Sandwich belt high angle conveyor with Zanella Engenhaira e Industria de Maquinas of Curitiba, Parana, Brazil. The project is part of a cement factory in the municipality of Pitimbu. The factory arrangement was laid out to accommodate protected areas, reduce]ing the environmental impact. This request for a small footprint was easily achieved by the DSI Snake at Paraiba, elevating 720 tph of lime- stone, iron ore, sand and clay at a 60-degree incline. Advancing the Technology for the Environment Brennand recognized the challenge of the raw materials they were transporting and were seeking a better han- dling of raw materials. This DSI Snake was the first to utilize a commercially designed DSI Wet Brush, a system that applies a minimal amount of moisture to mitigate side migration of the bulk material towards the edge of the belt sandwich.Most bulk materials don't need help from a Wet Brush, but some materials do have a ten- dency to migrate towards the belt's edges. The DSI Wet Brush utilizes precise water flow control and measurement that reacts to precise monitoring of the bulk material flow rate. A sonic, broad level sensor at the bulk material feed point along with a belt speed monitor provide all of the information required to con- trol the wet brush system. System interlocking maintains a perfectly dry system when there is no bulk material or the feed belt speed is zero. Material flow is measured continuously, and the wet brush automatically adjusts moisture for optimal response. The DSI Snake at Paraiba features an extended loading zone that is fed by five separate belt feeders and chutes. It includes a cross-belt magnet to remove any tramp iron and a material analyzer that ensures the correct raw mixture. Eventually, in production, the plant will have a capacity of 3,000 tpd of clinker and 1.5 million tpy of cement. The sandwich belt high angle conveyor technology has been used in a wide range of industries to convey many different materials. The applications described here show the suitability of these systems for carrying the array of bulk materials that are the raw feed for cement manufacturer. Dos Santos International is pleased to continue the development of high angle conveyors that are a part of environmentally conscious projects that offer smaller physical and carbon footprints. DSI Sandwich convey- ors offer a competent and reliable continuous elevating system for widely varying bulk materials such as those that are the raw feed to cement plants. Information for this article courtesy of Dos Santos Inter- national, www.dossantosintl.com. The DSI Wet Brush applies a minimal amount of moisture to mitigate side migration of the bulk material towards the edge of the belt sandwich.

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