haugen : spillage handling solutions

7/27/2019 HAUGEN : SPILLAGE HANDLING SOLUTIONS

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SPILLAGE HANDLING SOLUTIONS

USING VACUUM TECHNOLOGY

Karl T. Haugen

Managing Director

HAUGEN System AB, Sweden

MIDDLE EAST EXPORT OFFICE

DISAB Group


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Do you have problem like this?


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Or this?


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Vacuum technology

- a natural part of spillage handling

in the cement manufacturing technology!

Why?

Better internal and external environment

Increase of production efficiency

Reduce maintenance costs

Efficient recovery of valuable material

Increase operational profit


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Spillage handling main areas of operation

Cleaning Transport Recovery


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Going Green by Keeping it CleanThe introduction of professional cleaning can change the

whole plant's outlook and help generate pride in the facility.

Typical clinker transport system - Before and after spillage management


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Cleaning has many benefits for your plant

A clean electric motor has longer life time

Repair time is reduced if equipment is cleaned

Access to point of repair is quicker with vacuum removal


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Human Benefit

Less air pollution Less dust to free airLess hard manual

work

Safer working place

Cleaner working

place

Machinery to quickly

handle spillage

Less health risks by

handling material

Cleaning is pure profit - Human and Economical


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Spillage in your plant:

-Increase maintenance cost

-Decrease production efficiency

-Gives internal and external environmental problems


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Transport by vacuum will reduce plant down time

A vacuum loader can transport material more than 150 mtr

Cement can be sucked and blown back to the process

A vacuum loader can often pay for itself just by reducing plant downtime


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Recovery is pure economical profit

Large volumes of valuable material spills under belts and mills

Collected material spills can be returned to the

process without contamination


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We can recover this material to your process.

Value: SR 10 13 for 50 kg means SR 260.- / tonThere are hundreds of tons to be recovered.


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Enclosedtransportsystem

Minimumof spillage

at break down

Collectedat confined

spaces

Can be depositedUnder control

ISO 14000certification

Transport and recovery


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Reducing number of people for manual cleaningis pure economical profit

What is is needed for spillage management by

vacuum instead of shovel and wheel barrel:

Packing plant Stationary system 3 men

Raw mill Stationary system 3 men

Cement Mill

Clinker silos

Lime stacker

Cellars

Other areas Mobile unit 3 men

Above is dependendent upon production capacity of plant and local conditions


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Vacuum solutions for spillage handling

A fixed installation of a mid

effect vacuum unit for dailycleaning

Stationary vacuum systemMobile vacuum loaders

A heavy mobile vacuum unit to

handle emergency break downswith high volume of material

spillages.


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Mobile vacuum loader

Suck / Blow or Suction only

Powered by the truck diesel motor Powered by separate diesel motor

Emptied by a hi-lift system Mounted on a semi-trailor


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Vacuum loader Suction

Principles of operation


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Vacuum loader Blowing

Principles of operation


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MATERIAL WEIGHT

CEMENT AND / OR

CLINKER

10 m3

Cement haven a volume weight of ca 1,5 ton / m3.

Clinker will have a volume weight of ca 2 ton / m3

When we have cement will this weight be 15 ton.

When we have clinker will tihs weight be 20 ton

Almost all of this weight will be on the rear axles.

The vacuum loader weight is totally 10 400 kg..

The weight is when the container is empty.

The weight distribution on front and rear axles

are dependent upon the wheel base.

Most of this weight will be on the rear axles.

P 210/9-3210 require for Volvo FM 400

Wheel base of 4 900 mm:

Front axle 3,5 ton / Rear axles 6,9 ton

The axles of the truck will have permissable maximum weight to

ensure safety and long life time. Special axles can be supplied.

The Volvo FM 400 has a total permissable weight of 40 or 41 ton.

Front axle 8 ton or 9 ton. ( We require 9 ton )

Rear axles 2 x 16 ton = 32 ton

The truck itself has also a weight .The chassis weight of Volvo FM 400 is ca 8,1,ton.

This chassis weight is divided:

Front axle 4,7 ton / Rear axle 3,4 ton.

WB-Wheel baseThe maximum weight on the axles are:

Front axle: 3,5 + 4,7 = 8,2 ton

Rear axle cement: 15 + 6,9 + 3,4 = 23,2 ton

Rear axle clinker 20 + 6,9 + 3,4 = 30,3 ton

The max on rear axle is 32 ton. We have safety margin.

If we increase the container to 16 m3 it will be:

Rear axle clinker: 32 + 6,9 +3,4 = 4 2,3 ton

This is not acceptable for truck guarantees or safety.

UNIT WEIGHT

VACUUM LOADER

TRUCKS OWN WEIGHT

WEIGHT CALCULATION - AXLES


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Semi-mobile vacuum units Suction only

Mounted on an industrial towbar trailor


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Filter separatorVacuum unit

All material collectedto one point

Easy handling

Tailor made

Stationary vacuum system

Vacuum system


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Basic design of a stationary vacuum system


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Typical lay-out drawing

Stationary vacuum systemPacking Plant

Ground floor

Material collected is wasteCollected in pre separator

Above ground floor

Material collected is recoveredCollected in filter separator

Returned to production

Recovered materialmust be sieved


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The contract was won on a single supplier justification basis.

Our latest turn-key supply in the GCC area

Stationary vacuum system Emirates Steel Industries

Electric motor 110 kW

Air volume 4 000 m3/hMax vacuum 700 mbar

Main pipe diam 152 mm

Total system length 2 640 mtr

Commissioned in December 2009


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Our experience

Our customers gain


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Volumes of spillage to be collected influence

The air volume and max vacuum of the vacuum pump

The size and type of the separator

Air volume influence the filter size in the filter separator

Suction capacity is influenced by

Diameter of pipe and suction hoses used

Distance material is conveyed

Difference in height

Free-flowing material or sticky material

Size of particles to be collected

Collection of material from heaps or spread-out

Number of suction points in operation at the same time

Basic evaluation for designing a vacuum system


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Vacuum or Airflow

The vacuum unit create an air stream in a pipe

Material is mixed in to the air stream

The vacuum is to overcome pressure loss in theairflow system

OUR TECHNOLOGY IS AIRFLOW TRANSPORT


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Important factors

Vacuum pipe dimension Pipe dimension is too large>

Air speed is too low to transport material >

Material falls out of the air stream >

Clogging

Pipe dimension is too small>

High pressure drop >

High material speed >High wear


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Shall the installation be Mobile or Stationary?

Shall the vacuum unit have Electrical motor or Diesel engine?

Shall the collected material be returned to the process?

Where shall collected material be disposed or returned?

Plant lay-out information?

Basic information needed for making a suitable proposal?


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SEND US DRAWINGS WITH

BASIC INFORMATION ANDPICTURES

WE WILL MAKE THE LAY - OUT

DRAWING AND COMPONENTS

BOQ

YOU BUY THE COMPONENTS

LOCALLY OR FROM US

USE OUR SUPERVISOR TO

ASSIST YOUR LOCAL

ERECTION CREW

Stationary vacuum system design free of charge


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Users of our vacuum technology

Yamama Saudi Cement Co., KSA

Saudi Cement, Hofof, KSA

Jordan Cement, Amman. Jordan

ADRA Cement, Syria

Union Cement Co., Ras AlKhaimah, UAE

ECC, Egypt

Assiut Cement, Assiut Egypt

Ciment Egyptienne, Cairo, Egypt

National Cement, Cairo, EgyptTourah Cement, Cairo, Egypt

Ciment National, Lebanon

Irish Cement, Ireland

Italcementi,

CCB, Belgium

Blue Circle Cement, England

Kantvik, Finland

Kerman Cement, Kerman, Iran

Lafarge Karsdorfer Zement, Germany

Lafarge Cement, Dunbar Works,

Ciment Lafrage, France

Cementa AB, Slite, Sweden

A.P.C.M., England


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Mordov Cement, Russia

Norcem A/S, Norway

Partek OY, Pargas, Finland

Podolsky Cement, Ukraine

Pulau Dammar Laut,Singapore

Sangyong Cement, Seoul,South Korea

Vassiliko Cement, NicosiaCyprus

Valenciana De Cementos,

Spain Titan Cement, Kamari,

Greece

Siam Cement, Bangkok,Thailand

Acimento, Mercin, Turkey

Sukohlosk Cement, Russia

Tebessa Cement, Algeria

More users of our tecnology

Other industries Saudi Arabia

SABIC Hadeed. Jubail 3 unitsNational Steel Co.

Al Tuwairqi Group, Dammam 1 unit


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How can I use the vacuum technology without

making the investment? Use a vacuum contractor !

Most cement plants in Europe use a vacuum contractor

- They are called in when you need the service

- Your employees focus on cement production

- The cost is on operational budget and not on the investment budget

- The service of a vacuum contractor is by day, month or year

ARMTURE, Dammam now offer ISM Industrial Spillage Management.

Vacuum contractor service with modern vacuum loaders all over KSA


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Industrial Spillage Management

Integration of

Outsourced Contract Vacuum Cleaning with

Site Surveying and Reporting

ISM, DammamA Division of Armture


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Inspect Report Clean & Fix

Planning is Critical

Setting the Standard

SUCCESSFUL VACUUM CONTRACTING SERVICEUSED BY LAFARGE, UK

Contracting service that demand more than sucking cement:


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A new cement industry contracting service in Saudi Arabia

Armture for Industrial ProjectsP.O.Box 5348, Dammam 31422 ,

Tel: + 966 3 80 60 979. Fax: + 966 3 80 60 [email protected]


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Other applications for vacuum technology

Railvac excavator London Underground Ship docks - blast material

Steel plants Heavy sludge Ports

We have 3000 vacuum systems in operation in many different applications globally.


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www.haugensystem.com

[email protected]

SPILLAGE IS NOT A DEPARTMENT ISSUE -

IT IS A PLANT ISSUE !


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This machine I sold

26 years ago to

Jordan Cement.

It is still in operation

- and so am I.

Thank you for your attention!


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haugen : spillage handling solutions

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