Warehouse for cement and other bulk materials using new technologies.
Energy efficient railroad cement warehouse
We offer custom design services, supply of equipment and other possible assistance in the construction and launch of a complex for transshipment of cement and other bulk materials. Enterprises that have introduced these technologies for working with bulk material into their production chain began to consume 5-10 times less electricity, this is a significant reduction in costs aimed at solving the problems of transshipment, transportation and storage of material.
Pneumatic conveying of cement
Working with cement based on the principles of “Pneumatic Equipment Technology”, it was possible to achieve a significant reduction in the amount of compressed air used to transport it, while increasing production efficiency. So, for example, the specific consumption of compressed air, when transporting cement (bulk density – 1.2 m3 / t) in a dense layer by pumps “Beaver”, is reduced in comparison with competitors by more than 5-8 times, and fluctuates around 6- 9 Nm3/t cubes of normalized air per ton at a distance of 100m. and productivity 120 t/h. The working pressure in this case is from 0.2-0.3 MPa, and the energy costs are approximately equal – 0.7 – 1.2 kWh / t.
Main competitive advantages of pneumatic conveying systempumps”</ strong>Beaver“, working on the basis of the principle“Pneumatic Equipment Technology”
The pneumatic chamber pump and the equipment included in the line should be considered not as separate objects, but as a single “pneumatic transport system”, which includes both the pump itself and the transport line with all its elements and assemblies, which sometimes have a decisive importance in the process of material pneumatic conveying. The fundamental difference between this pneumatic transport system and others similar in name lies in the way the material is moved in the pipe. Beaver pneumatic chamber pumps move the material through the pipe in a dense layer at a speed of 1-3 m/s, depending on the material. The implementation of this process, in comparison with other methods of moving bulk materials, entails a number of significant advantages, including:
- Several times reduced air consumption, more than 5 times, for transporting material in comparison with similar pneumatic transport methods, as a result of savings in energy consumption and high payback depending on productivity.
- The possibility of using compressor equipment with low productivity.
- Minimized abrasive impact on elements and components of the pipeline (hundreds of times compared to jet pneumatic transport), there is no need to purchase “abrasive-resistant bends”, as a result, a very high rate of preservation of the physical and mechanical properties of the material after the end of the transportation process.
The reliability of the entire pneumatic transport system has increased, among other things, due to a decrease in the speed of material movement in the pipe by tens or even hundreds of times, and, as a rule, an increased wear life of the equipment.
. . . RAILWARE WAREHOUSE PROJECTS.
Innovative railway pit for transshipment of cement, grain and other bulk materials, from hopper cars, designed on the basis of a new technology for pneumatic transport of bulk materials.</ p>
Short description:
Cement is unloaded from the wagon into a receiving hopper with a volume of up to 60m3.
Further, through four “Aero C” pneumo-layer gates, or directly through the loading nozzles, the material enters one or more “Beaver” pneumo-chamber pumps with a volume of 1m3 or more.< /span>
In some cases, transportation of cement from the pump to the silo, carried out in a dense layer* through the pipeline DN 80 – 200 mm., is made through a tie-in into the outlet cone of this silo (by “bottom cut”). At the same time, the specific consumption of normalized air can vary from 1.5 to 6 Nm3/t, pressure 0.05 – 0.3 MPa. Specific electricity costs in this case are approximately equal to ~ 0.4-0.9 kWh/t. Note that you can use any available method of supplying material to the warehouse.
A hangar, for receiving and servicing a train, can be equipped with systems for extracting and cleaning polluted air – aspiration.
* – Only “Beaver” pumps actually carry out, in practice, the transportation of material in a dense layer, with a speed of material movement through the pipe up to 1-3 m/s.< /span>
A cement warehouse with a capacity of up to 500 tons, based on a new generation pneumatic chamber pump “Beaver”,with a total capacity of 30 to 240 tons per hour, total energy consumption from 50 kWh.
Main parameters:
- The cost of acceptance, storage and shipment is 20-30 rubles/ton
- Power consumption – from 50 kWh.
- Specific electricity consumption for unloading wagons, within the range of 0.9-1.2 kWh per ton.
- The throughput is from 30 to 240 t/h.
- Storage warehouse capacity – up to 500 tons
- Simultaneous unloading – 1-2 wagons, from two pits.
- Simultaneous shipment – 2-4 cement trucks.
Cement warehouse equipment:
- Pneumatic chamber pump “Beaver”, volume from 0.5 to 5 m3, in quantity from 1 to 4 pcs
- Clutch mechanisms and transport valves/gate valves – from 3 pcs
- Shupkn 20-50 pneumatic control and automation unit – 1- 4 pcs
- Receiving hopper with volume from 55 m3 – 1pc
- Assembled vibrocone – from 4 pcs
- Support steel structures of the railway span – set.
- “Aero C” system – 4pcs. (optional).
- “Aero C+” system – 2pcs. (optional).
- Metal structure hangar for receiving wagons – 1pc
- Efficient production aspiration system – 1 pc. (according to the project).
- Silo from 80 m3. – 2-6 pieces
- Warehouse support steel structures – 1 pc. (according to the project).
- Utility and technical premises – 1 pc. (by agreement).
- Aspiration system for receiving containers – kit.
- Elements and nodes of the pipeline Du 80-200mm. – kit (according to the project).
- SCADA system of required access level – kit.
- Compressor unit with a capacity of 5 m3/min, pressure P=0.8 MPa – from 1 pc. (by agreement).
- Air receiver/air collector with volume from 0.9 to 20 m3 – from 1 pc
Cement warehouse with a capacity of up to 1000 tons, based on a new generation pneumatic chamber pump “Beaver” , with a total capacity of 30 to 240 tons per hour, a total energy consumption of 50 kWh.
Main parameters:
- The cost of acceptance, storage and shipment is 20-30 rubles/ton
- Power consumption – from 50 kWh.
- Specific electricity consumption for unloading wagons, within the range of 0.9-1.2 kWh per ton.
- The throughput is from 30 to 240 t/h.
- Storage warehouse capacity – up to 1000 tons
- Simultaneous unloading – 1-2 wagons, from two pits.
- Simultaneous shipment – 2-4 cement trucks.
Cement warehouse equipment:
- Pneumatic chamber pump “Beaver”, volume from 0.5 to 5 m3, in quantity from 1 to 4 pcs
- Clutch mechanisms and transport valves/gate valves – from 3 pcs
- Shupkn 20-50 pneumatic control and automation unit – 1- 4 pcs
- Receiving hopper with volume from 55 m3 – 1pc
- Assembled vibrocone – from 4 pcs
- Support steel structures of the railway span – set.
- “Aero C” system – 4pcs. (optional).
- “Aero C+” system – 2pcs. (optional).
- Metal structure hangar for receiving wagons – 1pc
- Efficient production aspiration system – 1 pc. (according to the project).
- Silo from 80 m3. – 2pcs
- Warehouse support steel structures – 1 pc. (according to the project).
- Utility and technical premises – 1 pc. (by agreement).
- Aspiration system for receiving containers – kit.
- Elements and nodes of the pipeline Du 80-200mm. – kit (according to the project).
- SCADA system of required access level – kit.
- Compressor unit with a capacity of 5 m3/min, pressure P=0.8 MPa – from 1 pc. (by agreement).
- Air receiver/air collector with volume from 0.9 to 20 m3 – from 1 pc
Cement warehouse with a capacity of up to 1400 tons, based on a new generation pneumatic chamber pump “Beaver”, with a total capacity of 30 to 240 tons per hour, total energy consumption from 50 kWh.
Main parameters:
- The cost of acceptance, storage and shipment is 20-30 rubles/ton
- Power consumption – from 50 kWh.
- Specific electricity consumption for unloading wagons, within the range of 0.9-1.2 kWh per ton.
- The throughput is from 30 to 240 t/h.
- Storage warehouse capacity – up to 1400 tons
- Simultaneous unloading – 1-2 wagons, from two pits.
- Simultaneous shipment – 2-4 cement trucks.
Cement warehouse equipment:
- Pneumatic chamber pump “Beaver”, volume from 0.5 to 5 m3, in quantity from 1 to 4 pcs
- Clutch mechanisms and transport valves/gate valves – from 3 pcs
- Shupkn 20-50 pneumatic control and automation unit – 1- 4 pcs
- Receiving hopper with volume from 55 m3 – 1pc
- Assembled vibrocone – from 4 pcs
- Support steel structures of the railway span – set.
- “Aero C” system – 4pcs. (optional).
- “Aero C+” system – 2pcs. (optional).
- Metal structure hangar for receiving wagons – 1pc
- Efficient production aspiration system – 1 pc. (according to the project).
- Silo from 80 m3. – 2-6 pieces
- Warehouse support steel structures – 1 pc. (according to the project).
- Utility and technical premises – 1 pc. (by agreement).
- Aspiration system for receiving containers – kit.
- Elements and nodes of the pipeline Du 80-200mm. – kit (according to the project).
- SCADA system of required access level – kit.
- Compressor unit with a capacity of 5 m3/min, pressure P=0.8 MPa – from 1 pc. (by agreement).
- Air receiver/air collector with volume from 0.9 to 20 m3 – from 1 pc
Cement warehouse with a capacity of up to 2400 tons, based on a new generation pneumatic chamber pump “Beaver” , with a total capacity of 30 to 240 tons per hour, and more, with a total energy consumption of 50 kWh.
Main parameters:
- The cost of acceptance, storage and shipment is 20-30 rubles/ton
- Power consumption – from 50 kWh.
- Specific electricity consumption for unloading wagons, within the range of 0.9-1.2 kWh per ton.
- Throughput capacity – from 30 t/h.
- Storage warehouse capacity – up to 6000 tons
- Simultaneous unloading – 1-4 wagons, from two pits.
- Simultaneous shipment – 2-6 cement trucks.
Cement warehouse equipment:
- Pneumatic chamber pump “Beaver”, volume from 0.5 to 5 m3, in quantity from 1 to 4 pcs
- Clutch mechanisms and transport valves/gate valves – from 3 pcs
- Shupkn 20-50 pneumatic control and automation unit – 1- 4 pcs
- Receiving hopper with volume from 55 m3 – 1pc
- Assembled vibrocone – from 4 pcs
- Support steel structures of the railway span – set.
- “Aero C” system – 4pcs. (optional).
- “Aero C+” system – 2pcs. (optional).
- Metal structure hangar for receiving wagons – 1pc
- Efficient production aspiration system – 1 pc. (according to the project).
- Silo from 80 m3. – 2-6 pieces
- Warehouse support steel structures – 1 pc. (according to the project).
- Utility and technical premises – 1 pc. (by agreement).
- Aspiration system for receiving containers – kit.
- Elements and nodes of the pipeline Du 80-200mm. – kit (according to the project).
- SCADA system of required access level – kit.
- Compressor unit with a capacity of 5 m3/min, pressure P=0.8 MPa – from 1 pc. (by agreement).
- Air receiver/air collector with volume from 0.9 to 20 m3 – from 1 pc
Reconstruction of a railroad cement warehouse
Our company is engaged in the reconstruction of inefficient and energy-intensive industries.
In 2015, we reconstructed and put into operation the railway pit of the railroad cement warehouse in St. Petersburg.</p >
There are several existing problems that caused the customer to contact our company:
- Obsolete equipment in need of constant and costly maintenance.
- The need to reduce high energy consumption in manufacturing.
- Insufficient cement handling capacity
- Inconvenience of unloading cement from hopper cars
- Ecology and high costs of the aspiration system
In this project, we used completely new, previously unused technologies and principles of working with cement.
Due to the use of new-generation Beaver pneumatic chamber pumps and a more efficient principle for receiving cement from a wagon, we managed to reduce the specific energy consumption for transporting cement from 19.0 kWh/t to 0.8-1.0 kWh/t, almost 20 times.
At the same time, increase productivity from 35 to 70 t/h, while ensuring the convenience and speed of unloading cement from the car.< /p>
BasicThe benefits of this offer are – low air consumption, many times increased reliability of equipment, pipeline elements and assemblies, reduced energy costs and solved a number of problems to reduce the cost of aspiration air purification systems.
** – New approaches to cement transportation are implemented in this project. One of them is a patented method of inserting the conveying pipeline into the outlet cone of the silo, based on the principles of “Pneumatic Equipment Technology”, providing a positive effect in reducing energy costs. In world practice, only we have implemented this method of transporting material to a silo.
On our website you will find a video on the topic: “Reconstruction of a railroad cement warehouse”
After a preliminary analysis, we developed a project based on “Beaver technology”, with its further implementation in this production.</p >
