SPILLAGE HANDLING SOLUTIONS USING VACUUM TECHNOLOGY

Karl T. Haugen Managing Director HAUGEN System AB, Sweden

MIDDLE EAST EXPORT OFFICE

DISAB Group

Do you have problem like this?

Do you have Or problem this? like this?

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

Spillage handling main areas of operation

Cleaning

Transport

Recovery

Going Green by Keeping it Clean

The 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

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

Cleaning is pure profit - Human and Economical

Human Benefit

Less air pollution

Less dust to free air

Less hard manual work

Safer working place

Machinery to quickly handle spillage

Less health risks by handling material

Cleaner working place

Do you have problem like this?

Spillage in your plant: -Increase maintenance cost -Decrease production efficiency -Gives internal and external environmental problems

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

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

We can recover this material to your process. Value: SR 10 13 for 50 kg means SR 260.- / ton There are hundreds of tons to be recovered.

Transport and recovery

Collected at confined spaces Enclosed transport system

Can be deposited Under control

Minimum of spillage at break down

ISO 14000 certification

Reducing number of people for manual cleaning is pure economical profit

What is is needed for spillage management by vacuum instead of shovel and wheel barrel:
Packing plant Raw mill Cement Mill Clinker silos Lime stacker Cellars Other areas Stationary system Stationary system 3 men 3 men

Mobile unit

3 men

Above is dependendent upon production capacity of plant and local conditions

Vacuum solutions for spillage handling

Mobile vacuum loaders Stationary vacuum system

A heavy mobile vacuum unit to handle emergency break downs with high volume of material spillages.

A fixed installation of a mid effect vacuum unit for daily cleaning

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

Vacuum loader Suction Principles of operation

Vacuum loader Blowing Principles of operation

WEIGHT CALCULATION - AXLES

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

UNIT WEIGHT VACUUM LOADER

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.

TRUCKS OWN WEIGHT

WB-Wheel base

The 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 = 42,3 ton This is not acceptable for truck guarantees or safety.

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

Semi-mobile vacuum units Suction only

Mounted on an industrial towbar trailor

Stationary vacuum system

All material collected to one point Easy handling Tailor made

Vacuum system

Vacuum unit

Filter separator

Basic design of a stationary vacuum system

Typical lay-out drawing Stationary vacuum system Packing Plant Ground floor Material collected is waste
Collected in pre separator

Above ground floor Material collected is recovered

Collected in filter separator Returned to production

Recovered material must be sieved

Our latest turn-key supply in the GCC area

Stationary vacuum system Emirates Steel Industries
Electric motor Air volume Max vacuum Main pipe diam Total system length 110 kW 4 000 m3/h 700 mbar 152 mm 2 640 mtr

The contract was won on a single supplier justification basis. Commissioned in December 2009

Our experience Our customers gain

Basic evaluation for designing a vacuum system

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

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 the airflow system

OUR TECHNOLOGY IS AIRFLOW TRANSPORT

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

Basic information needed for making a suitable proposal?

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?

Stationary vacuum system design free of charge

SEND US DRAWINGS WITH BASIC INFORMATION AND PICTURES 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

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 Al Khaimah, UAE ECC, Egypt Assiut Cement, Assiut Egypt Ciment Egyptienne, Cairo, Egypt National Cement, Cairo, Egypt Tourah 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

More users of our tecnology

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, Nicosia Cyprus Valenciana De Cementos, Spain Titan Cement, Kamari, Greece Siam Cement, Bangkok, Thailand Acimento, Mercin, Turkey Sukohlosk Cement, Russia Tebessa Cement, Algeria
Other industries Saudi Arabia SABIC Hadeed. Jubail 3 units National Steel Co. Al Tuwairqi Group, Dammam 1 unit

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

ISM, Dammam
A Division of Armture

Industrial Spillage Management

Integration of Outsourced Contract Vacuum Cleaning with Site Surveying and Reporting

ISM, Dammam
A Division of Armture

SUCCESSFUL VACUUM CONTRACTING SERVICE USED BY LAFARGE, UK

Contracting service that demand more than sucking cement:

Inspect Report Clean & Fix Planning is Critical Setting the Standard

ISM, Dammam
A Division of Armture

A new cement industry contracting service in Saudi Arabia

Armture for Industrial Projects

P.O.Box 5348, Dammam 31422 , Tel: + 966 3 80 60 979. Fax: + 966 3 80 60 883 info@armture.com

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.

www.haugensystem.com info@haugensystem.com

SPILLAGE IS NOT A DEPARTMENT ISSUE IT IS A PLANT ISSUE !

This machine I sold 26 years ago to Jordan Cement. It is still in operation - and so am I.

Thank you for your attention!