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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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Do you have problem like this?
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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Do you have problem like this?
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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ISM, DammamA Division of Armture
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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ISM, DammamA Division of Armture
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 883info@armture.com
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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
info@haugensystem.com
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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