Pipe Conveyor1

The KOCH Pipe Conveyor®KOCH Technology, Managementand a Passion for Projects

2005

/9, E

5

KOCHTransporttechnik GmbH

Karl-Koch-Straße 166787 Wadgassen/Germany

Tel.: +49(0)68 34 / 470-0Fax: +49(0)68 34 / 470-339E-Mail: [email protected]

www.pipeconveyor.de

The KOCH Pipe Conveyor®:No. 1 in the World

KOCH Leading Pipe Conveyor Technology

With more than 190 installed systems with more than 90 km

(56 miles) of conveying length located in 30 countries, the KOCH

Pipe Conveyor® is clearly No. 1 in the world. No other pipe

conveyor system is so fully developed, installed in so many

applications and so successfully tested in operation.

KOCH Pipe Conveyor® Systems: Setting New Standards.

The KOCH Pipe Conveyor®:The Superior Features.


KOCH Pipe Conveyors®

– Overcoming the SpatialChallenge:

� inclines up to 30°

� any desired horizontal and vertical curves with minimal radii of up to45 meters

� 60% spatial savings in contrast withconventional systems

The KOCH Pipe Conveyor ®

– the Clean Alternative

� protects the environment from volatilematerials

� clean conveying routes

� protects the conveyed material fromexternal contaminants

The Koch Pipe Conveyor ®:A System without Limits

� axial spacings of 5 km and more withouttransfer stations

� simultaneous conveying on the feed and return belt even of different materials

� multiple feed points

The KOCH Pipe Conveyor ®

– Cost Effectiveness:

� high availability

� low investment costs

� reduced operating costs

Conveying in tight spaces

KOCH Pipe Conveyors® integrate optimally in existing plants, and

minimize conveying distances, regardless of the landscape parameters,

thereby permitting cost effective line arrangements.

Dust free with minimal noise emissions, securelyprotected

KOCH Pipe Conveyors® transport bulk materials dust free with low

noise emissions and totally enclosed over roads, tracks, waterways

or open seas, through existing plants, over public streets, in environ-

mentally protected zones. Even contaminated materials are conveyed

without any negative environmental impact.

For all types of topography, flexible – and innovative

KOCH Pipe Conveyors® easily handle long distances and problematic

topographic areas. Customized designs incorporate complex client

needs: downhill conveying in difficult topographies; conveying various

materials in one system. Whatever is technically possible, we can

implement based on our experience from 190 operating systems –

and relying on the innovative competence of the market leader.

Cost effective and reliable

Limited spatial requirements, elimination of high cost and maintenance

intensive transfer stations as well as secure conveyance without

expensive housings assure the cost effectiveness of the KOCH Pipe

Conveyor® system. A high level of operating availability reflecting the

KOCH training program and KOCH service guarantees your invest-

ment decision.

feed belt

return belt

Panel

belt

idlers

conveyedmaterial

ply: steel or fabric

moulded edge

running side

carrying sidefeed belt loading point

closed pipe

conventional discharge point


Ring distributed idlers guide the belt pipes in the KOCHPipe Conveyor ® to the discharge. A proprietary systemassures quiet operation. Special mechanisms guaranteethat the belt pipes are not overloaded.

The KOCH Pipe Conveyor®:Fully Developed Technology,Operationally Tested Details.

Each KOCH Pipe Conveyor® incorporates extensive know how for

dealing with the most varied types of materials – and the experience

from implementing more than 190 systems.

Fully developed technology as well as the most state of the art

planning and design aids such as, for example, special software and

extensive data banks, form the basis for the success of the KOCH

Pipe Conveyor®. Numerous specially developed design elements,

tested and optimized in actual operation, make all the difference.

Thus, to assure the highest level of reliability even with widely

fluctuating load factors, the belt construction of the KOCH Pipe

Conveyors® is designed using the finite element method and computer

simulations. Using overload panels and a level monitor for the material

flow, the KOCH Pipe Conveyor® in its base model provides a double

guarantee against overfilling. Guide stations along the standard

conveyor sections always hold the belt in the proper alignment

along the entire line. The belt scale, which can be installed in the

closed belt pipe section, was specifically developed for use in the

pipe conveyor.

A multitude of supplementary components – from spillage conveyors

through belt turning stations for the simultaneous conveying of

different materials – complete the offerings of the KOCH Pipe

Conveyor® line and lay the foundation for the development of new

conveying designs for new tasks, new materials, and new applications.

And do it reliably and according to time schedules – from the

initial layout through the bid process, fabrication, erection and

commissioning.

In the material loading area, the conveying belt is open.The conveyed material is supplied in the same way asin a conventional belt conveyor. Then special devicesenclose the belt carrying the conveyed material. Thediameter of the closed pipes can be selected dependingon the conveyed material between 150-850 mm forconveying volumes up to 9,200 m3/h.

At that point, the belt forms a sealed pipe for the entireconveying line. Thus, the content is protected againstexternal influences while the environment is protectedagainst any potential material losses. The flexible beltpipe design allows for directional changes without requir-ing transfer stations – thereby enhancing both costeffectiveness and operating reliability.

The belt opens on its own before the material dischargepoint and the material is discharged.

Following the material discharge, the belt is closed again – thisexcludes the possibility of contaminating the conveyor line withspilled material.

The KOCH Pipe Conveyor ® in OperationThe heart of the KOCH Pipe Conveyor®: an elasticbelt with special design characteristics to assurea long service life despite widely fluctuating loads.

The KOCH Pipe Conveyor®:Customized Designsfor Every Application.

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Kronospan Inc / Switzerland,Particle Board PlantSecure conveying of wood chips directly acrossroads and rail tracks. KOCH’s design to crossrail tracks and roads without supports: a 57 mlong curved bridge with both horizontal and verticalcurves.

Marti Inc / Switzerland,Lötschberg Base TunnelClean and secure in the tightest space: Duringthe construction of the Lötschberg Base tunnelKOCH Pipe Conveyors® transported overburden,concrete gravel and quarry sand using a smallwindow gallery parallel to the rolling traffic of theconstruction site. The system becomes extranarrow for that purpose. Two of the conveyorsoperate as a dual strand with one on top of theother while the third runs transversely along thetunnel ceiling – at times in 3 D curves with radiiranging between 75 and 160 meters.

Lenzing Inc / Austria,Synthetic Fiber ProductionConveying remnant materials through a tight,haphazard layout. The KOCH Pipe Conveyor ®

handles the task brilliantly. To integrate the plantseamlessly into the existing environment, theconveyor runs a line at times 30 m high carriedby specially designed supports mounted onexisting buildings.

Wismut Inc / Germany,Uranium Mining StockpileTransporting contaminated material for a distanceof 1.8 km over streets, a river and an intercity railline – passing inhabited areas. The KOCH PipeConveyor ® successfully handles all its tasks atno additional cost. Following a retrofit to increasecapacity after 7 years of reliable operation, thesystem can now convey the increasingly commonclumpy material as well as the rolling bulk material.

KOCH Pipe Conveyors® reliably transport the most diverse materials: wet and fly ash,coal and substitute fuels from recycled industrial wastes, wood chips and raw materialpellets, filtered slurries and biomass, coarse overburden and the finest powders such asgypsum or cement.

KOCH Pipe Conveyor® handle conveying tasks in the basic industries and in powerplants, in lime mills and cement plants, in the paper products, particle board and syntheticfiber industries, as well as in smelting plants – all in an environmentally secure systemthat protects the material conveyed while saving space and costs.

KOCH designs pipe conveyor systems for every conceivable application from small,compact units to convey within a plant through kilometer long systems for overlandconveying. Designed individually based on the client’s requirements, adjusted carefullyin every detail to the environmental parameters as well as the characteristics of theconveyed material.

Deutsche Steinkohle AG, SBW Ensdorf /Germany, Bituminous Coal MineDifficult topography, steep inclines. This KOCHPipe Conveyor ® transports tailings over virtuallyimpassable terrain including a 28° incline to reachthe mine pile. The unit is designed to be mobilein order to compensate for pile depressionswithout any problems.

Famsa / Switzerland, Stone QuarryVirtually impassable mountainous terrain withinclines up to 29°, strict protective laws for flora,fauna and residents: This KOCH Pipe Conveyor ®

successfully carries up to 500 tons of gravel inan environmentally protective manner from thequarry to the plant located 208 m lower – andthen carries up to 300 tons of slag back up onits return. The plant also makes use of the eleva-tion drop to generate electrical power.

CEZ a.s., Elektrarna Melnik /Czech Republic, Power PlantTransporting wet ash from the power plant to thedisposal area: The 2 km long KOCH Pipe Con-veyor ® fulfills its task by winding its way throughthe plant, the surrounding landscape and anembankment using 3 horizontal and 4 verticalcurves. In order to be able later to return the ashfor processing into the power plant, the conveyorsystem is designed to be reversible – convertiblein 24 hours.

Malayan Cement / Malaysia,Cement ProductionIn this unit, fresh cement is conveyed to a shiploading station at sea – securely protected in theKOCH Pipe Conveyor ® against the high humidity.Since 1995, the system has proven to be highlyreliable and available for operation under extremeconditions.

The KOCH Pipe Conveyor®:Flexible and Expandable– Right up to TurnkeyIndustrial Systems.

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VAI, Lime Plant Steyrling / AustriaSeveral sequential pipe conveyors to transportlime dust and quick lime – over a heavily traf-ficked federal highway and a rail line. The KOCHdesign is all-inclusive right through the screeningsystem to distribute the material according toparticle sizes.

Thyssen Steel Inc / Germany,Smelting IndustryNew avenues in steel plants: In this KOCHsystem, for the first time a pipe conveyor trans-ports the smelting sand from the pig iron pro-duction process – guaranteeing low noise andcontaminants emissions. 3 post drying silos withdischarge belts, one distributor tower with a

For larger tasks, the entire KOCH product line spanning all outputlevels is available to supplement the pipe conveyor. Thus, wedesign and supply customized conveying systems for any require-ment – right up to turnkey systems, for example, power plant coalfeeding systems or port loading and unloading facilities.

Service for smooth operation and long service life

KOCH Pipe Conveyors® are characterized by their long service lifeand reliability. Each installation includes a thorough system trainingcycle and comprehensive technical documentation to assure smoothoperation. A fully trained staff handles the start up and commissioningand is always available during the service life of the unit: for main-tenance and conditioned monitoring and servicing based on aspecial KOCH inspection program, either as express service or toadapt the system if the tasks or the parameters of operation change.

The KOCH Pipe Conveyor®: The conveying system

which can handle all challenges. When will you

challenge us?

rotating chute to feed the material onto atransverse belt conveyor to supply the adjoiningcement plant or onto a quay belt conveyor tosupply a mobile KOCH ship loading unit com-plete this system.

Petrozuata / Venezuela, Refinery TerminalA 2.3 km long KOCH Pipe Conveyor® bringsmoisture sensitive sulfur as well as petroleumcoke dust free and safely to a loading platformin the open sea. Aside from the ship loadingwith the loading quay, a 1.8 km long jetty anda specially designed KOCH ship-loading unit,this turnkey KOCH system includes a storagefacility with complete infrastructure, stackerand portal reclaimer.

VCP Votorantim / Brazil, Paper Mill2 KOCH Pipe Conveyors®, one to transportwood chips and the other for biomass. Thefact that the line passes over a settling pondnecessitates support spacings of at times 40meters with very small curve radii. KOCH beltconveyors supplement the system.

Nuh Cimento / Turkey, Cement ProductionThe KOCH Pipe Conveyor® as switch hitter:This system conveys as needed clinker orcement for harbor loading and simultaneouslybrings back coal following the turnaround onthe return belt to the factory. The unit passesthe public roads and places along its path inan underground tunnel. The narrow con-struction design of the pipe conveyor minimizesthe tunneling costs.

MUEG / Germany, Lippendorf Coal FiredPower PlantAt a length of approximately 2.2 km, the longestdual pipe conveyor in Europe is also one ofthe most productive, conveying approximately1.1 million tons of wet and dry ash, gypsumand filter cakes as well as 125,000 tons ofREA water (in a parallel strand of fiberglasspipes) per year. This pipe conveyor is part ofa complete KOCH plant for power plant wastedisposal – including the innovative KOCH“Reaction Belt” for the preparation of ashesand REA waters.

Heidelberger Zement AG, BeremendiZement / Hungary, Cement ProductionInnovative design to simultaneously protectthe environment and the material: In this KOCHcircular blending system, we for the first timeinstalled a pipe conveyor to carry off the clay/lime mix. The requisite even feed of the pipeconveyor is assured by special mechanismssuch as a rotary disc and a proprietary elec-tronic control.

PCLA / Slovak Republic,Cement ProductionA pipe conveyor for the dust free transport ofcoal to the cement kiln – part of a completeKOCH coal feeding system consisting of beltconveyors, round blending pile, stacker, bridgereclaimer, sampling units, magnetic separators,belt scales and a covered railcar dumping unit.

The KOCH Pipe Conveyor®KOCH Technology, Managementand a Passion for Projects

2005

/9, E

5

KOCHTransporttechnik GmbH

Karl-Koch-Straße 166787 Wadgassen/Germany

Tel.: +49(0)68 34 / 470-0Fax: +49(0)68 34 / 470-339E-Mail: [email protected]

www.pipeconveyor.de

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Pipe Conveyor1