Spec. 1000

ZAVEH TORBAT CEMENT CO.New Cement Plant 3 500 t/d Clinker ProductionA 44.0046.2.001 Rev.1December 2004

1000 Raw Material Preparation Department

1100 Crushing Plant

Item Description (norm./design)

1111 FH 1 1 Limestone Feed Hopper

1111 AF 1 1 Apron Feeder

1111 SX 1 1 Spillage Conveyor

1111 FH 2 1 Alluvium Feed Hopper

1111 AF 2 1 Apron Feeder

1111 SX 2 1 Spillage Conveyor

1111 SP 1 1 Roller Screen

1112 IM 1 1 Impact Crusher

1115 BC 1 1 Discharge Belt Conveyor

1115 CA 1 1 Maintenance Crane

1117 BF 1 1 Bag Filter Crusher Dedusting

1117 FN 1 1 Bag Filter Fan

1115 BC 2 1 Belt Conveyor

1117 BF 2 1 Bag Filter

1117 FN 2 1 Bag Filter Fan

1115 BW 1 1 Belt Scale

1115 MS 1 1 Magnetic Separator

1


1115 AN 1 1 Online Analyser

1115 CH 1 1 Two Way Chute

1111 FH 3 1 Iron Ore Feed Hopper

1111 VC1 1 Vibration Feeder


1115 CH2 1 Two Way Chute


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General Data:

warranty capacity / Output total: 1 000 t/h

warranty capacity / Output crusher only: 800 t/h

design capacity roller screen: 1 200 t/h

design capacity main apron feeder: 1 200 t/h

design capacity discharge belt conveyor: 1 400 t/h

feed material “A”: alluvium, 200 – 1 000 t/h

feed material “B”: limestone, 50 - 400 t/h

feed material “C”: iron ore, intermittent

feed moisture of alluvium: max. 10 %

feed moisture of limestone: max. 4 %

feed moisture of mixed feed: max. 7 %

bulk density alluvium: approx. 1.5 t/m3

bulk density limestone: approx. 1.5 t/m3

feed size of alluvium: max. 500 mm

feed size of limestone: one edge length max. 1 500 mm

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feed size limestone quarried: max. 0.8 m3

acc. to quarry blasting,run of minestandard serial blasting

feed size of iron ore: max. 500 mm

total product sizein square mesh DIN 4226: 95 % < 80 mm

99.5 % < 100 mm

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1111 FH 1

1 Limestone Feed Hopper

volume: approx. 150 - 200 m3

feeding: dump trucks,

two side feeding

material of construction: concrete,

steel plate wear liningof the inside walls

sonar level control: 1 piece

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1111 AF 1

1 Apron Feeder

capacity nom. / design: 200 - 1 000 / 1 200 t/h

inside width: 2 070 mm

c-t-c distance: 11 600 mm

inclination: approx. 23°

operating speed: 0.09 - 0.20 m/s

motor: 2 x 55 kW FC

speed: 1 500 rpm

Base frame of heavy steel construction.

Tractor chain elastically pre-stressed.

Track rollers mounted on the base frame.

Apron feeder deck of welded steel plates.

Apron plates replaceable by fixing bolts to the two chain strands.

Aprons with special sealing to prevent spillage.

Impact table at the feed point, impact roller supports mounted on rubber blocks.

Drive sprockets with easy replaceable gear rim segments.

Drive shaft with pillow blocs and anti-friction bearings.

Planetary gear reducer with coupling, torque blade, motor support, shrinking disc.

Central automatic grease lubrication for bearings of apron feeder.

Tachometer speed control system.

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1111 SX 1

1 Spillage Conveyor

type: trough / scraper bars

location: underneath the apron feeder

gear motor: 5.5 kW

Drive shaft with anti friction bearings.

Chain wheels.

Round link steel chain with scraper bars.

Take-up shaft with anti-friction tension bearings.

Tension spindle with springs.

Steel trough with rails.

Spillage chute steel plate design.

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1111 FH 2

1 Alluvium Feed Hopper

volume: approx. 80 m3

feeding: dump trucks,

two side feeding

material of construction: concrete,

steel plate wear liningof the inside walls

sonar level control: 1 piece

8


1111 AF 2

1 Apron Feeder

capacity nom. / design: 50 – 400 / 500 t/h

inside width: 1 600 mm


inclination: approx. 23°

operating speed: 0.09 - 0.20 m/s

motor: 1 x 55 kW FC

speed: 1 500 rpm

Base frame of heavy steel construction.

Tractor chain elastically pre-stressed.

Track rollers mounted on the base frame.

Apron feeder deck of welded steel plates.

Apron plates replaceable by fixing bolts to the two chain strands.

Aprons with special sealing to prevent spillage.

Impact table at the feed point, impact roller supports mounted on rubber blocks.

Drive sprockets with easy replaceable gear rim segments.

Drive shaft with pillow blocs and anti-friction bearings.

Planetary gear reducer with coupling, torque blade, motor support, shrinking disc.

Centralised automatic grease lubrication for bearings of apron feeder.

Tachometer speed control system.

9


1111 SX 2

1 Spillage Conveyor

type: trough / scraper bars

location: underneath the apron feeder

gear motor: 5.5 kW

Drive shaft with anti friction bearings.

Chain wheels.

Round link steel chain with scraper bars.

Take-up shaft with anti-friction tension bearings.

Tension spindle with springs.

Steel trough with rails.

Spillage chute steel plate design.

10


1111 SP 1

1 Roller Screen

capacity nom. / design: 1 200 / 1 400 t/h

width: 2 100 mm

length: 5 100 mm

gap size / screening: 80 mm / 0 - 70 mm

overflow: > 70 – 1 300 mm

underflow capacity: 600 - 700 t/h

motor: 2 x 37 kW

Roller screen comprising forged steel shafts.

Double-row roller bearings.

Double seals.

Roller chain connection of shafts with protective guard.

Drive by two motors with couplings, spur gear and chain drive.

Motors pole-reversible.

Cleaning of roller screen by anti-clogging scrapers.

Support structure with wear plates on the side walls.

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1112 IM 1

1 Impact Crusher

capacity: 800 t/h

type: single rotor

rotor diameter : 1 800 mm

rotor width : 2 250 mm

rotor speed: 33 m/s

inlet opening: 1 800 x 2 270 mm

motor required: 960 kW

motor speed : 1 000 rpm

Housing, with liners, two parts.

Hydraulic actuated hinged housing.

Disc-type rotor with blow bars.

Shaft, clamping sets, anti-friction bearings.

Impact apron at front and rear side with hydraulic adjustment.

Mechanical locking device.

Hydraulic adjustable grinding path.

Hydraulic cylinders with hydraulic unit.

Rotor speed indicator.

Grease gun for rotor bearings.

Motor pulley, v-belts, flexible coupling, base frame,

Anchor bolts and nuts.

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Inlet hood

Steel plate design.

Rubber- and chain curtain.

Crane jib for electrical hoist.

Inlet chute plate.

Crusher discharge box

Designed as surge and buffer hopper.

Level control.

Steel plate design, flanges, bolts, service door.

Dust collecting flange.

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1115 BC 1

Discharge Belt Conveyor

capacity nom. / design: 1 000 t/h / 1 400 t/h

width: 1 800 mm


inclination: horizontal

conveying speed: 0.4 - 0.9 m/sec

layer hight: 0.18 – 0.40 m

motor: 45 kW FC

Gear reducer.

Drive pulley and tail pulley carried in anti-friction bearings.

Profile steel framework with standard high support legs.

Top roller station with 30° trough angle.

Standard support idlers and impact idlers.

Multi-layer rubber belt, belt cleaning by means of spring-loaded scraper.

Zero speed, misalignment- and cord switches.

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1115 CA 1

1 Maintenance Crane

(-Technical Data-)

lifting capacity: 50 t

1117 BF 1

1 Bag Filter Crusher Dedusting

(-Technical Data-)

capacity: 50 000 m3/h

dedusting: crusher and transfer point

1117 FN 1

1 Bag Filter Fan

(-Technical Data-)

capacity: 50 000 m3/h at 30 mbar

motor : 75 kW / 1 500 rpm

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Raw Material Transport:

1115 BC 2

1 Belt Conveyor

( -by Customer- )

type: trough belt conveyor

width: 1 400 mm

c-t-c distance: approx. 105 m

inclination: 20 m

conveying speed: 1.68 m/sec

capacity nom. / design: 1 000 t/h / 1 400 t/h

motor required: 110 kW

Gear reducer.

Drive pulley and tail pulley carried in anti-friction bearings.

Profile steel framework with standard high support legs.

Top roller station with 30° trough angle.

Standard support idlers and impact idlers.

Multi-layer rubber belt, belt cleaning by means of spring-loaded scraper.

Zero speed, misalignment- and cord switches.

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1117 BF 2

1 Bag Filter

(-Technical Data-)

dedusting: transfer tower

1117 FN 2

1 Bag Filter Fan

(-Technical Data-)

1115 BW 1

1 Belt Scale

for installation into belt conveyor 1115 BC 2

belt width: 1400 mm

accuracy: 0.5 % in the range of20 - 100 % of nominal capacity

1115 MS 1

1 Magnetic Separator

( -by Customer- )

installation: above belt conveyor 1115 BC 2

type: electro-magnet

operating height: 200 mm

connecting load: 2.2 kW

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1115 AN 1

1 Online Analyser

( -included in EE.00: Electrical Control & Automation Equipment- )

Measures the full flow on-line and tracks the current and cumulative pile composition. In case that the result of the analysis differs from target, signal transmission will control the speed of the apron feeders to the crushers.

Principle: each element emits gamma rays, when activated by neutrons.

Computer in the CCR (operator´s station):Operator console is the user interface with the Neutron Analyser.It communicates using a low capacitance twisted and shielded pair cable, and within the stacker reclaimer through a field bus.

The measuring quality depends on the specific belt loading, belt speed and material height.

Due to the analyzer tunnel the idler angle passing through the analyzer should be at 45° (otherwise reflection of gamma rays).

Conveyor belt should have no chlorine content and no steel reinforcement (this would have an adverse effect on signals for oxides like SO2, Al2O3 or CaO).

Distance between the belt scale and the analyzer shall be 2 - 5 m in order to achieve a short time delay.

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1115 CH 1

1 Two Way Chute

( -Technical Data- )

location: transfer tower

drive: electric

1111 FH 3

1 Iron Ore Feed Hopper


1111 VC1

1 Vibration Feeder


conveying capacity: 140 t/h

1115 BC 4

1 Belt Conveyor


conveying capacity: 140 t/h iron ore

conveying capacity: 1 400 t/h limestone

19


1115 CH2

1 Two Way Chute


location: pre bin housing raw mill

drive: electric

1115 BC 5

1 Belt Conveyor


conveying capacity: 140 t/h iron ore

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1000 Raw Material Preparation Department

1310 RAW MATERIAL STORAGE

Item Description (norm./design)

1311 BC1 Belt conveyor to stacker

1311 ST1 Stacker

1312 RE1 Bridge reclaimer

1312 BC1 Belt conveyor from reclaimer

1315 BC1 Belt conveyor

1317 BF1 Bag filter

1317 FN1 Fan

Supporting Structure, Operating Platforms

Ductwork, Chutes, Connecting Elements

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General Data

Stockyard arrangement: Longitudinal

Stockyard type: pre blending of:LimestoneAlluvium

Stacking pattern: Chevron

Storage capacity: 2 x 30,000 t (covered)

Pile width (each): approx. 28 m

Pile height (each): approx. 11 m

Pile length (each): approx. 150 m

Bulk density: 1.45 t/m3

Angle of repose: 38°

Grain size: 0 – 80 mm, 5 % >120 mm

Type of stacker: Travelling stacker withluffing movement

Stacking capacity actual / design: 1,200 / 1,400 t/h

Type of reclaimer: Bridge type

Reclaiming capacity: 500 t/h / 700 t/h

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1311 BC1

Belt conveyor to stacker

Belt width: 1,400 mm

c-t-c- Length: approx. 350 m

Inclination: 10 m

Conveying speed: 1.68 m/s

Material flow (design): 1,400 t/h

Material to be conveyed: mixed material


Temperature: ambient

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1311 ST1

Stacker

Boom Conveyor

Conveying capacity (design): 1,400 t/h

Belt speed: 2.09 m/s


Tripper

Rails

Control House incl. Operator’s Panel

Switch gears

Cables

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1312 RE1

Bridge reclaimer

Handling capacity: 500 t/h

based on a density of: 1.45 t/m3

Length of horizontal portion of chain 28.0 m

Electrical Equipment

Control

Type of control PLC unit

Control House

control house, suitable sized to contain all required electrical control and power switch gears

Switchgears

Power supply and signal exchange

Safety devices

Cables

Rails for Reclaimer

Rail length: 315 m

Type of rail: A 100 or equal

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1312 BC1

Belt conveyor from reclaimer


Material flow (norm/design): 500 t/h / 700 t/h




1315 BC1

Belt conveyor


Material flow (norm / design): 500 t/h / 700 t/h




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1317 BF1

Bag filter

Capacity: 15,000 m3/h

Dedusting: transfer points


1317 FN1

Fan

Capacity: 15,000 m3/h at 30 mbar

Supporting Structure, Operating Platforms

For access to maintenance openings and inspection areas of the relevant equipment.

Fabricated of rolled steel profiles with gratings, railings and stairs or ladder.

Ductwork, Chutes, Connecting Elements

Dedusting ductwork in steel plate design, flanges, seals, mechanical damper at every dedusting point.

Chutes designed for technological demands, inspection opening.

Connecting elements at flanges and supports as screws, washers, nuts.

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Documents

Spec. 1000