3-DEM and ASGCO FLO-CONTROL

Transcription

1 3-DEM and ASGCO FLO-CONTROL

2 3-DEM TRANSFER POINT DESIGN AND FABRICATION 3-DEM Transfer Point Design The performance of transfer chutes is an essential part to the productivity of the conveyor belt systems in the bulk solids industry. Transfer point design, fabrication and installations utilizing ASGCO 's 3-DEM (Discrete Element Methods) chute analysis program is a revolutionary way to handle granular and particulate material by streamlining the process from the point where material leaves the head pulley until it is deposited onto the receiving conveyor for a more deliberate control of the material as it flows from one conveyor to another. 3-DEM Transfer Point Design controls the dust by keeping the column of material together so that air does not become entrapped in the material flow, then forced back out of the flow carrying dust, when the material is loaded on the receiving belt. These techniques are easily applied to both existing and new installations, resulting in significant cost improvements and system efficiencies. Discrete Element Methods (DEM) ASGCO 's 3-DEM Complete Transfer Point Design and Fabrication, is a revolutionary way to handle granular and particular material handling problems through computer simulation and 3-D CAD. Combined with our conveyor and material handling knowledge and engineering capabilities we are able to make transfer point problems a thing of the past. Increase Production Capabilities - by helping to eliminate spillage, chute plugging, belt wear, dust control and noise. Optimize Life on Conveyor Belt and Components - by minimizing impact and top cover wear by using a soft or curved chute loading design. Minimize Material Spillage - in the design by center loading the material, load the material at a uniform rate and optimize the material flow in the direction of travel after the belt is fully troughed. Reduce the Need for Dust Control and Suppression - by minimizing the dust through loading the material at a uniform rate through a curved of soft loading design, maintain effective skirting, internal wear liners and dust curtains staggered throughout the loading area. There are ten steps that need to be completed to have a troublefree transfer point. The complete conveying system needs to be evaluated and then a comprehensive design analysis provided to incorporate all of the necessary goals outlined by the customer along with the changes discussed to reduce the airborne dust while continuing to maintain full load capacity. 1. Take current drawings of existing transfer and render them accurately in 3-D CAD and fill out Data Sheet. 2. Identify chute geometry restriction and manufacturing limitations. 3. Identify customer project goals (i.e. flow restrictions, dust emissions, optimize chute and belt life). 4. Identify material properties and develop representative particle description. 5. Make design changes to chute geometry. 6. Simulate performance using 3-DEM Chute Design software. Before After 7. Evaluate simulation results and choose the best design that meets the project goals. 8. Detail the new design for manufacturing. 9. Manufacture the new transfer point including other conveyor components. 10. Installation of the new transfer chute and other conveyor components (i.e. belt cleaners, skirting systems and load zone beds or rollers). 1

3 3-DEM /FLO-CONTROL CASE STUDIES Improving Conveyor Belt Tracking and Reducing Airborne Dust on a Redesign of a PRB Coal-Fired Power Plant Conveyor Transfer System PROBLEM: This transfer point was a major problem area for the PRB coal yard. While in reclaiming operation, the chute would build- up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added, but the problem still remained. Due to the angle of discharge onto the 60 receiving conveyor, off center loading caused serious belt mistracking and constant spillage. SOLUTION: The existing transfer chute was modeled and re-designed using ASGCO 's 3-DEM material modeling software, to allow the coal flow to smoothly transfer from the supply conveyor to the center of the receiving conveyor. This new design eliminated the off center loading conditions due to the varying coal load which cause belt mis-tracking and material spillage. The new design loads the coal onto the receiving belt directly in the center and flows in the direction of belt travel. Airborne dust and spillage is virtually eliminated with this new design. HOOD SPOON RESULTS: The new transfer chute now operates without build-up and the PRB coal is center loaded onto the 60 receiving belt at the same speed and direction. This reduces wear and belt mis-tracking as well as fugitive dusting and spillage clean-up. There is no longer a need for chute vibrators and the plant has still not re-installed the heaters. ASGCO Helps Northeastern US Coal Burning Power Station Improve Material Flow and Reduce Maintenance Costs PROBLEM: A major US coal burning power plant was experiencing constant chute plugging after recent upgrades to its coal yard. These issues were compounded by spillage due to holes being formed almost immediately in the new round chutes that were installed. Because of the round design of the chutes, repairing the holes and replacing the liners became cost and time prohibitive. SOLUTION: After surveying the loading system, ASGCO technicians recommended a 3-DEM Chute Analysis program to redesign the failing chute sections, along with an advanced liner system that would allow for easy maintenance and minimal stocking. The 3-DEM cutting-edge simulation identifies the optimal design for full capacity flow under all conditions with no build up or plugging while also decreasing the wear on the internal liners. BEFORE AFTER RESULTS: The redesigned ASGCO Flo-Control chutes completely eliminated the plugging and buildup and allowed for increased tonnage flows even with high moisture, low quality coal. Because of the efficient design of the new ASGCO Flo-Control chutes, internal liner wear life was increased over 12 times longer in high impact areas of the chutes. When these wear liners are due for scheduled replacement, the installation can be performed in as little as 3 hours, using standard sized liners that can be stocked for a very low cost. 2

4 FLO-CONTROL (HOOD & SPOON) ASGCO Flo-Control transfer point solutions solve the problems of material flow from the discharge pulley, through the chute until it reaches the receiving belt conveyor. After analyzing the flow of the material we incorporate a Hood deflector as the material leaves the discharge pulley. This Hood deflector with adjustment control allows for fine-tuning of the material stream to direct the material for the optimum flow. The receiving end or bottom end of the conveyor, ASGCO utilizes a Spoon design to ensure uniform direction of the material without impact to the chute or the receiving conveyor belt. The new chute can incorporate a new hood insert or a complete remodeling of the entire top and bottom of the transfer point. The head chute which will direct the material down through a lower Spoon section that will direct the flow in the direction of belt travel and centered on the belt. The ideal transfer point design would need to take into account the following: Center load the material Load material at a uniform rate Load in the direction of belt travel (receiving conveyor) Load at the same speed the belt is moving (receiving conveyor) Load material with minimum impact At the same time, the transfer point structure has to prevent: Plugging Dust creation Chute wear and belt wear Material spillage Complex transfers are not a problem. ASGCO has the expertise and the experience to solve transfer point challenges in a multitude of applications: Stackers and Reclaimers Crusher Feed and Discharge Large Vertical Drop Ship Loaders Heated Chutes Bucket Reclaimer...and many more! SPOON Ceramic Liner HOOD Adjustable material deflector (hood) lined with impact and abrasion resistant wear liners are easily maintained to direct and concentrate the material flow to the center of the chute. The adjustable impact and abrasion resistant lined Spoon bottom chute ensures that the material is soft-loaded at approximately the same speed as the receiving conveyor, is also properly center loaded on the conveyor, as well as designed to eliminate any flow restrictions that would cause the potential for buildup. Key Conveyor Components for Efficient, Safe & Reliable Transfer Point Design To create an efficient, safe and reliable transfer point there are many essential products that eliminate spillage, control dust, support the belt and make the system run safer and more productive. - Load Zone Support - Conveyor Belt Support - Effective Belt Cleaning - Flo-Control Chutes - Skirting & Dust Control - Safety & Maintenance - Conveyor Wear Liners - Tail Pulley Protection A positive load zone belt support coupled with an easy to adjust skirting seal is a must. Belt alignment is also very important to insure that the belt enters the load zone properly and the load is centered on the conveyor. Properly designed and installed belt cleaning systems are a key part in minimizing carry-back and dust control. Provisions must also be made to allow for easy access for maintenance and replacement wherever possible. All of these components must work together as a complete system. 3

5 3-DEM SOLUTIONS Benefits of Hood and Spoon Design: High Impact and Low Velocity are Avoided Coherent Constant Speed Loading Prevention of Spillage, Wear and Degradation Heavy Duty Chute Inspection Door Flo-Control HOOD The HOOD maintains coherent stream without turbulence. Skalper Primary Belt Cleaner The design of a transfer point will greatly affect the life of components as well as maintenance costs and safety. Flo-Control SPOON The SPOON places load on receiving conveyor with proper speed and minimal impact, minimizing dust creation and material degradation. Heavy Duty Chute Inspection Door Clamp-Mount Chute Tail Box Slide-N-Roll Impact Cradle Bed Slide-ler

6 CONVEYOR COMPONENTS BELT CLEANERS Skalper Primary Belt Cleaner Our newly enhanced Skalper series of conveyor belt pre-cleaners have been installed and have solved carry-back problems all over the world. The simple and highly effective Skalper belt cleaner removes carry-back from the conveyor system. Excellence performance of our patented one piece blade maintains an effective cleaning edge throughout the life of the blade E-Z Torque Tensioner (lifetime warranty) torsion style tensioning system provides a constant consistent tension throughout the life of the blade Quick-Change Blade stainless steel pin blade change-out system is a one-minute, no-tool operation. Blade Indicator Wash Box Belt Cleaning System The ASGCO Wash Box is installed as a secondary conveyor belt cleaner and is designed to work on the return side of the conveyor belt. Fully enclosed system that contains the wash waste fluid and carry-back Dual sets of Razor-Back Secondary belt cleaners and dry wipe. Two spray bars, nozzles and valves soften the carry-back to provide gentle cleaning. Removable Inspection/service doors on each side, with wash down hose included. Can be customized to meet exact application needs CONVEYOR SAFETY Chute Inspection Doors Chute Inspection and Access Doors are a necessary part of any material handling system. Add an inspection door to your existing head chute for access to cleaners, for chute clean-out, and blade change-outs. Safety - inspection screen guard standard on every door for the ability to safely inspect equipment while it is running. Re-designed Frame - has a 45 degree flange to shed fines from accumulating on the interior of the door. Low Profile Steel Construction - with EPDM dust seal that can withstand temperatures from -40 degrees F to 200 degrees F. Safe-Guard Return Idler Guard ASGCO Safe-Guards prevent injuries from pinch points and will catch the return idler or other material if it should fall. Complies - with MSHA Title 30 mechanical equipment guards. Durable UHMW - slotted cage helps prevent material build-up. Easy to Clean Out - drop pin / wedge clamps to be able to drop and open side of the cage for maintenance. Universal Mounting Brackets - can be used with CEMA B, C,D and E (and F) idlers up to 7 in diameter. Mounting Hardware - made from powder coated A-36 steel or stainless steel. Safety Screen Custom Sizes Available. Fully adjustable for full range of idler sizes. 5

7 CONVEYOR COMPONENTS LOAD ZONE SUPPORT Slide-lers ASGCO Slide-lers give you the ability to change rolls under the loading skirt area without having to remove adjacent idlers. This allows the Slide-ler to fit into tight or confined spaces ensuring proper rolling support and changing an idler roll just got easier. Improves Safety - by allowing maintenance to easily remove the rollers without having to remove any of the idler frames. Rollers slide out for easy removal. Slide-N-Roll Slide-N-Roll Beds provide for an effective load support while helping to eliminate dust and spillage in the conveyor load zone. Increase Belt Life - by removing the gaps, scalloping and pinch points between the belt and the skirt liners that can cut and gouge the belt. Seals the Transfer Point - by supporting the belt edge on a flat surface that allows the skirting to work more effectively for an effective seal. Slider bars are easy to remove and replace. Pro-Zone Pro-Zone is a patent pending modular conveyor belt load-zone system that optimizes the sealing for air/dust tightness of the receiving conveyor belt. Environmentally Friendly due to significant reduction of airborne and fugitive dust. Increased Productivity and longer conveyor belt life because the completely sealed load zone helps eliminate material turbulence and conveyor belt cover abrasion. SKIRTING & ADS DRY FOG DUST CONTROL SYSTEMS Clamp-Mount Skirting Our Clamp-Mount skirting clamps help eliminate spillage and dust in the conveyor transfer point. The Clamp-Mount installs easily and allows for one person to replace or reposition the skirt rubber. Increase Conveyor Performance - by helping to eliminate spillage and dust in the loading zone. Reduce Downtime - by the simple clamp adjustment and release to allow repositioning or changing out skirting in minutes versus hours, without tools. Alternative Clamps include a stainless steel, a mine-duty, a low-profile 6 (150mm), and an economical single clamp. Standard Double Clamp-Mount Low Boy Clamp-Mount ADS Dry Fog Dust Control System ADS Dry Fog Dust Collection Systems are highly efficient, patented, fine particulate scrubbers that use very little water, no chemicals, and do not increase the overall moisture content of the flowing material by more than a few hundredths of a percent. The ADS Dry Fog System is offered through a partnership with The Raring Corporation. ADS Dry Fog systems - significantly reduce fugitive dust from a variety of material handling points, including conveyor transfer points, trippers, reclaimers, crushers, screens, ship loaders-unloaders, and discharge chutes. 6

8 10/2015 ASGCO Complete Conveyor Solutions 301 Gordon Street Allentown, PA T T FX