Your partner for solutions in the handling of bulk materials

Transcription

1 Schüttguttechnik Bulk material technology Manutention des produits en vrac Your partner for solutions in the handling of bulk materials

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3 Table of contents STAG sets the pace 4 Made-to-measure solutions 5 Corporate history 8 Our technical research centre 9 Comprehensive services 10 Engineering, project management 13 Applications which our customers trust 15 The cement, lime and gypsum industries 16 3 The construction materials industry 17 The energy and power generation industry 18 Biomass and other alternative fuels 19 The chemical industry 20 Other fields of application 21 Technologies 22 Pneumatic conveying systems 24 Mechanical conveying systems 26 Discharge systems for silos and bunkers 27 Transhipment systems for bulk materials 29 Silo containers for rail and road transportation 30 Crushing, milling and other technologies 31

4 STAG sets the pace For more than 50 years now our tried-andtested products and solutions have proved their worth in day-to-day applications. The outstanding quality of our systems and their technological edge underpin the success we have had with our many satisfied customers. 4 Our core skills are in the storing, conveying and metering of bulk materials. Each of our high-quality package solutions bears the signature of our own engineers, who have developed tailor-made components and systems for a range of highly diverse process engineering requirements with their day-today practicality in mind.

5 Made-to-measure bulk materials handling solutions increase our customers efficiency Subsystems and complete systems Today, STAG systems are to be found in many industrial applications either as subsystems or complete turnkey systems. Our customers come from a wide range of industries. We are involved in the concrete, lime and gypsum industries, in wasteto-energy and coal-fired power station operations, in gravel dressing and concrete mixing works, as well as in the paper, cellulose and chemical industries. In other words, you will find STAG systems or components wherever bulk materials handling forms a crucial part of the production process. Reliable and economical solutions Our integrated and trail-blazing bulk materials handling solutions benefit from a combination of mature technology, efficiency in application and a comprehensive range of after sales services. We provide our customers and partners with expert and professional consultation tailored to the situation in hand. This leads to long-term optimum solutions perfectly geared to customer-specific requirements 5

6 Individual project management and everything from one source Our comprehensive bulk materials handling expertise in various industries and the basic technologies we have developed in-house in the areas of pneumatic and mechanical conveying and ensiling enable us to design complex package solutions that may well go beyond our usual operative range. We provide project management and engineering services, installation and commissioning of systems, test runs in our technical research centre, and a range of other services. Everything from one single source, without the need for others to be involved, from one professional partner who assumes full responsibility for the entire project. 6 Innovative systems for bulk materials storage, conveying and metering delight our customers every day Our top priority is to improve the quality of our products and services continuously and permanently. This improvement process is driven by our proximity to our customers, and expressed in personal and direct relationships with users and long-term business partners. Our innovative solutions, expertise and the personal commitment of our employees help us please our partners. «STAG moves» is therefore not just «another» company slogan, but really does reflect our corporate philosophy.

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8 Take a look at our corporate history 8 Take a look at our corporate history and you will see that our roots go back to the 1950s. Our company was founded in 1954 and at first focused on transporting bulk cement to large construction sites using our own fleet of trucks. Since then, STAG has developed into a professional and highly specialised engineering company and general contractor for the design and construction of bulk materials systems. Thanks to our past, we are fully aware of our customers needs when it comes to handling bulk materials. STAG today is an international and independent company located in Maienfeld, Switzerland, specialising in bulk materials technology in all its facets. Guaranteeing high quality standards in systems engineering and construction over the long term is one of the most complex challenges facing our company. Continuous improvement of our business processes is the foundation for optimising all the parameters influencing quality. We use the experience gained in completed projects systematically to improve our project management capabilities further as well as to improve the process safety of the technologies applied these efforts translate directly into an increase in the quality of our products and services. Basically no two systems are the same. Customers expectations of our systems are as multi-faceted as the applications and the people operating them. Our quality management efforts focus entirely on satisfying our customers.

9 We subject both components and processes to the toughest of tests in our technical research centre The test findings from our technical research centre directly influence the design and development of our tried-and-tested systems solutions. We conduct process engineering tests under real-life operating conditions, for example learning more about pneumatic conveying processes or the ensiling properties of new products. Bulk materials analyses in our own laboratory We thoroughly analyse the characteristics of bulk materials in our inhouse laboratory. We analyse the grain-size distribution, conduct Jenike shear tests, identify air retention capabilities, measure settling velocities and determine long-term compacting rates. Laboratory and field analyses provide information on the properties of the bulk materials concerned, thus allowing us to classify accurately determined parameters when identifying process engineering requirements. Using an up-scaling model we extrapolate such data to each and every system size. 9 Functionality tests before delivery This procedure yields huge benefits for our customers, as they will know that our systems have passed the litmus test before we install them. We can demonstrate all the functionalities under real-life conditions in our technical research centre. Such thorough test routines guarantee that the systems design concerned meets customers requirements perfectly.

10 Comprehensive service means that we are always at your service whatever questions you may have STAG s service package is very comprehensive. We will be there for you as reliable partners, throughout the lifetime of our systems, with fast response times and providing uncomplicated support whenever you need us. We can react quickly and flexibly through our continuously growing network of sales and service partners. 10 Our services go beyond mere systems maintenance and optimisation. They also include in-depth analyses of bulk materials, process engineering tests in our own technical research centre, the installation and commissioning of systems, inspections, revisions, spare part supply (most of them in stock) as well as technical training sessions and seminars for our customers. Services for silo wagons and bulk transporters STAG s long experience with silo wagons for transporting bulk materials by rail makes it a real expert in such logistical materials solutions. We are able to offer our customers optimum service as well as unrivalled availability through our own, purpose-built service stations.

11 Customised services for you and your business STAG draws up customised service packages for all its customers, based on their individual needs and expectations. These are then transposed into an optimum service package. Just let us know what you need or what you are interested in, and we will provide you with a made-to-measure proposal. We are always close at hand We are at your service whenever you need us with a comprehensive range of services tailored to your needs. Our experts have plenty of time for personal consultation whenever their advice is needed. They inspect your systems, optimise existing systems, and undertake repairs and maintenance work. We also keep spare parts for our customers in stock for whenever they may be required in the course of the lifetime of a system s smooth operation. You will particularly appreciate the instant performance of our service staff whenever unforeseen problems crop up, fast delivery of spares is needed, or our flying doctors have to join you for on-the-spot troubleshooting. STAG s professional and prompt services always meet the highest expectations of its industrial partners. Spare parts supply services STAG operates a comprehensive spare parts warehouse to help its customers keep their own stock levels and costs down. Thanks to our state-of-the-art spare parts warehousing and IT stock control systems, our customers can get all spares for STAG components at short notice. A large selection of third-party products used in our systems is also available at any time. The range of products includes valves, slide valves, seals and filtering materials, to name just a few. Reliable and fast shipment of the right spare parts brings major benefits to our customers. Our spare parts service-, which is an integral part of our overall customer care philosophy, contributes decisively to enduring customer relations based on trust. 11

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13 Engineering, project management and systems engineering and construction from an initial idea to a turn-key installation When it comes to systems engineering and construction STAG manages entire projects for its customers from initial ideas to turnkey installations. - Our wealth of engineering expertise enables us to be available as independent consultants and project managers to our customers. STAG s integrated approach results in optimum all-in-one solutions for the handling of bulk materials. Even if you are only interested in individual modules or components to complement an existing system, you can still benefit from our expertise. Our company is internationally renowned for its professional implementation of complex solutions. Our broad range of services fully meets the demanding expectations of our customers. From first thoughts about a customised system to a turn-key installation consolidated know-how from one single source. 13

14 Project management and consultation services Owing to our many years of experience, more and more customers either entrust us with the management of a complete project or ask for case-based consultation services. Our engineering department is an independent partner to many companies and offers support, for instance, in the following areas: 14 Our consultation activities include: Invitations to tender, submissions, evaluation of bids and contract management Exercising powers of attorney for clients ATEX explosion protection concepts Cost-benefit analyses, investment appraisals Systems engineering and construction, general mechanical engineering solutions Project management, construction-site management, construction supervision Quality, cost and progress control Risk analyses etc.

15 Applications which our customers trust Focusing on a few selected industries, the application examples on the following pages show the diversity of environments in which our products are used. 15

16 The cement, lime and gypsum industries STAG products are applied in the cement, lime and gypsum industries in a wide variety of ways. Our core competencies include the areas of alternative energies and manufacturing process applications. The handling of alternative fuels in cement production ranges from meat-and-bone meal to dried sewage sludge and plastics. We offer all the technology needed for the delivery, intermediate storage, treatment, metering and injection of the materials into the rotary cement kiln. Integral solutions for lignite handling STAG also offers turn-key solutions for lignite handling, from delivery (either by train or truck) to transhipment, and from the provision of appropriate storage capacities to the metering and injection of the material into the combustion systems. 16 Practical applications Wagon unloading systems Metering systems Mechanical and pneumatic conveyor systems Transhipment and silo systems Applications for the following products: Ash from combustion systems Bypass kiln dust Lignite Iron (II) sulphate, tin sulphate Foundry sand and granulated cinders Gypsum Limestone dust, lump lime, lime, hydrated lime and other lime products Microsilica Raw meal Sawdust Cement products

17 The construction materials industry One of STAG s core skills is the handling of construction materials, as this is where its mature technology in pneumatic conveying and mass flow discharge from silos comes to full fruition. The construction materials industry stands out for its high standards of quality and its everincreasing demands. The bottom filling of storage silos Yet another specialist application catered for by STAG is the bottom filling of storage silos for the production of mixed plaster. The material has to be fed carefully into the storage silos, free of any segregation. Our special dense phase conveying technology, combined with counter-flow bottom filling provides the best possible solution and meets the highest expectations. Tried-and-tested technologies guarantee the mass discharge flow from the storage silo. Applications for the following products: Screed and flowing screeds Dry mortar and mixed plasters Adhesives 17

18 The energy and power generation industry This industry s main applications are for the removal of ash from boiler and filter systems. They range from elaborate transportation and treatment systems to silos for intermediate storage and loading facilities for bulk transporters (containers or big bags). Handling of the materials involved in flue gas treatments The handling of flue gas cleaning additives is another field of application. Thanks to our know-how we have equipped power plants all over Europe with complete adsorption systems. These systems include all elements of bulk materials handling from delivery, storage, distribution, and metering to their injection into the flue gas treatment process. 18 Applications for the following products: Ash from waste-to-energy power plants (boilers and flue gas treatment) Ash from coal-fired power stations (electrostatic filters) Ash from sewage sludge incinerator installations (boilers and flue gas treatment) Ash from the combustion of bark, paper sludge and wood (boilers and flue gas treatment) Activated charcoal Lignite coke Bicarbonate Hydrated lime Mixtures of hydrated lime and coal Soda ashes

19 Biomass and other alternative fuels More and more bulk materials handling systems are being used, especially in the paper and cellulose industries, but also in the generation of renewable energy in biomass power plants. These solutions usually include hopper systems with innovative discharge technologies that allow for optimum storage and metered feeding of the fuels into the actual power plant systems. Practical applications Hopper filling systems Hopper discharge systems Metering systems Sizing systems Mechanical conveyor systems Applications for the following products: Barks and shredded wood waste Various sewage sludges Plastics 19

20 The chemical industry There are many STAG applications in the chemical industry. New developments frequently feature among them, but there are also volume products such as terephtalic acid, salt and soda. Our technical research centre has an experimental laboratory, where we analyse the properties of new and untested products to learn as much as possible about how to handle them. This way, we are on the safe side when assessing the functionality of our systems. Practical applications: Big bag filling and discharge systems Metering systems Mechanical conveyor systems Pneumatic conveyor systems Transhipment systems (from silo rail wagons and bulk road transporters to silo systems) Silo discharge systems 20 Applications for the following products: Salt Soda Terephtalic acid Washing powder etc.

21 Diverse fields of application in other industries Apart from the applications we have presented so far we have also managed and completed projects in industries that we have not listed separately. Basically STAG is your first port of call for all questions concerning the handling of bulk materials. Words like «impossible» and «no» or «never» are not part of our vocabulary. We accept the challenge to find the best possible bulk materials handling solution for each and every customer. Simply give us a ring or send an and give us an idea of your problem. 21 Practical applications To give you an even greater insight into the diversity of our activities we have listed some further projects which we have successfully implemented These examples complement this review of our far-reaching fields of operation: Salt stores and municipal salt transhipment systems Vacuum/pressure pneumatic conveying systems to clean silo wagons Slag processing and transport systems for waste-to-energy power plants Sludge handling in water treatment plants Hydraulic transport and metering of glass beads All types of train-to-truck transhipment systems

22 Technologies for reliable, safe and economical installations The overall quality of a complex system is only as good as the quality of its individual components. This is why we design and manufacture the key components of our systems ourselves. Technologies that we have developed in-house and improved continuously on the basis of our many years of experience form the backbone of our reliable, safe-to-operate and economical systems. Another advantage of our corporate strategy is our independence in the market. The wealth of experience gained from implementing our projects contributes to the permanent development of our technologies. Having our technical research centre allows us to test our newly-won findings directly, and then to implement them thus turning ideas into first-class products. 22 Operational safety and economic efficiency The highest levels of operational safety and maximum economic efficiency are what our customers expect from their bulk materials transfer systems. Customer benefits are always at the top of STAG s agenda and our experts focus on them right from the word go. STAG technologies Pneumatic conveying systems Mechanical conveying systems Discharge systems for silos and hoppers Transhipment systems for bulk materials Silos for rail and road transportation Processing of bulk materials (crushing and grinding) Filling heads for small containers Filling heads for vehicle-mounted containers Sampling systems for pneumatic conveyors

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24 Pneumatic conveying systems STAG supplies conveying technology for all types of bulk materials applications involving fine and large-grained powders, free flowing or viscous products, transportation over short or long distances, large or small conveying capacities, and standardised or specialist applications. 24 Two different pneumatic conveying procedures Whenever pneumatic conveying systems are an option, our customers can choose between two different technologies. The decision is taken on the basis of the individual customer s requirements and its immediate application. Depending on the situation we either use the tried-and-tested STAG dense phase conveying system with transporters and the unique Dense Flow Pipe System (DFS) or the conventional lean phase conveying systems with injectors and butterfly valves. Either system may be the system of choice and have its respective benefits in the field of application. Often some combination of the two technologies is needed to arrive at an optimal solution. Conveying pipes made-to-measure for the application in hand Conveying pipes tailored to the product and the application in hand are a crucial prerequisite for the smooth operation of any transportation system. Specialist solutions like pressure-monitored double-wall conveying pipes are part of STAG s standard range. The use of appropriate direction change elements in the shape of standard elbow pipes (with or without wear-and-tear protection) or of STAG s tried-andtested flow diverter pots must be well planned. The diverter valves are also of crucial importance. The flow diverter pots, combined with appropriate fittings at the diverters outlets, are functionally equivalent to a high-quality diverter valve.

25 Transportation involving fluids Transporting fluids involves another pneumatic conveyor system that is normally used for large mass flows. The bulk solids are fluidised and thus made free-flowing, and gravity does the rest. That means that an appropriate slope must in each case exist between the location of the product and its intended destination. Investigation of the properties of bulk materials None of the conveyor systems addressed can be safely discharged without detailed knowledge of the properties of the bulk materials concerned. STAG disposes of decades of experience of projects that have been implemented and of extensive know-how in this field as a result of the findings of its own technical centre. 25

26 Mechanical conveying systems The basic unit for the mechanical conveyance of bulk materials for our most frequent fields of application is the chain conveyor, which is also known - under the name of its inventor - as the Redler unit. The function is based on the movement of an endless chain, that is driven in a rectangular trough by an interlocked transmission chain. In addition to its use as a horizontal conveyor up to a length of 40 meters, chain conveyors are also used as slope conveyors and vertical conveyors with slope angles from 25 to 90 degrees and with possible conveyance heights up to 30 m. The robust equipment is applied as discharging, loading or separating units. In the case of horizontal conveyors using intermediate troughs, as many loading and discharging points as desired can be arranged, which makes this system extremely flexible. 26 Pipe and trough feed screws, bucket conveyors and conveyor belts STAG deploys all other mechanical conveyor techniques, as well as chain conveyors. We have acquired specific knowledge of discharging from and deploying pipe and trough feed screws, bucket conveyors and conveyor belts. Such equipment is used whenever it can contribute to an optimal overall solution. Strengths of chain conveyors The advantages of chain conveyors can be summarised as follows: they take up little space they can be easily integrated into existing plant closed and dust-tight method of construction suitable for bulk solids at high temperatures can be used for bulk materials that abrade construction is to a large extent self-supporting explosion-proof (conforming with ATEX)

27 Discharge systems for silos and bunkers The storage of bulk materials in silos and bunkers calls for individual and mature discharging systems. The bulk material concerned predetermines the technology to be deployed. Appropriate solutions and variants of them are determined in our technical centre and implemented using empirical values obtained from STAG s previous relevant experiences. Basically we distinguish between mechanical and pneumatic discharge systems. SiLex SiLex, a mechanical discharging system, was specially developed for slow-flowing products, or products that are not fluidisable or are only very poorly fluidisable, with a bridging diameter of a maximum of two thirds of the silo diameter. Particular attention was paid, in the course of this development, to the ease of retrofitting the system into existing silos or into funnel-shaped bunkers. 27 Sliding frame thrust plate carrier The sliding frame thrust plate carrier system is another mechanical discharging system. This technology is deployed in round silos with flat bottoms, and when the bulk materials concerned have very poor flow properties and large bridging diameters. It is, however, also deployed in applications in which a large variety of products is expected to be in the same silo. The transmission or thrust plate carrier discharge for bunkers works on the same basis, but is deployed specially for the emptying of rectangular, large surface-area bunkers.

28 Chain conveyor Chain conveyors are also a tried and tested technology for discharging from silos and bunkers. This discharging system is deployed particularly for slow-flowing products and for sludges. The chief advantage of its design is the longitudinal slot shape that results from it, and that the drawing-off can be varied and metered. Pneumatic discharging technologies As well as the mechanical discharging techniques mentioned above there are pneumatic discharging systems. The same principle applies here, that different systems are installed for different products. Fluidised jets in different versions are deployed as pulse jets or triplex jets, but fluidised lava or fluidised streams are also deployed in silos with cones or flat-surface floors and for bulk materials that can be more or less easily fluidised. According to the version in use, service and inspection are likewise possible from the outside, as is retro-installation. 28 Integration of the research centre s findings None of the systems addressed can be safely discharged without detailed knowledge of the solid matter concerned. Our empirical values and matching laboratory tests as to air retention capacity and shear testing in our research centre ensure that we are absolutely sure about our interpretation of such systems.

29 Transhipment systems for bulk materials Bulk materials are increasingly transported in silos by rail or by silo trucks. The latter are deployed for local delivery to customers. Transhipment facilities with appropriate storage capacities are the link between them. It is, however, the case that more and more major building sites are equipped with transhipment facilities. But it also the case that more and more smaller customers and other users of bulk materials are settling for rail transport. STAG is a leader when it comes to transhipment and rail unloading facilities, having constructed more than 40 such plants of its own. Simple handling, combined with great efficiency and operational safety, are the main features of these STAG plants. Cement, lime, gypsum, salt, lignite, micosilica, flue ash, and terephtalic acid are the main products passing through such facilities, but many other bulk products use them too. Semi- and fully-automated rail unloading systems Several decades of experience of pneumatic rail unloading facilities has led to this technology having been developed and optimised. We are thus in a position to offer semi- and fully-automated rail unloading facilities that not only simplify handling, but also reduce the need for manpower. Used in combination with STAG s Dense Flow Pipe System, movement performances are improved, energy consumption is reduced, and operational safety is enhanced.

30 Silo containers for rail and road transportation In our capacity as general representatives of FFB Feldbinder-Spezialfahrzeugwerke within Switzerland, with our own service workshops, we make reliable business partners for firms using silo containers for rail and road transportation. A particular STAG strength is the engineering of rail containers and the maintenance and servicing of bulk materials wagons in its own workshops. STAG engineering for silo containers as rail car superstructures is recognised and enjoys a distinguished international reputation. Our customers are the European and Asian manufacturers of complete rail car systems. 30 Re-development of the rail car The new Holcim rail car represents the latest joint project development. Not only has the discharging mechanism been redeveloped but there is also now a fully automated pneumatic closure as a replacement for manual dome covers. The main advantage of this is that automation of the dome closure forms the corner stone for developing fully automatic loading of silo rail cars and silo trucks. This development is a prerequisite for the total automation of loading processes. Another of the new product s advantages lies in accident prevention. The possibility of remote silo servicing means it is no longer necessary for a man to climb up on to the rail car or truck, thus eliminating the danger of him falling, especially in bad weather and in the winter.

31 Crushing, milling and other technologies It is necessary to dress and to pulverise bulk materials for various applications involving pneumatic and mechanical materials handling technology, and also in silo technology. One has to distinguish basically between crushing and milling processes. In crushing processes it is only the oversize that is pulverised, while in milling processes the entire spectrum of grain sizes is changed. STAG lump breaker STAG s lump breaker is a high-grade, quality product, which is deployed principally in the chemical industry and in applications where the requirements for aggregation are high. A single or double-face lump breaker is deployed, according to individual requirements and the throughput capacity. STAG impact mill STAG s impact mill has been specially developed for the treatment of boiler ash from combined heating and power stations, and for the ensuing pneumatic conveyance of loading into silos. By using the impact mill the ash arising is treated in such a way that it cannot lead to any functional disturbances in its subsequent pneumatic movement, when being discharged from the silo, or in any truck unloading procedure that may be necessary. 31 The filling of big bags and bulk materials containers Another field of application for STAG components is the unloading of big bags and the loading up of bulk materials containers of all kinds. Big bag unloading facilities are available as standard equipment for the most varied of applications. Other technologies from STAG s comprehensive range: Small contain filling-head, activated pneumatically and dust-tight Vehicular container filling-head, used for the filling up of road truck and rail car containers for bulk materials Samplers, for taking samples in pneumatic supply pipes.

32 STAG AG Industriestrasse 11 CH-7304 Maienfeld STAG GmbH Hauptstrasse 8 DE Saarlouis Tel: +41 (0) Fax: +41 (0) Verkaufsniederlassung DE Raisting office@stag.net office@stag.net