like form Presently, raw sugar factories operation are continuous This operation could only be achieved with the aid of Conveyors

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1 Conveyor Systems at the Appleton Sugar factory To be presented at the 68 th annual conference of the Jamaica Association of Sugar Technologists, November 11, 2005 at The Sunset Jamaica Grande Resort, Ocho Rios by Keith Richards & Trevor Cameron

2 Introduction Factories were small and operated in a batch like form Very time consuming and costly. Presently, raw sugar factories operation are continuous This operation could only be achieved with the aid of Conveyors

3 The intention of this paper is to: (a) Describe different types of bulk solid conveyors (b) Share some of the factors that are usually (c) considered during bulk solid conveyors selection and the general type of conveyors that best suit these factors Describe the conveyors used in the different sections at Appleton sugar factory.

4 SOME TYPES OF BULK SOLID CONVEYORS A. Belt Conveyor B. Screw Conveyors C. Bucket Elevators D. Flight Conveyors E. Vibrating or Oscillating Conveyors

5 Belt Conveyor Most commonly used Orientation - Horizontal or inclined dp depends d on the angle of repose of fthe solid. Usually made of Fbi Fabric Reinforced rubber Segmented metal (lath) Plastic

6 Belt Conveyor The benefits of belt conveyors for cane and bagasse conveyors are ; Reduction in energy consumption Ease of operation Reduction in maintenance

7 Screw Conveyors Called worm conveyor One of the oldest and most versatile conveyor Used for free flowing materials Consists of a helical screw rotating in a U- shaped trough Orientation - horizontal or inclined with some loss of capacity.

8 Screw Conveyors Compared to belt Conveyors; Less efficient Cheaper Easier to maintain Usually used; Over short distances Elevation is required greater than the solid angle of repose To deliver a metered flow of solids

9 Bucket Elevators The simplest and most dependable units for making vertical lifts Consist of buckets fitted to an endless chain or belt Can handle a wide range of solids

10 Bucket Elevators Four main types of bucket elevators. (a) Spaced Bucket Centrifugal discharge dschage elevators (b) Spaced Bucket Positive discharge elevators (c) Continuous basket elevators and (d) Super Capacity bucket elevators

11 Flight Conveyors Also called drag slats conveyors Can be used both horizontal and inclined Used to transport lumps and fibrous type material

12 Flight Conveyors Consists of; Chain - Endless with laths/slats Lugs - Attached to the chains at equal intervals Runners - Metal strips to support the chain Laths - Pulled over metal sheeting called bedding to support the conveyed solid

13 Flight Conveyors Can be arranged in parallel and with one main drive Can be used to handle large tonnages at once.

14 Vibrating or Oscillating Conveyors These are directional throw units Consists of ; 1. A spring 2. Supported horizontal pan 3. Eccentric arm 4. Rotating eccentric weights 5. An electromagnet or a pneumatic or hydraulic cylinder

15 Vibrating or Oscillating Conveyors Main disadvantage Vibration that is usually transmitted to their supporting structures

16 CONVEYOR SELECTION Factors to consider ; The throughput Length of travel Change in elevation Material Characteristics Process requirement Life expectancy of usage Comparative cost

17 APPLETON S CONVEYOR SYSTEM

18 Cane Washing Plant Used to receive the cane from the fields Slat conveyor with a bed angled at 45 0 Comprises ten (10) sets of drag chain Angled slat conveyor was used to enable washing leveling eling and handling high bulk volume

19

20 Auxiliary Cane Carrier Segmented metal belt type conveyor Specifications Three (3) sets of roller Chain Interconnected with 520 metal slats Total width is 1524mm (60") Selection Ensure that all the cane comes in contact with the knife and shredder blades Offers strength and stability in the heavy duty cane preparation process.

21 Drag Conveyor Flight conveyor Used to retrieve cane droppings from the washing plant Horizontal at its loading point but ultimately travels at an angle of 50 0 Specifications 38 lathes measuring 34 pitch of 24 total chain length per side of 76

22 Knifed cane belt conveyor Rubber belt conveyor Inclined trough Selection of this belt is based on the fact that the belt passes two tramp iron magnets Specifications 1800mm in width m/s (variable speed )

23

24 Shredded cane droppings conveyor Transports droppings from the tail end of the knifed cane belt conveyor Comprises two (2) screw 90 0 to each other. Specifications The first conveyor is 20 inches in diameter Second - 12 inches Combined length of 25 feet

25

26 Mill Inter-carriers Slat conveyors Feeds vertical Donnelly chutes located ten feet (10 ) above the next mill. Specifications Inclined at lathes 30 inches pitch

27

28 Bagasse Elevator The first bagasse carrier in closed loop system Specifications Inclination Slats - 60 Width - 41 Pitch - 2 feet

29

30 Main Bagasse Conveyor Flight carrier Fitted with Gt Gates Screens for sieving bagasse for use as bagacillo The bagasse goes to storage THEN to boilers Bagasse feed to boilers completely independent of the milling operation

31 Main Bagasse Conveyor Specifications Orientation - Horizontal Length Lathe - 120

32

33 Bagacillo screw conveyors Directly below the Main bagasse carrier Transports bagacillo to the mud mixer Two enclosed screw conveyors in series Significantly reduces dust Specifications Length - 48 Screw diameter - 12

34

35 #2 Conveyor A rubber belt carrier Carries the bagasse directly to bagasse bin

36

37 Reclaimers Carry out the task of both stacking and retrieving the bagasse for use at the boilers. Bagasse is sent to a rubber belt during the retrieving process. They are automated

38

39 #3 Conveyor Rubber belt conveyor Fed from bagasse bin Horizontal H i t lat its loading point Ultimately travels at an angle of 40 0 Discharges at upper section of Discharges at upper section of boiler

40 #4 Conveyor A slat conveyor Selected because feeds bagasse to Boiler - gates had to be installed in conveyor bedding Gates feed four twenty feet (20 ) vertical Gates feed four twenty feet (20 ) vertical chutes

41

42 # 5 Conveyor Rubber belt Returns excess bagasse from #4 conveyor to the main carrier Shortest carrier in the closed loop

43 Sugar Conveyors

44 Pre-drying sugar screw conveyors Three Screw conveyors in series Transports moist sugar to the cascading sugar dryer from centrifuges Fully enclosed for hygienic purposes p

45

46 Cascading sugar dryer Rotates about slightly inclined horizontal axis Hot air moving counter currently to sugar Sugar exits into either of two inclined screw conveyors Sugar lumps to be re-melted Export grade sugar sent to sugar belt.

47 Post drying sugar screw conveyors 2 off Located to each other

48 Sugar Belt The final conveyor in the sugar process Loading point is horizontal Changes to an angle of 70 0 Transport sugar to large 500 ton sugar bin

49 CONVEYOR CONTROL SYSTEM Used to reduce the possibility of damage to self and equipment To manage the loading of materials

50 Common devices and methods used Load cells at Appleton are as follows Control Washing plant Magnetic Pick Ups (MPU s) All belt carriers Electrical probes Control knifed cane belt speed Interlocks Prevent chokes Visual monitoring stations Cameras for monitoring boiler conveyors

51 Conveyor start up sequence

52 CONCLUSION The use of conveyors has contributed to remarkable improvement in the factory operations. Continuous operations possible by using bulk solid conveyors Control systems put in place to improve the safety of personnel and equipment To optimize efficiency, conveyor selection is of utmost importance to any factory

53 The End

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