The KOCH Pipe Conveyor KOCH Technology, Management and a Passion for Projects Karl-Koch-Straße 1 66787 Wadgassen/Germany Tel.: +49 (0)68 34 / 470-0 Fax: +49 (0)68 34 / 470-339 E-Mail: info@kochtrans.de www.pipeconveyor.de 2005/9, E5 KOCH Transporttechnik GmbH
No. 1 in the World 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 Superior Features. 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, securely protected 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 environmentally 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 investment decision. KOCH Pipe Conveyors Overcoming the Spatial Challenge: inclines up to 30 any desired horizontal and vertical curves with minimal radii of up to 45 meters 60% spatial savings in contrast with conventional systems The KOCH Pipe Conveyor the Clean Alternative protects the environment from volatile materials clean conveying routes protects the conveyed material from external contaminants The Koch Pipe Conveyor : A System without Limits axial spacings of 5 km and more without transfer 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
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. In the material loading area, the conveying belt is open. The conveyed material is supplied in the same way as in a conventional belt conveyor. Then special devices enclose the belt carrying the conveyed material. The diameter of the closed pipes can be selected depending on the conveyed material between 150-850 mm for conveying volumes up to 9,200 m 3 /h. ply: steel or fabric At that point, the belt forms a sealed pipe for the entire conveying line. Thus, the content is protected against external influences while the environment is protected against any potential material losses. The flexible belt pipe design allows for directional changes without requiring transfer stations thereby enhancing both cost effectiveness and operating reliability. The belt opens on its own before the material discharge point and the material is discharged. conventional discharge point Following the material discharge, the belt is closed again this excludes the possibility of contaminating the conveyor line with spilled material. Panel 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. running side carrying side moulded edge feed belt loading point closed pipe feed belt belt idlers conveyed material return belt The heart of the KOCH Pipe Conveyor : an elastic belt with special design characteristics to assure a long service life despite widely fluctuating loads. The KOCH Pipe Conveyor in Operation Ring distributed idlers guide the belt pipes in the KOCH Pipe Conveyor to the discharge. A proprietary system assures quiet operation. Special mechanisms guarantee that the belt pipes are not overloaded.
Customized Designs for Every Application. 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 material pellets, filtered slurries and biomass, coarse overburden and the finest powders such as gypsum or cement. KOCH Pipe Conveyor handle conveying tasks in the basic industries and in power plants, in lime mills and cement plants, in the paper products, particle board and synthetic fiber industries, as well as in smelting plants all in an environmentally secure system that 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 overland conveying. Designed individually based on the client s requirements, adjusted carefully in every detail to the environmental parameters as well as the characteristics of the conveyed material. ❶ ❶ ❸ Kronospan Inc / Switzerland, Particle Board Plant Secure conveying of wood chips directly across roads and rail tracks. KOCH s design to cross rail tracks and roads without supports: a 57 m long curved bridge with both horizontal and vertical curves. Marti Inc / Switzerland, Lötschberg Base Tunnel Clean and secure in the tightest space: During the construction of the Lötschberg Base tunnel KOCH Pipe Conveyors transported overburden, concrete gravel and quarry sand using a small window gallery parallel to the rolling traffic of the construction site. The system becomes extra narrow for that purpose. Two of the conveyors operate as a dual strand with one on top of the other while the third runs transversely along the tunnel ceiling at times in 3 D curves with radii ranging between 75 and 160 meters. Lenzing Inc / Austria, Synthetic Fiber Production Conveying remnant materials through a tight, haphazard layout. The KOCH Pipe Conveyor handles the task brilliantly. To integrate the plant seamlessly into the existing environment, the conveyor runs a line at times 30 m high carried by specially designed supports mounted on existing buildings. ❺ Deutsche Steinkohle AG, SBW Ensdorf / Germany, Bituminous Coal Mine Difficult topography, steep inclines. This KOCH Pipe Conveyor transports tailings over virtually impassable terrain including a 28 incline to reach the mine pile. The unit is designed to be mobile in order to compensate for pile depressions without any problems. Famsa / Switzerland, Stone Quarry Virtually impassable mountainous terrain with inclines up to 29, strict protective laws for flora, fauna and residents: This KOCH Pipe Conveyor successfully carries up to 500 tons of gravel in an environmentally protective manner from the quarry to the plant located 208 m lower and then carries up to 300 tons of slag back up on its return. The plant also makes use of the elevation drop to generate electrical power. CEZ a.s., Elektrarna Melnik / Czech Republic, Power Plant Transporting wet ash from the power plant to the disposal area: The 2 km long KOCH Pipe Conveyor fulfills its task by winding its way through the plant, the surrounding landscape and an embankment using 3 horizontal and 4 vertical curves. In order to be able later to return the ash for processing into the power plant, the conveyor system is designed to be reversible convertible in 24 hours. ❸ ❺ ❹ ❹ Wismut Inc / Germany, Uranium Mining Stockpile Transporting contaminated material for a distance of 1.8 km over streets, a river and an intercity rail line passing inhabited areas. The KOCH Pipe Conveyor successfully handles all its tasks at no additional cost. Following a retrofit to increase capacity after 7 years of reliable operation, the system can now convey the increasingly common clumpy material as well as the rolling bulk material. Malayan Cement / Malaysia, Cement Production In this unit, fresh cement is conveyed to a ship loading station at sea securely protected in the KOCH Pipe Conveyor against the high humidity. Since 1995, the system has proven to be highly reliable and available for operation under extreme conditions.
❶ ❶ VAI, Lime Plant Steyrling / Austria Several sequential pipe conveyors to transport lime dust and quick lime over a heavily trafficked federal highway and a rail line. The KOCH design is all-inclusive right through the screening system to distribute the material according to particle sizes. Thyssen Steel Inc / Germany, Smelting Industry New avenues in steel plants: In this KOCH system, for the first time a pipe conveyor transports the smelting sand from the pig iron production process guaranteeing low noise and contaminants emissions. 3 post drying silos with discharge belts, one distributor tower with a ❸ ❹ ❺ ❸ ❹ ❺ rotating chute to feed the material onto a transverse belt conveyor to supply the adjoining cement plant or onto a quay belt conveyor to supply a mobile KOCH ship loading unit complete this system. Petrozuata / Venezuela, Refinery Terminal A 2.3 km long KOCH Pipe Conveyor brings moisture sensitive sulfur as well as petroleum coke dust free and safely to a loading platform in the open sea. Aside from the ship loading with the loading quay, a 1.8 km long jetty and a specially designed KOCH ship-loading unit, this turnkey KOCH system includes a storage facility with complete infrastructure, stacker and portal reclaimer. VCP Votorantim / Brazil, Paper Mill 2 KOCH Pipe Conveyors, one to transport wood chips and the other for biomass. The fact that the line passes over a settling pond necessitates support spacings of at times 40 meters with very small curve radii. KOCH belt conveyors supplement the system. Nuh Cimento / Turkey, Cement Production The KOCH Pipe Conveyor as switch hitter: This system conveys as needed clinker or cement for harbor loading and simultaneously brings back coal following the turnaround on the return belt to the factory. The unit passes the public roads and places along its path in an underground tunnel. The narrow construction design of the pipe conveyor minimizes the tunneling costs. MUEG / Germany, Lippendorf Coal Fired Power Plant At a length of approximately 2.2 km, the longest dual pipe conveyor in Europe is also one of the most productive, conveying approximately 1.1 million tons of wet and dry ash, gypsum and filter cakes as well as 125,000 tons of REA water (in a parallel strand of fiberglass pipes) per year. This pipe conveyor is part of a complete KOCH plant for power plant waste disposal including the innovative KOCH Reaction Belt for the preparation of ashes and REA waters. Heidelberger Zement AG, Beremendi Zement / Hungary, Cement Production Innovative design to simultaneously protect the environment and the material: In this KOCH circular blending system, we for the first time installed a pipe conveyor to carry off the clay/ lime mix. The requisite even feed of the pipe conveyor is assured by special mechanisms such as a rotary disc and a proprietary electronic control. The KOCH Pipe Conveyor : Flexible and Expandable Right up to Turnkey Industrial Systems. For larger tasks, the entire KOCH product line spanning all output levels is available to supplement the pipe conveyor. Thus, we design and supply customized conveying systems for any requirement right up to turnkey systems, for example, power plant coal feeding systems or port loading and unloading facilities. Service for smooth operation and long service life KOCH Pipe Conveyors are characterized by their long service life and reliability. Each installation includes a thorough system training cycle and comprehensive technical documentation to assure smooth operation. A fully trained staff handles the start up and commissioning and is always available during the service life of the unit: for maintenance and conditioned monitoring and servicing based on a special KOCH inspection program, either as express service or to adapt 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? PCLA / Slovak Republic, Cement Production A pipe conveyor for the dust free transport of coal to the cement kiln part of a complete KOCH coal feeding system consisting of belt conveyors, round blending pile, stacker, bridge reclaimer, sampling units, magnetic separators, belt scales and a covered railcar dumping unit.
KOCH Technology, Management and a Passion for Projects KOCH Transporttechnik GmbH Karl-Koch-Straße 1 66787 Wadgassen/Germany Tel.: +49(0)68 34 / 470-0 Fax: +49(0)68 34 / 470-339 E-Mail: info@kochtrans.de www.pipeconveyor.de 2005/9, E5