Cement Works - 1 - Limestone Crusher Building

Discussion in 'Industrial & Commercial' started by Jim Freight, Aug 20, 2020.

  1. Jim Freight

    Jim Freight Full Member

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    Finally started on the structures that will comprise the cement works and adjacent colliery.

    The cement works core is the Walthers kit with extra buildings added for both pre and post activities of cement production, including initial crushing, another Walthers kit, plus additional structures for pre-mix/grind and post processing of the raw clinker before the silos. The colliery the other side of the industrial branch line track provides fine coal for the furnace. This arrives via overhead conveyor into a hopper for weighing and storage before processing in the fuel mill attached the cement works building at the flame end of the rotary furnace.

    Limestone arrives by dumper truck from the quarry and is elevated to the roof entry point. The crushed material leaves via the hoppers into railway wagons for external customers or via the adjacent conveyor exit to the bulk storage warehouse of the cement works.

    The pictures here show the initial assembly and painting of the crusher building which has been converted to be a 'left-hand' version of the original kit which was a little tricky in places. Anyway this is my first attempt at such a structure and spray painting which so far is a mix of acrylic Expo primers and a little Humbrol silver. I have tried so far to create a used but not neglected look to the buildings.

    The next stage will be to further flatten the satin shine of the silver with a matt coating before adding more weathering with powders, and further detail when bedded down into the layout.

    Constructive comments and suggestions welcome, Jim

    1_DSCF7641.JPG 2_DSCF7644.JPG 3_DSCF7646.JPG 4_DSCF7636.JPG 5_DSCF7638.JPG
     
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  2. Kimbo

    Kimbo Staff Member Moderator

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    Loverly modelling Jim, :tophat:
    Kim
     
  3. Jim Freight

    Jim Freight Full Member

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    Thanks :)
     
  4. paul_l

    paul_l Staff Member Administrator

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    Very nice Model Jim, I have a couple of Walther Kits sitting in the todo box, seeing your build I may have to pull my finger out and give them a go.

    Paul
     
  5. Jim Freight

    Jim Freight Full Member

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    Thanks Paul, this and the other buildings for the colliery and cement works have sat on my 'todo shelf' for 9 years! :facepalm:
     
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  6. ianvolvo46

    ianvolvo46 Staff Member Moderator

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    Quality build :tophat::tophat::tophat:

    Ian vt
     
  7. jakesdad13

    jakesdad13 Staff Member Moderator

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    That looks amazing Jim :tophat::tophat::tophat::tophat: I reckon I've seen a YouTube video on building something very similar a year or so ago. The finished model once weathered up looked fantastic. If an O gauge version was available I'd be very tempted!

    Cheers, Pete.
     
  8. Keith M

    Keith M Staff Member Moderator

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    Hi Jim.
    I too have used the Walthers Cement Works kit on my layout, though mine is laid out in a different format since the kit itself is very adaptable. I also bought the motorising kit for the rotary furnace, controlling it it on DCC by my Lenz handset. The buildings lend themselves to plenty of additions and alterations and it's easy to do with matching 'Plasticard'. I also added the lightning conductor and aircraft warning light to the chimney though stopped short of smoke due to the smoke detector in the room.

    IMG_0607.jpg
     
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  9. Keith M

    Keith M Staff Member Moderator

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    IMG_0604.jpg
     
  10. Keith M

    Keith M Staff Member Moderator

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    IMG_0606.jpg

    Keith.
     
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  11. Jim Freight

    Jim Freight Full Member

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    Thanks Ian :)
     
  12. Jim Freight

    Jim Freight Full Member

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    Thanks Pete.

    The video you maybe thinking of is :- where the New River Mining model is enhanced, it is one of my key references for building and 'decorating' my colliery and cement works structures.

    Jim :)
     
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  13. Jim Freight

    Jim Freight Full Member

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    Looks very good Keith.

    Is the cement works chimney that height or have you increased it, at that height, added to the upper deck of my layout which is multi-deck I think I will have to put soot stains on the ceiling too :avatar:.

    I like the added touch of the incoming 3 phase electrical supply with pole mounted transformer, just noticed that on a picture this afternoon of the Edna mine in Colorado on which the New River Mining kit is based, I must consider that too.

    The rotary kiln rust looks challenging to paint and weather, ok, I know what to aim for :thumbs:.

    Thanks, Jim
     
  14. Keith M

    Keith M Staff Member Moderator

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    Hi Jim.
    Back in the 70's, as an Electrician I spent 18 months working on H J Enthoven's lead smelter at South Darley in Derbyshire, where they had a very similar rotary furnace, so I had memories to work from, also the Hope Valley Cement works is not that far from where I live so again having seen that many times I've just copied bits to suit, adapting where needed. The High Tension pole transformer is just something I added in since these works were usually 'out in the sticks' so no underground supply generally. I have some 6.6Kv pylons elsewhere on the layout too, it all adds to the detail mix. I have increased the height at the base of the chimney by around 60mm, but since it's a loft layout, I can't get too near to the sloping ceiling. If you're making electrical 'insulator pots', try some M4 nylon screws with the head cut off, just paint either brown or white and glue in position. In 4mm scale, you can't actually see that it's a thread, it just looks like the usual high tension insulators.
    Keith.
     
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  15. Jim Freight

    Jim Freight Full Member

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    I thought I could sense an engineering background in your past :thumbs:

    In the kit instructions they say put the chimney where you want to.

    My web researching of cement manufacturing suggests that it should be at the high end of the rotary kiln as the flame is at the lower end, or is this quite wrong?

    I would expect the smoke stack to be mounted on a rectangular brick/concrete base, the exhaust gases from the kiln being cleaned up a little before being piped to near the base of the smoke stack.

    Definitive details are hard to come by outside of the business and besides the scale of some the industries we model would need a fullsize football pitch in 1:76 scale to be realistic, however our lofts are not quite that big :scratchchin:

    Thanks for the info, Jim
     
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  16. jakesdad13

    jakesdad13 Staff Member Moderator

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    Yep, thats the one!
     
  17. Keith M

    Keith M Staff Member Moderator

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    Hi Jim
    My reasoning regarding which way the slope of the furnace should be (towards or away from the chimney) is that the raw materials would be put in at the upper end and as the drum revolves and heat acts upon the material, it would then work it's way down the slope to the bottom of the furnace so the slope would be down towards the chimney. Certainly on the lead smelter this was the case as I recollect, but being lead, the fumes were drawn by large fans through what was called a 'Baghouse', basically sets of cotton sleeves above a vee shaped casing in the bottom of which was a motor driven worm screw. Periodically, the sleeves were mechanically shaken to dislodge lead laden dust which was then drawn by the worm to an outlet for disposal. This was to conform to regulations preventing the emission of lead dust into the surrounding area, the cleaned air then being discharged up the chimney and I'd imagine similar regulations (at least in the UK) would apply to cement works despite being lower in toxicity than lead.
    Keith.
     
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  18. gormo

    gormo Staff Member Administrator

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    G`day Jim,
    That`s quite an impressive build.......well done...:thumbs::thumbs::thumbs::thumbs::thumbs:
    :tophat:Gormo
     
  19. Jim Freight

    Jim Freight Full Member

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    Thanks for the insight, Jim :thumbup:
     
  20. Jim Freight

    Jim Freight Full Member

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    :gday: Gormo, thanks, Jim
     

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