Cement Works - 10 - Site Map Explained

Discussion in 'Industrial & Commercial' started by Jim Freight, Dec 30, 2020.

  1. Jim Freight

    Jim Freight Full Member

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    Sep 9, 2019
    This is how all the cement works buildings (some to be built) fit together and connect to the railway serving it.

    Materials are transferred between buildings mainly by conveyors, some aerial, others below ground (typically silo discharging), open with basic cover for raw materials, enclosed for others.

    Between each process step there is a storage facility so process rate fluctuations at one step have limited knock effect to the following step.

    Fluctuations can be due to incoming supply disruptions, downtime of machinery for maintenance or repair, or variation in customer demand.

    Freight traffic by rail :-
    In - silica sand, gypsum, explosives, loco coal, maintenance materials, and fine coal if conveyor issues.
    Out - raw limestone, bulk cement, bagged cement, scrap and waste.

    Site Layout.jpg

    Diagram Key:

    1 Access road to the limestone quarry with turn and dump area for the quarry dump trucks, (Foden FR6/45 28T Dump truck)
    2 Explosives magazine for quarry blasting materials, within a secure fenced compound.
    3 Delivery platform for explosives and other quarrying materials.
    4 Industrial branch leading to further light industry.
    5 Primary limestone crusher feed grating where the quarry trucks unload, elevator lifts the crushed stone to the secondary crushers.
    6 Secondary crushers.
    7 Output to crushed limestone bulk store via conveyor
    8 Output to bulk hoppers for loading into hopper wagons (up to 4x 48T ICI).
    9 Arrival/departure siding for wagons.
    10 Bulk storage for crushed limestone.
    11 Pre-mix where silica sand is added to the limestone, includes a large hopper for the mix.
    12 Silica sand delivery shed for unloading COVHOP wagons and storage silos.
    13 Main access road and run around loop.
    14 Headshunt/loop for shunting bulk limestone wagons.
    15 Mix pre-heat and exhaust gas cleaning.
    16 Flue for exhaust gas.
    17 Rotary kiln for creating the clinker, fired with pulverised coal.
    18 Clinker cooling and raw grind, fuel mill in basement to pulverise the coal for the kiln.
    19 Reserve coal bunker in event of conveyor issues from the colliery.
    20 Bulk store, compartmentalised for clinker and incoming coal from colliery.
    21 Coal hopper for supplying cement works via conveyor or loading wagons for rail delivery.
    22 Coal and water for site shunting loco.
    23 Post mix, grind clinker and mix in gypsum to create the cement powder.
    24 Gypsum silo and air fluidising equipment to unload PRESFLO wagons.
    25 Bulk cement storage silos.
    26 Transfer house for cement from silos to dispatch.
    27 Silos for loading bulk cement wagons, PRESFLO and CEMFLO.
    28 Canopied platform for loading bagged cement into vans and receiving site supplies.
    29 Bagged cement warehouse.
    30 Loading bays for road transport of bagged cement.
    31 Lorry parking area.
    32 Cement (carousel) bagging plant.
    33 Industrial branch from the marshalling yard.

    My earlier articles may be found at https://platform1mrc.com/p1mrc/index.php?forums/industrial-commercial/

    Last edited: Dec 30, 2020
    Andrew Laing and jakesdad13 like this.
  2. Andrew Laing

    Andrew Laing Full Member

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    Jan 19, 2020
    Lots of potential and a well thought out plan.
  3. Jim Freight

    Jim Freight Full Member

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    Sep 9, 2019
    Thanks Andy, it evolved as I researched the cement industry.

    The more of the cement process that was added the more varied the traffic into and out of the site could be.

    I tried to be logical about how the sidings would serve the works, every part with a purpose, nothing surplus, lengths of sidings and positions of loading and unloading facilities on them such that they did not interfere with each other. For example, bulk raw limestone and bulk cement can operate without interfering. Van loading separate from both of them. Site loco servicing siding such that it can access either routes. With a run around loop to suit four 48T hoppers.

    jakesdad13 likes this.

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