Cement Works - 18 - Bulk Store Clinker & Coal

Discussion in 'Industrial & Commercial' started by Jim Freight, Sep 12, 2021.

  1. Jim Freight

    Jim Freight Full Member

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    Structure (20) on the site map,

    https://platform1mrc.com/p1mrc/index.php?threads/cement-works-10-site-map-explained.5333/

    stores the clinker from (18) prior to delivery to post-mix (23) and the coal delivered directly from the colliery (21) to be crushed in (18) and be the fuel for the kiln flame (17).

    Each process stage in the manufacturing of cement has a storage facility between them to allow for variations in supply and demand of each process, whether it be due to restricted supply from the previous step due to e.g. downtime for maintenance, or a temporary slow down in demand such as a pause in loading wagons for dispatch. This is known as 'decoupling' and is applicable to process flows (and incidentally professional software design).

    The bulk clinker store provides a buffer for clinker leaving the kiln, as a plus it is easier to store clinker than the final cement mix as it is less susceptible to moisture, this store is based on an earlier system which implements first in last out. Although simple it can result in some material potentially never leaving or staying too long and getting damp so it takes more management.

    Contemporary systems work on a first in first out basis, mine however is based on early 1960's techniques. The clinker leaves the store via it's transfer house to enter the post-mix building (23). This type of bulk store building can contain more than one material as it is internally divided to keep the materials separated. In my works it also receives fine coal directly from the colliery across the tracks via a conveyor from the colliery hoppers, (21). This also acts to decouple the coal supply rate from the coal consumption rate of the kiln. From the store its is fed to the basement of the kiln building where it is crushed to a very fine powder and pumped to the burner with air forming a combustible gas like fuel for the kiln burner.

    In the event of delivery issues the coal maybe be discharged from the colliery hoppers (21) into wagons for a short transfer to the reserve coal store (19).

    The first set of images show the completed building with a conveyor off-cut representing a ground level conveyor to the kiln building (18).

    The corrugated surface coal streaking in image 4 is distorted by the fringing effect of image resolution vs corrugation pitch and is much more subtle than shown.

    1DSCF8701.JPG

    2DSCF8702.JPG

    3DSCF8707.JPG

    4DSCF8703.JPG

    5DSCF8704.JPG

    The second set of images show the nominal placement of the store in the cement works site which varies from the original site map in two ways, first the store and kiln buildings are next to each other whereas originally they were linked by an aerial conveyor. Secondly and this is a change between the two sets of images too is that the ground level conveyor has been eliminated.

    The reasoning is as follows, the coal crusher is in the kiln building (18) basement which is a likely arrangement, so why not have the coal conveyor below the surface with it exiting the bulk store at the required level. That would simplify the prototype's installation and mean that the coal storage in the bulk store can be somewhat deeper and hence higher capacity.

    6DSCF8709.JPG

    7DSCF8713.JPG

    Next, packing and dispatching of bagged cement.

    Jim
     
    Last edited: Sep 12, 2021
    jakesdad13 likes this.

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