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Introduction

Comparison

Energy Savings

Belt Bucket Elevators


versus
Pneumatic Transport

Assessment

Special Features

Introduction

Energy Savings -

Belt Bucket Elevators vs. Airlifts

With their ability to handle large capacities and lifts of 130 m and more,
Belt Bucket Elevators offer significant advantages compared to airlifts :

only 25 33 % of the energy which is required for airlifts


reduced dedusting volume
reduced exhaust fan power with preheater feeding
reduced noise level as no air blowers are required

Introduction

Energy Savings -

Comparison chart based on


conveying capacity of 200 t/h
kW required

Airlift
Belt Bucket Elevator

Introduction

Energy Savings -

Belt Bucket Elevators vs. Airlifts

ROI assessment theoretical comparative study

This study consists of:


Example 1 kiln capacity nom. 2,000 / max. 2,200 t/d clinker
Example 2 kiln capacity nom. 3,000 / max. 3,300 t/d clinker
Today, we will focus on example 2
featuring a kiln capacity of nom. 3,000 t/d

Comparison

Example 2 kiln capacity 3000 t/d

Feeding of preblending silo

Feeding of preheater tower

CC = 60 m 300 t/h raw meal

CC = 100 m 225 t/h raw meal

Comparison

A) Power Savings on conveying

Example 2 - kiln capacity 3000 t/d

required power kW

300
280

250
200

240

Silo feeding

150

Preheater
feeding

100
50
0

58
Airlift

Total 520 kW

71

Elevator
vs.

129 kW

391 kW saving

Comparison

B) Power savings on dedusting

20.000 m/h
20 kW

vs. 11.000 m/h


vs.

11 kW

9.000 m/h saving


9 kW saving

Comparison

C) Power savings on Exhaust fan

Example 2 - kiln capacity 3000 t/d

required air m/h

30.000

28.000

20.000
Preheater
feeding

10.000
0
0

Airlift

Elevator

Saving on air volume 28,000 m/h

56 kW power saving

Comparison

D) Power for additional handling equipment required for the


bucket elevator

Example 2 - kiln capacity 3000 t/d

required power kW

20

20

15
Silo feeding

10
5
0

Airlift

Preheater
feeding

Air slide Screw &


valves

additional power required for the elevator solution :

+ 24 kW

Comparison

Summary of Power Savings

Total savings Example 2 - kiln


capacity 3000 t/d
450
350

432

391

250
150
50

56

-24

-50
conveying
391 kW
dedusting
9 kW
exhaust fan
56 kW
add. equipment -24 kW

Total 432 kW

Assessment

Yearly savings

Example 2
Kiln Capacity 3000 t/d
Total Power Saving 432 kW

Based on
7200 h / per year of operation

3,110,400 kWh

and US$ 0.1 / kW h

US$ 311,040

(depending on country of
installation)

Assessment

Investment Costs
Example 2 kiln capacity 3000 t/d
Silo feeding
Weight

US$

Preheater feeding
Weight

US$

Aumund supplies and services

13 t

180,000

15 t

230,000

Local manufacturing part

34 t

68,000

47 t

94,000

Additional equipment

38,000

Field assembly

47 t

60,000

58,000
62 t

80,000

Civil work

13,000

15,000

Electrical installation

23,000

25,000

382,000

502,000

Total
Total investment costs

US$ 884,000

Assessment

ROI Assessment
Example 2 kiln capacity 3000 t/d

Total investment costs

US$

884,000

Yearly savings

US$

311,040

ROI

3 years

Assessment

Increased kiln capacity


by exploiting the power saving for exhaust fan

Depending on the kiln system, the fresh air can be used to


increase the kiln capacity by 3% to 5%.
The following additional benefits are possible as well:
Increased hot gas volume for the exhaust fan to supply to raw mill
and / or coal mill system
Increased drying efficiency of raw mill and / or coal mill system
Reduced electricity consumption of raw mill and / or coal mill
system

Comparison

Summary of Power Savings

Total savings Example 2 - kiln capacity


3000 t/d
450
350

432

391

250
150
50

-24
0

-50
conveying
391 kW
dedusting
9 kW
exhaust fan
0 kW
add. equipment -24 kW

Total 376 kW

Assessment

Yearly savings

Example 2

Kiln capacity 3000 t/d

Power Saving of 376 kW and increased kiln capacity


Based on 7200 h / year operation

2,707,200 kWh

and US$ 0.1 / kWh (depending on


country of installation)

US$ 270,720

Based on 3% capacity increase


3000 t/d x 0.03 x 300 d/y

27,000 t / y

and additional profit of US$ 7.00 / t


(depending on country of installation)

In total

US$ 189,000

US$ 459,720

Assessment

ROI Assessment
Example 2 kiln capacity 3000 t/d

Investment costs

US$

884,000

Yearly savings

US$

459,720

ROI

2 years

Assessment

Summary of advantages and disadvantages

Belt bucket elevator

Energy consumption

Dedusting volume

++

--

(lower volume)

Capital investment

Airlift

(higher volume)

Assessment

Maintenance: belt bucket elevator vs. airlift


Airlift

* lubrication (oil filling control) of


blowers
* filter cleaning at air blower inlet

Bucket elevator

* lubrication of drive bearings


* control of belt shore hardness
once a year

Special Features

AUMUND high capacity bucket elevators


Primarily installed in the cement industry
and designed to suit the
demand for :

high availability

long service life of the chain or belt

temperature resistance

reduced wear and maintenance

Special Features

Distinguishing Features of the AUMUND Belt


Bucket Elevator
Large bucket opening combined with narrow spacing
Direct and uniform feeding and
continuously discharging of the buckets
Less spillage and scooping

Low stress on bucket fixing

Special Features

Distinguishing Features of the AUMUND Belt


Bucket Elevator
Steel re-inforced belt

longitudinal steel ropes with close


spacing
=

high tensile strength


less belt thickness
smaller drum diameter

additional cross wires

high strength for bucket fixing


tear-off resistance

Special Features

Distinguishing Features of the AUMUND Belt Bucket


Elevator
Belt splicing Clamping connection

Steel ropes cast in a resin


compound
Clamped steel ropes

Special Features

Distinguishing Features of the AUMUND Belt Bucket


Elevator
Benefits of the steel re-inforced belt

* Belt ends prepared in the workshop

* Fixed rate of elongation (max. 0.25 %)

* No need for belt shortening on site

Special Features

Distinguishing Features of the AUMUND Belt Bucket


Elevator
Drive drum and tensioning unit
Flat drive drum surface for even load
distribution between belt & drum
Belt centering achieved with minimum slope at
drum edges
Removable segmented friction lining for easy
maintenance
Tensioning unit for uniform and stable belt
run, no off-track, tolerance only 1 mm

Special Features

AUMUND Belt Bucket Elevators Development over


the past 20 years
1600

1.500

1.300

1400
1200
1000

810

800

620

600
400
200

80

220

200
93

360

280
120

140

1991-1995

1996-2000

1980-1985

CC m

1986-1990

Capacity t/h

Installed power kW

Special Features

Number of AUMUND Belt Bucket Elevators installed


over the past 20 years

total number installed in 2001:

129

Special Features

The trend for large belt bucket elevators for feeding of raw meal silos and
preheaters is steadily increasing
since kiln capacities nowadays often reach 10,000 t/day
and lifting heights of 130 m and more are required for multi-stage
preheater and pre-calcining system

AUMUND will be there to meet the challenge