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Stockyard Equipment Design Criteria

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cristina sucre

on 3 July 2015

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Transcript of Stockyard Equipment Design Criteria

Product:
Up to a maximum lumps of 4”
Equipment:
Luffing and traveling stacker
Bridge reclaimer
Also possible to stack in chevron using an elevated tripper car. However, some segregation problems may occur.
Typical data:
Typ. Capacity : 2 x 45,000 T
In : 500 / 2,000 T/h
Out : 300 / 1,200 T/h
Max. Pile: 50 m wide
Luffing
Slewable
Tripper Car
Crawled mounted stacker

Shiploaders
Shipunloaders
Slewing cranes
Barge loading and unloading systems
Ecological hoppers


Conventional
Pipe Conveyors
Curve Conveyors



Stackers (luffing, slewable, tripper car)
Reclaimers (bridge, portal, semi-portal, side reclaimers)
Bucket wheel stacker/reclaimers
Crawler mounted machines
Bulk Marine Terminals
Complete Conveying Systems
Stockyard and Blending Beds
(Longitudinal and Circular)
Over 50 Year’s experience in Materials Handling
Integrated project management – Turnkey Projects
Stockyards and Blending Beds
Main Equipment
Bridge Reclaimer
Blending vs Storage
CONCLUSIONS

BLENDING EFFICIENCY
Required information
Stockyards and Blending Beds
Process:
Raw Materials
Fuel
Additives and correctives
Material Characteristics:
Lump size
Free flowing
Sticky materials
Other:
Blending requirements with other materials
Homogenization (lumps size and/or chemical composition
Available space at the plant
Future expansions plans
Water ground lever or phreatic level
Plant Production capacity
Plant working shifts per day and week
Stockyard Equipment - Design Criteria
PHB WESERHŰTTE
History of PHB
GROUP STRUCTURE AND KEY FIGURES
Material Handling Installations
Power and Industrial Plants
Electrical Infrastructures
Equipment and Systems
Design and Manufacture by PHB
Bucket Wheel Reclaimers
Portal Reclaimers
Semi Portal Reclaimers
Side Reclaimers
Storage Capacity
Stockyards and Blending Beds
Buffer Storage between quarry and process
Optimum stockyard capacity depends on the following factors:
Required consumption of the product during the process of the plant.
Crushing capacity or shipping capacity of the product.
Numbers of shifts per day.
Number of working days per week.
Proximity of the sources of the product to the plant.
The capacity of the stockyard should guarantee at least 5 days of production. Nowadays some plants have managed to reduce the buffer storage capacity down to 3.5 days of production.
Storage Capacity of final products is determined by the production of the plant and the capacity and efficiency of the dispatch system
Linear Arrangement
Simple process: one pile for stacking, one pile for reclaiming
Storage Capacity can be easily expanded
Volume capacity not limited
It's possible to change the chemical compositions of the pile without emptying the whole stockyard
Possible to store and blend more than one type of product in the same stockyard
Finished Pile Philosophy
All equiment above groud

Circular Arrangement
Ideal when there is a limitation of space at the plant
Continuous process: no interruption on pile relocation. Fully automatic
Stockyard limited to a maximum of 80,000 m3
Compact
No pile-end effect
High continuous homogenization effect is needed
Optimum utilizations of the required space
It's not possible to change the chemical composition of the full pile without emptying the whole stockyard
It may required a reclaiming underground reclaiming tunnel
Cone-shell
Chevron
Chevcon
Windrow
Strata
Required feeding capacity to the plant
Feeding capacity from crusher
Lump size
Blending Efficiency
Free flowing or Sticky material
Blending requirement with other materials
Homogenization (lumps size and/or chemical composition
Stacker Unit
Reclaimer Unit
INFLOW
CRUSHER
Why to blend?
Industries using kilns and furnaces, such as cement, iron, steel making, non-ferrous metallurgic, glass, etc., usually requited a very uniform feed
Plant Process
Outflow
Bedding Efficiency
%CaCO3, SiO2, LSF, etc.
OUTPUT
AVERAGE
INPUT
Standard Deviation
Practical Measurements
Significant number of Samples ( >50 )
From Input and Output Respectively
Representative Sample (~ 3x biggest size grain)
Significant time frame (~ 1 Pile )
CHEVRON STACKING PATTERN
Product :
Up to a maximum lumps of 4”
Equipment :
Luffing/slewable stacker
Bridge reclaimer one Harrow
Typical data :
Capacity : 65,000 T
Maximum diameter: 120 m
In : 500 / 2,000 T/h
Out : 300 / 1,200 T/h

BLENDING BEDS
STACKING PATTERNS


Reclaimer Units
Stacker Units
BLENDING BEDS

Material Flow
BLENDING EFFICIENCY
xi = % of CaCO3 of a sample i

x = media of all sample
n = number of sample
Definition :
Bedding Factor
Determination :
CHEVRON STACKING PATTERN
STRATA STACKING PATTERN
STRATA STACKING PATTERN
Only for Linear Stockyards
Product :
Suitable solution for sticky materials
Piles < 30 m
- Side Reclaimer: 25 m wide
- Portal Reclaimer: 60 m wide
- Semi-Portal: 30 m wide
Building Height limitation. For enclosed buildings normally two arms are used
Equipment :
Luffing, travelling and slewable stacker
Side Reclaimer and portal reclaimer
Typical data :
Capacity < 55,000 m³
In : < 3,000 T/h
Out : Side Reclaimer: 500T/h Portal Reclaimer:
4,000 T/h (4 arms)

STOCKYARDS
CONE SHELL STACKING PATTERN
Product :
No blending effect is required
Equipment :
Longitudinal Piles:
Luffing (optional) and travelling stacker
Reclaimer: Side Reclaimer, Portal or Semi-Portal reclaimer
Circular Stockyards:
Slewable Stacker, luffing movement (optional)
Reclaimer: Side-Reclaimer or Portal Reclaimer
Typical data :
Capacity < 55,000 m³
In : < 3,000 T/h
Out :
Side Reclaimer: 500T/h
Portal Reclaimer: 4,000 T/h (4 arms
longitudinal); 2,000 T/h (2 arms
circular)


WINDROW STACKING PATTERN
Product :
Common raw material with possible addition of sticky materials - Large grain size distribution
Equipment :
Luffing/Slewable stacker
Bridge reclaimer
Also possible to use a shuttle bridge stacker and a bucket excavator. Expensive civil solution and high energy consuming.
Typical data :
Typ. Capacity : 2 x 35000 T
In : 500 / 2000 T/h
Out : 300 / 1200 T/h
Max. Pile: 50 m wide
BLENDING BEDS

CHEVCON STACKING PATTERN
CHEVCON STACKING PATTERN
STOCKYARD EQUIPMENT
DESIGN CRITERIA

(Type, capacity, dimensions)
Main Figures
Main Figures
STORAGE AND BLENDING YARDS
CT Andina – Mejillones (Chile) / Coal - Coke Handling System
STORAGE AND BLENDING YARDS
CT Andina – Mejillones (Chile) / Coal - Coke Handling System
SCOPE OF SUPPLY

STORAGE AND BLENDING YARDS
UNION FENOSA – MASA – Medusa Project (A Coruña – Spain)
Circular Stockyard STD 2000/24,5. Diameter: 105 m

STORAGE AND BLENDING YARDS
Mill station and material preparation up to bunkers
Conventional Conveyors system
Coal / Coke Stockyard – Capacity 750.000 tons.
Stacker and reclaimer machines
Complete electrical power and control installation
Complete fire detection and protection installation
Electrical and Mechanical Erection.
CCTV and comunication system
Under UBC 5 earthquake clasification.
Biomass material handling stockyard

CT Andina – Mejillones (Chile) / Coal - Coke Handling System
SCOPE OF SUPPLY

STORAGE AND BLENDING YARDS
ASLAND LAFARGE – Sagunto, Valencia (Spain)
Petcoke longitudinal stockyard with a combined stacker-reclaimer portal type, stacking capacity: 400 t/h
reclaiming capacity: 100 t/h, 45 m rail span

STORAGE AND BLENDING YARDS
MA’ADEN – Dap Granulation Plant (Saudi Arabia) - Longitudinal stockyard.
2 Portal scraper reclaimer with 3 scraper booms (2 main and 1 auxiliar) Reclaiming capacity 2000 t/h, 52 m rail span

STORAGE AND BLENDING YARDS
STORAGE AND BLENDING YARDS
CEMEX – El Yaqui (Mexico)
Coke Handling System
1 Luffing Slewing Stacker STD 300/16.7
& 2 Lateral Cantilever Reclaimer SKV 250/24

STORAGE AND BLENDING YARDS
CEMEX – El Yaqui (Mexico) - Limestone Handling System 1 Luffing Stacker ST 1000/19 & 3 Frontal Reclaimer LHO 750/29

STORAGE AND BLENDING YARDS
BP (British Petroleum) – Castellon’s Refinery (Spain)
Green Cok Handling System
STORAGE AND BLENDING YARDS
TOYO – Petrobras (Brasil) - Longitudinal stockyard.
Portal scraper reclaimer 270 t/h, 35 m rail span
Stacker 150 t/h, 24 m boom length.

STORAGE AND BLENDING YARDS
ATLÁNTICA DE GRANELES – Bilbao (Spain)
Longitudinal stockyard
Stacker 1000 t/h, 22 m boom length
Portal scraper reclaimer 200 t/h, 30 m rail span
STORAGE AND BLENDING YARDS
CEMEX – Mérida (Mexico)
74 m Circular stockyard, 33000 t limestone capacity for homogenizing Stacking capacity: 565 t/h. Reclaiming capacity: 360 t/h

STORAGE AND BLENDING YARDS
JAYPEE Group - DALA & BELLA (India)
Revamping:
Circular Stockyard KHO 900/400-D82 to RKHO 800/500-D82
Frontal Bridge Reclaimer LHO 800
STORAGE AND BLENDING YARDS
TERMINAL MARITIMA ALTAMIRA - (Mexico)
2 side scrapers for cereals, 350 t/h capacity

GENERAL PRESENTATION

GSN Petronor – Bilbao (Spain)
Sulphur & Coke Handling System – New Contract awarded to PHB

STORAGE AND BLENDING YARDS
CHIYODA – Assaluyeh Amonia Plant (Iran)
3 Portal scraper reclaimers with 3 scraper booms (2 main and 1 auxiliar)
Reclaiming capacity 100-1800 m3/h urea. 54 m rail span
GENERAL PRESENTATION

GENERAL PRESENTATION

GENERAL PRESENTATION

STORAGE AND BLENDING YARDS
Consignaciones TORO & BETOLAZA –(Bilbao, Spain)
Sodium sulphate handling terminal
Truck unloading system, Stackers ST 250/500-7, Reclaimer SKDW 700/18, Warehouse, Shiploader CTD 700/21,5 for 30000 DWT Vessels
STORAGE AND BLENDING YARDS
CEMEX – San Pedro de Macoris (Dominican Republic)
85 m Circular stockyard, 50000 t limestone and clay capacity for homogenizing Stacking capacity: 1300 t/h. Reclaiming capacity: 800 t/h
STOCKYARD EQUIPMENT
COAL & COKE – Capacity up to 5400 t/h
Endesa Prioriño Terminal (Spain)COAL STOCKYARD
1 Luffing Slewing Stacker machine STD 5400/47
Stacking Capacity: 5400 t/h
Boom Length: 40 m

Endesa Prioriño Terminal (Spain)
REFERENCES IN COAL HANDLING
Endesa Teruel TPP (Spain) COAL STOCKYARD
1 Luffing Slewing Stacker machine STD 2250/30
Stacking Capacity: 2250 t/h
Boom Length: 30 m
Endesa Teruel (Spain)
STORAGE AND BLENDING YARDS
PHOSPHATES – Capacity up to 3120 ton/h
2 Stackers (identical machines) & Transport System
Conveying System, belt width up to 1.400 mm
Stackers ST 3120 / 31
Stacking & transport capacity = 3120 t/h
Material handled: Phosphate
OCP Projet Laverie Mea – Khouribga (Morocco)
Phosphate Handling System
STORAGE AND BLENDING YARDS
CEMEX – Andorra Teruel (Spain)
Limestone Handling System – Circular Stockyard KHO 600/400 D74
Coal Handling System – Circular Stockyard STDSK 30/100 D55
Additives Handling System – Longitudinal Stockyard ST 200/5 & SKV 200/17
STORAGE AND BLENDING YARDS
SLAG Handling System
STORAGE AND BLENDING YARDS
Tudela Veguin – Asturias (Spain)
105 m Circular stockyard.
150000 t slag capacity.
COAL/COKE , ADDITIVES and LIMESTONE in Cement Plant
Jaypee Himachal Cement Plant (India)
Jaypee Himachal Cement Plan (India) – Scope of Supply:
KHO 2188-1250 D 102 – Circular Stockyard for limestone
KHO 250-250 D 70– Circular Stockyard for coal / coke
VP1 438/35 – Longitudinal Stockyard for additives

Holcim – Almeria (Spain)
COAL / COKE CIRCULAR STOCKYARD
Circular Stockyard – Diameter 105 m
90.000 tons Coal & Coke Total Capacity
Holcim – Almeria (Spain)
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