Application Requirement: At Shree Cement, Balodabazar which is 80 Km away from Raipur there was a requirement to convey limestone from mine to cement plant which is 1.5 KM away from the plant. In between plant and mine there is a small existing village and while conveying material additional precaution needed to be taken care as its crossing village to avoid any human causality and extra care was required to prevent air pollution. Earlier customer had planned for conventional troughed belt conveyors along the route.
Solution Provided: After Bevcon engineers site survey & thorough understanding of the requirement, Bevcon has come up with new proposal of Overland pipe conveyor by showcasing the advantages like avoiding multiple transfer points, flexibility in routing and reduced power consumption.
Considering the project time, customer encouraged the idea of going for ahead with pipe conveyor. The capacity of the new proposed overland pipe conveyor was 3100 tons and it was planned in two phases with each phase capacity of 1550 tons. The location is a hub of limestone mines and major cement majors like Ultratec, Ambuja and Emami etc are having cement plants.
Shree cements awarded the contract to us in the month of July 2014 with a supply completion deadline by December 2014. This deadline was quite challenging and as per industrial practice a 1.5 KM length of pipe conveyor would take at least 9 months.
As pipe conveyor is routed in “S” shape and crossing an existing village, statutory clearances and local clearances were taken by Shree cements. Belt plays a very vital role in a Pipe conveyor. We had selected Phoenix – India who is well experienced in pipe conveyor belt technology. In this project due to very tight curves of 300 meters radius, it was required for the belt to develop a good amount of transverse stiffness. Phoenix has designed the belt with the help of their principle co. Phoenix – Germany. The belt is of textile carcass and specially made with 1250/4 ply rating.
The material conveyed is of limestone of <65mm size. The pipe conveyor is very special having 600mm in diameter, 1.4KM long and with two opposite horizontal curves (forming ‘S” curve) of 300mm radius. As the customer has already fixed the conveyor route and as the prefixed route was not fitting as per the thumb rules of pipe conveyor radius, the belt carcass is specially selected and tailored to suit for this application.
The major challenge we faced during the commissioning of the pipe conveyor are twisting of pipe. As the pipe belt is new and hence stiff. So while tracking the belt the carrying and return side belt positions got more frequently disturbed. Also the belt was unable to seal properly at the edges. With the help of Thejo (belt tracking expert) services, we could get the belt tracked in position.
Bevcon has completed all the supplies before January 2015 and commissioned Pipe conveyor in the month of February 2015 and currently it’s running satisfactory and tested with a first phase of full capacity 1500TPH.