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Conveying & Loading Systems: Beumer develops and implements complex system solutions for the bulk materials industry throughout the world

The BEUMER Group uses its newly created Conveying & Loading Systems (CL Systems) division to develop and implement complex system solutions throughout the world for different industries, such as mining and the cement industry. The team is made up of experienced staff from the branches distributed around the world who work together on the projects. What they all have in common is that they understand the user, which means that they can develop tailor-made solutions. This is demonstrated by three impressive completed projects.

Dr Andreas Echelmeyer, who has headed the Conveying and Loading Systems division in the BEUMER Group at its headquarters in Beckum since August 2015, stated that “We can use our comprehensive expertise in system solutions to advise our customers and provide them with complete plant systems. Each industry poses its own unique challenges”. The most important point is to listen carefully to the customer and then ask the right questions. This can only be done locally. Employees positioned around the world are therefore in close contact with the customer. They are familiar with the specific customs of the particular country, understand the language and are wise to the particular requirements of the market and the customer. They identify appropriate potential and any possible need for action. The operators for whom BEUMER has successfully commissioned conveying plants includes the TPI Polene Public Company Ltd. The third largest cement producer in Thailand uses this complex system solution to transport crushed limestone from the quarry to the blending bed.

Difficult environment safely overcome

Dr Echelmeyer was aware that “The challenge lay in the nature of the ground between the quarry and the cement plant”. It was exceptionally demanding. We had to make allowances not only for numerous obstacles but also for a steep downhill section of the conveyor”. The team designed a complex, but above all cost-effective, integrated system comprising a total of eight belt conveyors covering a distance of 6,129 metres. BEUMER also supplied a PLC plant control system, transfer stations, filter systems and foreign body collectors.

The system is designed for a conveying capacity of 2,200 t/h. The key items in the limestone transport system are two downhill belt conveyors operating in the generator mode followed by a troughed belt conveyor with horizontal curves. The material passes from the crusher discharge belt the first two troughed belt conveyors. The material is then transferred to a long overland conveyor with a speed of 4.5 meters per second by an accelerator belt with a speed of 2.6 meters per second. Three more conveyors finally transport the material to the blending bed.

Cost-effective operation guaranteed

One particular feature of the downhill conveyors is their power generation. With a total of 640 kW/h generated energy that is fed into the power grid they make a substantial contribution to the cost-effective operation of the overall system. “We have a great deal of experience with conveying systems that can negotiate horizontal and vertical curves and operate in the generator mode” explained Dr Echelmeyer. During the development it was necessary, for example, to ensure safe and carefully controlled stopping of the large belt system to avoid problems during unavoidable events, such as a power failure.

BEUMER supplied four further belt systems with a total length of 989 metres to deal with the discharge from the blending bed and supply the material to the raw mill feed hopper. The conveyors were all built and installed in only eleven months. The commissioning phase, lasting three months, was followed by performance tests. The team then handed over the entire plant to the customer. Dr Echelmeyer emphasized that “We supervised and monitored the installation and commissioning to ensure long-lasting, trouble-free, operation. This always forms part of our service”. The standard scope of supply also includes intensive training of the operating and maintenance personnel.