Minerals & Cement

Minerals & Cement Cement Plant – Railcar Load Out Cement Plant – Feasibility Study Granule Plant – Rotary Dryer

PLANT SYSTEMS ENGINEERING RAILCAR LOAD OUT: CEMENT PLANT Project Requirements: A cement manufacturer wanted to off load finished cement from existing concrete silos to rail cars. Open air slides would be mounted inside the silos and would require structural support. Penetrations through the existing concrete silo structure would be required to feed closed air slides. The new air slides and dust control equipment would be mounted on an existing overhead structure re-engineered to support the new equipment. Compressed air piping would be required for the air slides. Solution Method: Model of open air slide Working with equipment supplier and its structural Claudius Peters Americas, we modeled support internal to the complex open air slide support and cement silo. silo penetration using SolidWorks. Field measurements verified the existing structures to enable analysis. External view of silo Compressed air penetration feeding piping manifold and closed air slide control valves Overall view of structure supporting air slides and dust control equipment THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax www.plantsys.com

PLANT SYSTEMS ENGINEERING FEASIBILITY STUDY: CEMENT PLANT Project Requirements: A cement manufacturer wanted to move finished cement from a new multi-cell silo to existing cement shipment bins using air slides. The distance was 250’ and the client did not want an intermediate towers supporting the air slide gallery. Determine the truss system for the 250’ gallery, supports and reactions at both ends, the logistics of lifting the gallery with cranes and the estimated costs. Can the client stay within budget if this method of cement transport is used? Solution Method: Using SolidWorks and structural design, we created general layouts, performed preliminary load calculations and member sizing for the air slide gallery and end support systems. Knowing the dead weight and center of gravity of the gallery (automatically calculated from SolidWorks), we worked with crane companies to determine lift logistics and to gather estimated pricing. Results: Using an unsupported, 250’ air slide gallery was technically feasible but due to the crane costs, the estimated cost of this overall project exceeded the clients budget. A different, less cost intensive method was selected to move the cement. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax www.plantsys.com

PLANT SYSTEMS ENGINEERING ROTARY DRYER: GRANULE PLANT Project Requirements: A granule manufacturer purchased a used 11’ diameter by 60’ long rotary dryer to dry crushed stone. The dryer and its drive train required extensive field measurements and reverse engineering to enable the design of the foundations, material handling and pollution control systems. Solution Method: After reverse engineering the dryer shell, drive and trunnions, our design included: • Foundations and pedestals for dryer and building. • Feed and take-away belt conveyors. • Pollution control systems considering elevated temp’s and moisture. • Gas train and combustion air piping • Structural steel for building and supports Overall view of dryer building and bag house mounted above the structure. Dryer shell and riding rings Burner end of dryer with natural gas and combustion air piping Pedestal foundation and access platforms for trunnion service THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax www.plantsys.com