Estudos de caso
Graymont Superior (P1314) - Planta de Calcário - Wisconsin, EUA (conteúdo na integra em inglês)
With proper belt support, the load is stabilized and material is contained throughout the transfer point.
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Desalinhamento severo na zona de carregamento diminui a segurança e aumenta períodos de inatividade
Depois da instalação do alinhador, a correia é centralizada, e cessam as paradas devido ao desalinhamento.
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O Maior Produtor de Talco do Mundo Melhora a Segurança dos Trabalhadores e Reduz os Custos de Limpeza com Limpadores de Correia
O sistema inadequado de limpeza da correia, estava causando o derramamento do material pastoso pelo chão, criando um ambiente de trabalho inseguro.
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Raspador CleanScrape® Melhora as Operações em Usina de Energia de Carvão (conteúdo na integra em inglês)
Uma usina de energia a carvão enfrentava sérios problemas de material fugitivo em um transportador de correia, que funciona 24/7. As cinzas e a água requerem uma limpeza constante, e o material úmido e abrasivo causaram desgaste prematuro dos componentes e apresentaram um risco potencial de deslizamentos e quedas. Os limpadores de correia padrão duraram apenas alguns dias, e os modelos reforçados com cerâmica duraram apenas duas semanas.
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Planta reciclagem de resíduos de minério ferro - Alemanha - QC1™ HD STS (conteúdo na integra em inglês)
A recycler of residuals from the production of iron and steel was experiencing extreme carryback on a main material transport belt, which was causing unsustainable plant pollution. An existing cleaner made from a horizontal metal plate tilted slightly to face the discharge chute did not adequately remove dust and fines from the cracks and divots in the belt.
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Planta de Agregado, Porto de Edimburgo, Escócia - Canhão de Ar (conteúdo na integra em inglês)
Aggregate Industries was experiencing clogging sand in its dual-spout pyramid hopper. Vibrators were used to loosen material, but vibrating metal walls turned the hopper into a giant horn, which caused a loud, unpleasant sound throughout the work area.
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Planta de Cimento - Ucrania - CleanScrape®
A cement plant located in Western Ukraine was experiencing extensive carryback on conveyors carrying slag. Fugitive material built up on floors and encapsulated rolling components, causing excessive downtime for maintenance and cleaning. Increased operational costs for labor and replacement parts inspired managers to seek alternatives.
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Stirling, Escócia - Fibra e Madeira (compensado) - CleanScrape® - (conteúdo na íntegra em inglês)
A producer of Medium Density Fiberboard and Chipboard was experiencing excessive carryback on the conveyor system transporting wood chips to the screening process. During this process the wood is damp and sticky, causing smaller particles to cling to the return side of the belt. This required extra labor to clean the area 2 hours per day, raising operating costs and affecting workplace safety.
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Planta de Cimento, Siam City, Tailandia - Raspadores - (conteúdo na íntegra em inglês)
Siam City Cement in Saraburi, Thailand was having trouble with excessive carryback and spillage along the length of their conveyor path. This posed a potential workplace hazard and required workers to be assigned for regular cleanup. Rolling components also needed frequent replacement, which led to expensive downtime and increased the cost of operation.
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Planta de Cimento, New Braunfels, Texas, EUA - Pontos Transferência - (conteúdo na íntegra em inglês)
The Martin Marietta Hunter Cement Plant experienced equipment breakage, belt damage and spillage issues on the B-06 conveyor leading from the limestone storage dome to the facility. The previous equipment was inadequate to handle the impact of limestone. Idlers cracked and cargo would not center sufficiently, causing excessive spillage around the transfer area and along the belt path, leading to long periods of downtime.
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Planta de Cimento, New Braunfels, Texas, EUA - Canhões de Ar - (conteúdo na íntegra em inglês)
The Hunter Cement Plant facility in New Braunfels, Texas was experiencing transfer chute clogging and conveyor belt backups from wet fines and aggregate on its partially-covered D-07 conveyor. Heavy seasonal rain caused serious spillage issues and accumulation in the chute, which halted plant production.
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Problemas de Entupimento de Chute e Derramamento Corrigidos com o Raspador CleanScrape® - Planta de Geração de Energia
Uma planta de geração de energia a partir do carvão enfrentava problemas de entupimento de chute e derramamento. Os raspadores primários e secundários existentes povocavam uma descaga irregular do material que se agarrava às paredes do chute e causava a obstrução exigindo tempo de inatividade periódica para ajustes. As lâminas eram consumidas rapidamente provocando fuga e derramamento de material sufucientes para até cobrir os raspadores.
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Planta Geração de Energia - Grand Island, Nebraska, EUA - Sistema de Vedação - (conteúdo na íntegra em inglês)
A coal-fired power plant was experiencing failures of the rubber/fabric seals at the top of the chute wall on its Train Unload Vibratory Feeder. Unable to handle the powerful vibration, the thin rubber seals allowed dust and fines to spill from the chute. Workers had to clean up at least once per month, and the spillage created a potential workplace hazard.
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Cana de Açucar - Malelane, Africa do Sul - Raspador Secundário - (conteúdo na íntegra em inglês)
A small power plant burns sugarcane bagasse that would otherwise be waste material from processing. The hot gas generator produces hot ash, which must be cooled with moisture and transported by conveyor. The moist ash is very difficult to remove from the conveyor, forcing operators to run a hose behind the existing scraper to wash the belt, wasting water and creating a mess.
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Planta de Carvão, Witbank, Africa do Sul - Pontos de Transferência - (conteúdo na íntegra em inglês)
A coal mine was experiencing heavy spillage and system damage along the length of a main conveyor due to inadequate loading zone equipment. Impact idlers allowed excessive belt sag, causing high volumes of spillage. Dust and fines fouled idlers, and rocks got lodged between the belt and the skirt, resulting in unscheduled downtime due to frequent equipment failures and chute liner replacements.
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Planta de detergente quimico - Johanesburgo, Africa do Sul - (conteúdo na íntegra em inglês)
A manufacturer of powdered washing detergents in South African was experiencing problems with carryback on one of its main conveyor belts. Small particles with a high moisture content clung to the belt and migrated to the rolling components of idlers and pulleys, resulting in equipment failures and mistracking. This caused excessive wear on the belt and shortened its life considerably.
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Planta de Mineração de Niquel - Pomalaa, Indonesia - Raspadores - (conteúdo na íntegra em inglês)
PT Antam Mining of Indonesia had inadequate belt cleaners causing belt damage, spillage and carryback on a reversing belt within the mine. The previous equipment did not keep a seal across the belt profile. Incomplete cleaning caused excessive carryback and spillage along the return belt path, increasing the need for cleanup.
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Planta Mineração Níquel - Sudeste de Sulawesi, Indonésia - Pontos de Transferência - (conteúdo na íntegra em inglês)
A nickel mining plant was experiencing excessive equipment wear and damage at a main transfer point leading from the rotary dryer, handling 71,430 tons per month of bulk material. The impact force of cargo on an unsupported belt was cracking idlers and bending the mainframe. The damage forced operators to shut down the entire system regularly to repair mainframe damage and replace broken equipment.
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Planta de Carvão - Wheatfield, Indiana - Suporte da Correia - (conteúdo na íntegra em inglês)
A coal-fired plant handling large quantities of synthetic gypsum was experiencing fugitive material problems, with dust and spillage piling up and large chunks of gypsum falling off the belt. Martin technicians determined that inadequate belt support was the primary cause of the problem, allowing material to escape from the transfer point’s loading zone.
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Novo Raspador Economiza Até 24 Horas Por Semana Em Tempo de Limpeza
Uma planta de agregados manuseia 1,5 milhão de toneladas de calcário por ano. Depois de enfrentar problemas de material de retorno em seus transportadores, eles queriam ter certeza de resolver o problema ao construir um novo transportador. A fábrica passou de 16 a 24 horas por semana, limpando. Houve também danos excessivos nos transportadores.
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Raspador CleanScrape® Melhora as Operações em Pedreira
Uma pedreira enfrentava problemas com material fugitivo em um de seus transportadores. Da pedreira até o interior da fábrica, uma parte da correia ficava exposta às mudanças climáticas extremas mesmo quando coberta. Como resultado, o material ficou aderido no lado de retorno da correia e em torno dos roletes, exigindo tempo de inatividade para manutenção e aumentando o custo de operação.
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Martin Arcoplate reduz paradas não programadas
An iron ore mine was experiencing premature deterioration on the wear plate of a transfer chute, leading to perforation and spillage. Every 60 days, operations would be interrupted while workers performed a potentially dangerous chute entry to cut out the material and replace it. Labor for cleanup, unscheduled downtime and expensive replacement equipment made the situation unsustainable.
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Martin Saves Cement Plant $5,000 Per Month In Labor And Equipment
A plant was experiencing major problems with dust and material spillage on their crusher discharge belt coming from the quarry. This required clean up a minimum of once every week. It was also causing premature failure and belt wear due to idlers freezing up. The plant estimated this problem was costing $5,000 per month in labor and equipment costs.
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Planta de Reciclagem - Johnson Controls (Enertec), Nuevo Leon, Mexico - (conteúdo na íntegra em espanhol)
Enertec is dedicated to the recycling of car batteries; they triturate and separate the plastic and the lead from the batteries, and then re-use it to manufacture new batteries. Their conveyor belt suffered from impact damage and misalignment. Some of the batteries ran down the back of the chute, which caused damage to the conveyor belt and also to the tail pulley.
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Planta de Cimento, Conch Cement, Suzhou, China - Raspadores Primario e Secundario - (conteúdo na integra em inglês)
A cement factory uses belt conveyors to transfer limestone and clay. The factory workers had to clean up the excessive spillage daily on the return belt. The labor intensity got very high when the spillage mixed with water on rainy days. The factory was replacing the blades frequently at a great expense as well as creating additional exiting safety hazards.
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Planta de Cimento - Panamá - Canhões de Ar - (conteúdo na íntegra em espanhol)
Workers at a cement plant were experiencing some difficulties achieving their volume needed due to the preheater's spoon. The issue developed because the number of air cannons needed to keep the material flowing was limiting the physical space. The plant realized they needed to find a solution that would promote material flow while optimizing space.
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O Workshop Foundations™ pode ajudar drasticamente no aumento da produção de sua planta
Uma fábrica de cimento na Colômbia sofreu graves problemas de derramamento em vários de seus transportadores, causando desalinhamento e dano às correias, e aos componentes de rolamento. A situação aumentou os custos de manutenção, devido à substituição prematura dos componentes da correia e do transportador, bem como a despesa com mão-de-obra de três pessoas para um turno inteiro, cada.
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A Martin Engineering oferece soluções confiáveis quando outros falham (conteúdo na integra em espanhol)
Uma mina estava com problemas de derramamento de material na zona de carga do seu transportador. Mesmo com equipamentos de um fornecedor anterior, os trabalhadores descobriram que o pó encheu o chute e grande quantidade de matéria-prima foi derramada em uma escada, criando um perigo potencial para o local de trabalho. As operações tiveram que ser interrompidas duas vezes no mês por até 24 horas, para que uma equipe de 4 a 5 pessoas pudesse limpar o local.
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VPlow Stops Premature Wear And Misalignment Of Conveyor Belt
A cement manufacturing plant was experiencing fugitive material on the non-carrying side of the conveyor. The spillage would collect on the underside of the belt during its return run, and the material became trapped between the head pulley and the belt. The problem caused premature wear of the belt, as well as misalignment, and had the potential to damage the tail pulley, as well.
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Planta de Carvão - China - Produtos para Pontos de Transferência Resolvem Problemas de Derramamento e Pó - (conteúdo na integra em inglês)
Uma planta de carvão enfrentava problemas de derramamento de material e geração de pó em dois pontos de transferência do transportador. Isso porque o material foi carregado nas correias viajando 500 fpm com pouco controle sobre o impacto ou a sedimentação do mesmo. O resultado foi geração de poeira e material fugitivo em toda a instalação. O projeto inadequado da calha causou o derramamento de material que se acumulou entre a correia e a polia traseira, prejudicando ambos.
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Chapas de Desgaste em planta de Cimento - São José do Mixira, Brasil -
A cement plant was experiencing wear damage to the underside of the bucket on its excavator. Scooping slag and clinker off of a cement floor covered with a layer of crystalline residue, the bucket would scrape against the coarse material, degrading the metal and reducing the structural integrity. As a result, the 24-hour operation experienced regular unscheduled downtime.
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Termeletrica, Adani Power Maharashtra Ltd., Gondia, India - Raspadores - (conteúdo na íntegra em inglês)
A coal-fired power plant in India was facing serious problems from dust, spillage and carryback on one of its 60 conveyors, which handles 5,000 tons per hour of bulk material. The condition became so severe that the fugitive material was posing a safety hazard, requiring personnel to work in close proximity to the moving conveyor, creating another potential risk.
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Pedreira - EUA - Pontos de Transferência - (conteúdo na íntegra em inglês)
Handling 20,000 tons of crushed rock per month put the client at huge risk for material and profit loss. The plant estimated they were losing several thousands of dollars in labor expenses every week! Cleanup was not only an expensive maintenance task but also a dangerous one. Airborne dust can garner negative attention from regulatory agencies and lead to fines.
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Planta de Papel - Sul dos EUA - Suporte e Vedação da Correia - (conteúdo na íntegra em inglês)
A liberação de poeira no ar pode causar problemas de saúde e atrair a atenção das agências reguladoras. Qualquer material que escape do transportador é uma perda - perda de material, lucro e eficiência. O derramamento também cria a necessidade de limpeza manual que leva horas-homem e é uma tarefa perigosa - colocando os trabalhadores em perigo.
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Siderúrgica - França - Raspadores Martin® - (conteúdo na íntegra em inglês)
Conveyors were equipped with belt cleaners with segmented carbide blades. The belt cleaners have not performed well. The site has had problems with carryback under the conveyor rollers causing offsets and blockages. Additionally, maintenance and service on the belt cleaners was very difficult.
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Armazenamento de Sal - Grupo Arkema, França - Canhões de Ar + Serviços Manutenção - (conteúdo na íntegra em inglês)
At the Arkema Group chemical site in France, a salt storage facility that stores and supplies salt had developed a lot of buildup from carryback along the belt. This buildup required a stop every six months for manual clean-up. After reviewing the system, Martin Engineering recommended two solutions.
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Planta de Cimento da Lafarge - França - Pontos de Transferência - (conteúdo na íntegra em inglês)
Lafarge Cement was experiencing excessive spillage from one of its conveyor belts. The material was a mix of sand and water. Every time the extractor started, a mixture of sand and water discharges and the conveyor belt could not contain the material, in its current design. Martin Engineering was called to inspect the system and recommended a complete upgrade of the transfer points.
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Arcelor Mittal - França - Canhão de Ar - (conteúdo na íntegra em inglês)
On the ship unloading conveyors at Arcelor Mittal in France, matter was accumulating along the belt and at the transfer points, which was reducing material flow. The client had to increase the number of stops to manually clean-up the material, generating fairly substantial additional costs.
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Repeat Client Hires Martin Engineering For Additional Product Installation
An aggregate plant needed a cleaning solution for its internal conveyors. Having already used the services and products from Martin Engineering in the past on other sites, they turned to Martin for help with this project. The solution recommended by Martin was to add Martin® QC1™ Cleaner HD with a Martin® Twist™ Tensioner.
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Termeletrica - EUA - Serviços - (conteúdo na íntegra em inglês)
The plant handles 1,000,000 tons of PRB coal per year and was experiencing carryback and belt wander on the rail unloading belt feeders. The carryback was reducing efficiency and profitability and increasing maintenance and cleanup expenses. Unsafe working conditions were a concern due to material accumulation on floors and walkways, creating slip/trip hazards along with fire hazards.
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Termelétrica - Turquia - Pontos de Transferência - (conteúdo na íntegra em inglês)
A coal-fired power plant produces over 300,000 tons per day. The plant was having trouble with dust and spillage at the conveyor transfer loading point in addition to excessive spillage and piles of fugitive materials under the conveyor belt. The problem led to manual cleaning and an increase in maintenance costs, resulting in regular and costly down-time and man-hours.
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Planta Cimento - Turquia - Canhão de Ar Multi Válvulas - (conteúdo na íntegra em inglês)
A cement plant in Turkey produced 9,500 tons of clinker per day. The rotary kiln entrance ramp area at the bottom of the preheater tower developed material flow problems because of the vertical angle of movement at the transition point and the horizontal angle of movement of the material.
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Planta de Cal da Lhoist - Reino Unido - Canhões de Ar - (conteúdo na íntegra em inglês)
An existing lime kiln had been upgraded in 2014 with the addition of a pre-heater element to allow the plant to burn waste-derived fuels to save on energy costs. The introduction of the pre-heater section with its push rod type design started to create build up issues. Production was now critical with many kiln stops for manual cleaning and rodding.
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Termeletrica - Sul dos EUA - Alinhador e Serviços de Manutenção - (conteúdo na integra em inglês)
A coal-fired power station was running into problems during the reclaiming and stacking out coal phase. The reclaim belt was consistently encountering tracking problems in both directions. Belt mistracking leads to material spillage, higher likelihood of worker injury, and increased maintenance expenses.
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Mina de Taconita, Centro Oeste dos EUA - Grades de Segurança - (conteúdo na integra em ingles)
The mine handles over 300 tons of crushed taconite per hour. Ore was continuously falling off of the belt, creating a safety hazard and putting workers in danger. The material spillage created the need for cleanup which is a dangerous maintenance task to perform since most conveyor accidents happen while performing maintenance and lubricating or checking the conveyor.
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Planta de Areia - Meio Oeste dos EUA - Serviços Manutenção - (conteúdo na integra em inglês)
Handling an abundance of sand every year, the plant had little time or resources to spend on inefficiency. Due to the lack of proper belt cleaning, spillage and carryback were present throughout the entire plant, leading to immense material loss. MSHA mandated corrective action be taken towards containment and collection to cut the amount of dust in half.
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Planta de Celulose (Filtragem de Pó de Casca) - Sul dos EUA - Dust Bags - (conteúdo na integra em ingles)
Uma fábrica de papel lida com 20 mil toneladas de casca todos os meses e estava encontrando problemas de poeira na polia principal do transportador perto da caldeira, criando a necessidade de limpeza manual. A OSHA considerou esta área perigosa com risco de explosão, então o cliente pediu a Martin para ajudá-los a controlar a poeira.
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Silos com cavaco de metal - Ordizia, Espanha - Canhões de Ar - (conteúdo na integra em espanhol)
Após a usinagem de vários itens, como torneiras e outras peças, o cavaco de metal que resta substrato, é armazenado em vários silos. Uma vez que esses silos estão cheios, o cavaco é descarregado em caminhões. O problema ocorreu quando este cavaco, misturado com fluido de corte, não podia ser deslocado do silo tornando quase impossível descarregar.
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Termeletrica - Cam Pha, Vietnã - Canhões de Ar - (conteúdo na íntegra em inglês)
The plant has had a problem with blockage in the coal silo since it started operation and has manually solved the problem by hammering the silo walls. In some cases the blockage was very serious and completely stopped the flow of material inside the silo discharge. The plant has been running at reduced efficiency and has had to stop production to remove the blockage manually.
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Termelétrica - Norte dos EUA - Canhões de Ar - (conteúdo na íntegra em inglês)
The plant handles ash and was experiencing material buildup on the sides of the hoppers. This created a safety concern for those employees who had to perform manual cleanup. Employee safety is important to management so they reached out to Martin Engineering to help eliminate buildup and the need for manual clean out.
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Termelétrica - Sul dos EUA - Sonic Horns - (conteúdo na integra em ingles)
A coal-fired power plant handles over a million tons of coal every year. The SCR catalyst screens had major build-up on them, decreasing productivity and efficiency. The existing sonic horns were not working properly and not improving the flow of material.
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Planta Cimento Holcim - Orizaba, Mexico - Pontos de Transferência - (conteúdo na íntegra em espanhol)
A cement plant was experiencing increased costs due to fugitive cargo and dust piling around the plant’s petroleum coke conveyor transfer point. The material blocked access, degraded conveyor components and required expensive maintenance. Outsourced labor using rented equipment needed weekly downtime to clean the area, further raising the cost of operation and lowering production.
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Caminhão de Sal - Mainlius, Illinois, EUA - Vibrador Industrial - (conteúdo na íntegra em inglês)
Manlius Township was finding that truck drivers carrying road salt for melting winter snow and ice were having difficulty getting the entire load to empty out of the truck bed. This not only delayed the drivers in effectively spreading the material to improve road safety, but it also encouraged drivers to engage in potential unsafe activities, such as climbing into the truck bed to shovel out the remaining material.
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Minério de Ferro - Minera del Norte Cemesa, México - Acessórios para Alinhamento - (conteúdo na íntegra em espanhol)
Minera del Norte´s Cemesa iron ore mining unit was having serious tracking problems with the conveyor belt leading from the primary crushing area. After drifting into constant contact with the frame, longitudinal tears formed on the belt, which reduced the usable width from 36 inches (914 mm) to 32 inches (812 mm). This caused spillage and lowered the production volume.
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Air Cannons Prevent Buildup on Kiln Walls
A mine was experiencing build up on the kiln walls, requiring continuous manual cleanup. This presented potential safety hazards for workers and increased man hours and overall expenses. Martin Engineering recommended installing Martin® 150-Liter Hurricane Air Cannons with retractable nozzles as well as Martin® Thermo Safety Shield.
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Martin Program Offers Hispanic Workers Advanced Training
With a diverse and multilingual company culture, the Hanson Aggregate Servtex Plant located in New Braunfels, TX was having problems finding advanced training for its Spanish-speaking staff. Most of the courses given by outside specialists with a deep understanding of the plant’s processes were conducted in English.
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Arcelor Mittal, Michoacán, México - Grades de Proteção - (Conteúdo na íntegra em espanhol)
A plant had safety guards installed around the tail pulleys on some of its conveyors, fabricated with a heavy structural plate attached to the base of the conveyor frame. The main problem was their excessive weight and the difficulties encountered when they needed to be removed. This extended the time needed to service the pulleys and created a greater risk of injury or accident.
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XHV Air Cannons Unplug Wet Bark At Paper Manufacturer
One of the largest specialty paper manufacturers in North America, handling 300 tons of wet bark per hour, began experiencing a plugged chute. This blockage not only decreased productivity, but also created safety concerns. Manually unplugging the chute took an estimated two hours per day, adding to maintenance expenses as well as putting workers in danger.
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Conveyor Belt Support Products Eliminate Spillage And Increase Productivity
Handling tons of PRB coal, a plant was having problems with dust and spillage at their conveyor transfer points. This material loss was costing the plant money in the form of decreased productivity, potential regulatory agency fines, and the cost of man hours to clean it up.
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Air Cannons Knock Down Sticky Coal From Hopper Walls
A power plant was having trouble with coal conditions. The material was wet and slightly sticky, which made it stick to the walls of the hopper, so much so that the material would accumulate and create a blockage in the hopper. Production couldn’t run smoothly, requiring temporary shutdowns so employees could manually knock down the material from the walls of the hopper.
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Industrial Vibrators And Air Cannons Clear Blockage In Hopper
A steel plant was having trouble with iron ore sticking to the walls of the hopper. The wet and slightly sticky material would accumulate in the hopper creating a blockage. Production couldn’t run smoothly and the plant had to hire people to continuously knock material off the wall of hopper to keep the flow of material running smoothly.
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Soluções para Pontos de Transferência Corrigem Desalinhamento da Correia Transportadora
Desalinhamento da correia estava causando desgaste prematura da vedação da correia e, portanto, causando o derramamento do material. Na tentativa manter a correia alinhada, os operadores da planta estavam constantemente ajustando a correia mecanicamente. Isso foi ineficaz para a planta e o custo para substituir os equipamentos desgastados foi alto.
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Sonic Horns Eliminate Dry Particulate Buildup
A coal-fired power plant handles 5,000 tons of fly ash per month. The buildup of ash was causing velocity increases of the flue gas through both inlet ducts to the precipitator. This was causing opacity spikes in emission, increasing the risk that the plant would face large regulatory fines from the EPA.
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Air Cannons Drastically Reduce Unscheduled Outages At Cement Plant
A plant produces over a million tons of cement every year. Due to the large production volumes, material was building up on the raw feed material inlet chute to the feedshelf in the preheat tower. The plant was incurring unscheduled outages due to buildup and blockages, costing tens of thousands of dollars per year.
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Tracker™ Installation Corrects Spillage and Fugitive Material
Um produtor de aço líder na Índia estava com problemas no alinhamento da correia transportadora em sua planta de sinterização, localizada ao sul do país. Com capacidade para produção de 14,3 milhões de toneladas por ano de material a granel, a correia transportadora principal foi se desalinhando, causando derramamento excessivo e pilhas de material fugitivo.
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Belt Cleaners Save Client $100K Per Year
The Springerville Generating Station handles 7 million tons of sub-bituminous coal per year. The coal yard was having problems with dust control, carryback and increasing wash down costs which negatively impacted the plant's production. Plant personnel were able to save more than $100,000 per year through the solution generated by the Martin team.
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New VPlow Prevents Conveyor Belt Damage
Luminant Sandow handles 31,200 tons of lignite per month. The plant had an existing v-plow installed, at one point, which allowed the nose of the plow to dip down from wear or belt slack. When the nose would dip, the plow would dig into the belt, causing belt damage and even ripping of the belt. This problem cost the plant $26,000 plus labor.
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Refinaria de coque - Mexico - Raspadores - (conteúdo na íntegra em inglês)
A petroleum coke refinery was experiencing spillage from materials adhering to the belt in the return. The operating staff had to manually clean the area and return the material back into the belt, creating unnecessary risk to workers and slowing down production, which increased operating costs.
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Easy-Access Air Cannons Increase Productivity
A large cement plant in Texas producing 900,000 tons of cement per year realized they had a problem with the air cannons on the feed shelf leading to the clinker. There was no access to the air cannons and they were in need of constant repair. To reach them, employees had to place scaffolding around the clinker.
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Arcelor Mittal - Michoacán, México - Alinhador - (conteúdo na íntegra em inglês)
An integrated steel complex producing flat steel (steel slabs) and long steel for both domestic use and export was having a problem with belt misalignment on one of the main conveyors, causing spillage of coal along the sides of the belt. As a result, the conveyor had to be shut down regularly so employees could manually clean the area.
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Dust Surfactant System Helps Open-Pit Copper Mine with Excessive Dust
An open-pit copper and molybdenum mining complex outside of Phoenix, Arizona was experiencing excessive dust off the stockpile and it was exceeding the permitted levels.
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Sistema Surfactante de Pó Melhora a Segurança dos Funcionários em mina de cobre
Um complexo de mineração a céu aberto estava sofrendo problemas de geração de pó. Para tentar solucionar o problema, uma calha foi instalada ao longo de uma correia transportadora entre a britagem e a moagem. A poeira estava em toda a extensão da correia transportadora, causando exposição à saúde dos funcionários e risco de queda.
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Soluções de Ponto de Transferência Reduzem a Geração de Poeira em Pedreira
Uma pedreira em Cedar Rapids estava tendo problemas com a fuga de pó. O Departamento de Saúde foi notificado de que a poeira severa estava chegando em um bairro residencial. O Departamento de Saúde enviou um trailer para medir as partículas de poeira perto do bairro residencial e os resultados revelaram que a poeira excedeu os requisitos legais.
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Belt Cleaners Save Copper Mine $22,000 Per Week In Downtime
An Arizona copper mine was experiencing excessive spillage from their conveyor belts feeding materials to the crushing facility. The carryback was so excessive they had to clean the area once per shift. Martin recommended a new cleaning system. The customer is now saving $22,000 per week and the cleaning requirements have changed drastically.
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Air Cannons Eliminate Blockages Caused By Sticky Iron Ore
At the largest cement producer in Texas, when iron ore would come in wet, or it would rain, the ore got very sticky and would stick to the inside of the silo. TXI would shut down for regular 24 hour periods so they could manually air lance the resulting blockage that was causing low feed rates. Working with Martin Engineering, they developed a plan to install a series of air cannons.
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Sonic Horn Eliminates Downtime From Ash Accumulation
Ash accumulation issues had been forcing Alaskan Brewery Company to shut down its equipment to cool and manually clean the swirlers and collectors of its ash handler on a weekly basis. The process required an outage of 3-4 days, including as much as twelve hours of maintenance time with bottle brushes and bead blasting.
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Silo Cleaning Salvages 40 Tons of Cementitious Material
Over time, material dust in the three pneumatically-loaded silos began building up, first on walls and ridges and eventually clinging to all the interior surfaces. The severity of the problem became apparent to system operators when they noticed the walls of the silos actually starting to bulge outward. The need for repairs was clear and immediate, but the material build-up presented a serious obstacle.
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Instalação de Soluções de Contenção de Pó em Fábrica de Processamento de Açúcar
Uma usina de processamento de açúcar na Califórnia manuseia aproximadamente 10 mil toneladas de açúcar bruto por ano através da planta. Um dos pontos de transferência estava sofrendo com problemas de derramamento de material. Eles entraram em contato com um representante da Martin (ACT). A ACT recomendou a melhoria do ponto de transferência com mesas de suporte, chapas de desgaste, cortina de pó e vedação.
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Washbox™ Cleaner Eliminates Dust and Carryback on Long Overland Conveyor
A metal mine in the Western US with long overland conveyors was having trouble with dust and carryback. The mine had to work with a high altitude location which resulted in cold weather and low humidity, long conveyor length, sticky material capable of hardening like concrete, and limited water. It was determined that the overall operation would be better served with a system that washed the belt.
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Steel - Arcelor Mittal; Lazaro Cardenas, Michoacan, Mexico - Canhões de Ar (conteúdo na integra em inglês)
Rainy weather was causing buildup problems at a steel production plant. The material was accumulating on the walls of the hoppers causing a consistent production bottleneck. To knock down the buildup, the plant resorted to hitting the walls with tools. The frequency of the production stoppages were proving to be too costly - with high labor expenses, shortened refractory life and reduced hopper efficiency.
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Siderurgica - Altos Hornos de Mexico; Monclova, Coahuila, Mexico - Mesa de Impacto - (conteúdo na íntegra em ingles)
As production increased at a steel production facility in Mexico, the existing impact cradles started to fail. After inspection, Martin® Impact Cradles were recommended due to the extreme operation conditions. Martin® Impact Cradles had been installed in the client's other mines so they were familiar with the product and knew these impact cradles would solve the problem.
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Truck Vibrator Prevents Clogging In Turf Sweeper Screens
GreensGroomer had problems with one of their turf sweepers returning material back onto the turf. With powerful, dual Cougar® DC Truck Vibrators in the collection baskets, any infill material that is collected is quickly returned to the field making the removal of unwanted debris from synthetic turf, easier and more efficient.
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Air Cannons Stop Material Buildup with No Unscheduled Shutdowns
The Büyükçekmece cement plant located west of Istanbul, Turkey had to manually dislodge material buildup in one of their cyclones in order to maintain throughput. The unscheduled shutdowns to allow cleanout of the cyclone of the cone and deep tube interfered with production schedules and exposed maintenance staff to potential hazards.
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Cement Plant Gets Extensive Conveyor System Overhaul
Like most cement manufacturing sites, GCC Dakotah employs an extensive conveyor system to handle raw materials and move finished product. GCC determined that significant upgrades could be made on conveyor transfer points to reduce spillage and dust emissions in the South Dakota facility. The upgrade included six transfer points on four conveyors.
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Belt Support Products Prevent Coal Accumulation
A coal plant produces a wet coal slurry that is pressed into fuel cakes, which drop down a 5 meter chute. With belt speeds of around 3.6 meters per second, the operation processes approx. 1.6 million tons per month. The large volume of material and relatively high speed had a tendency to release small amounts of spillage, which collected into significant accumulations.
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Martin® Hurricane Air Cannons Correct Ratholing In Chute
Soon after the plant went online, and the high-volume ramped up, engineers started noticing bottlenecks. They noticed a slowdown due to a material build-up in the chute feeding the export silo and discard bin. Operators determined that the freshly-pressed cakes were sticking to the walls of the chute, narrowing the space for product transfer and leaving “rat holes” which restricted flow.
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Conveyor Belt Cleaner Resolves Carryback In Aggregate Application
A limestone company had a significant amount of material being carried back along the underside of the conveyors. This carryback would accumulate and create mounds of spillage that would pile up in excess amounts causing operational issues. For safety reasons and to increase production, the crew was required to shovel and wash carryback spillage daily.
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Filtro de pó proporciona ambiente consciente na produção de carvão
A Orlando Utilities Commission - Stanton Energy Center (SEC) queria aumentar a segurança, limitando a poeira e o derramamento de material em um dos seus principais transportadores. Os engenheiros queriam reduzir as partículas no ar, eliminar uma fonte potencial de acidentes e quedas, e reduzir o tempo de limpeza e manutenção, permitindo que a mão-de-obra seja utilizada em outros lugares.
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Multi Port Air Cannon Saves Client Hundreds Of Thousands Per Year
Over time, operations personnel noticed a drop in SCR performance, and during a scheduled plant outage they inspected the system and discovered that fly ash contained in the exhaust stream was accumulating in the top layer. To address the situation, the plant was forced to enlist a contractor to come on-site 2-3 times each year during scheduled plant outages and evacuate the build-up.
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Belt Cleaner And Washbox™ Reduce Carryback By 99%
An innovative Michigan power supplier wanted to reduce surface dust and airborne particles, and reduce cleanup time at its PRB coal operation. Coal at the facility is fed either by rail, with a dumper that inverts the car and empties it directly onto a feeder conveyor, or with front loaders working off stockpiles in the yard. Both methods have the potential to generate dust.
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Existing System Jeopardizes Output Capacity And Employee Safety
Izmir Cimentas manufactures 5,550 tons per day of clinker from two production lines. They had an under-performing existing system, which was jeopardizing the plant’s output capacity by failing to remove accumulated material from the preheaters. The build-up issue needed manual removal on a daily basis, which required at least two hours’ maintenance each time.
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Soluções em Auxilio de Fluxo resultaram num projeto mais eficiente
Votorantim Cimentos is one of the world’s leading manufacturers of cement, concrete and aggregates building two new plants as part of a massive $2 billion investment to enhance production throughout Brazil. These new plants are expected to produce approximately 8,500 tons of clinker per day between them. Starting in the early design stages of the project, Votorantim has maintained an intense focus on efficient material flow.
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MartinPLUS® Silo Cleaning Service Clears Cement From Storage Vessel
The Eagle Materials Illinois Cement facility experienced severe blockage of Type I cement in its 80,000 ton capacity storage silo when a support cable on the reclaim screw conveyor came loose, sending thousands of pounds of material down into the silo at one time. Like most cement manufacturers, the plant uses large storage vessels to hold finished material until its ready for shipment.
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Filtro de pó e sistemas de supressão de pó atenuam a poeira do carvão na PRB
Construída há mais de 50 anos, uma usina a carvão com cinco unidades em Omaha, NE, foi inicialmente projetada para queimar carvão de alto teor de enxofre produzido no meio-oeste. Embora agora limpa, a planta não foi totalmente otimizada para a total de mitigação de poeira necessária ao manusear o carvão na PRB.
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Técnicos de serviço MartinPLUS® Substituem Chutes e Vedações
Ao longo do tempo, os operadores começaram a notar aumento da poeira e derramamento nos pontos de transferência em quatro de seus transportadores de 42 polegadas. O problema foi atribuído às calhas desgastadas e as vedações.
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Martin® Air Cannons Optimize Material Flow
A cement facility includes a state-of-the-art, six-stage precalciner/preheater with a rated capacity of 660,000 tons of clinker per year. Efficient material flow is a key component of Drake's dry-process manufacturing, and accumulation in storage bins, process vessels or feed pipes could choke even this well designed system. The facility's system required some fine tuning.
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New Transfer Chute Improves Material Handling Operations
The Vancouver Wharves terminal in North Vancouver, BC delivers inbound and outbound services to shippers moving cargo between all regions of western Canada, handling mineral concentrates, liquids (diesel and jet fuel), sulfur and specialty agricultural products. The terminal handles more than 600,000 metric tons of mineral concentrate per year across five different storage buildings.
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Copper Mine Solicits Martin's Expertise For Conveyor Belt Improvements
A copper mine in Arizona is a mine-for-leach operation and produces copper cathodes. The operation consists of two open pits feeding a crushing facility with a capacity of 103,000 metric tons-per-day. The crushed ore is delivered to a single leach pad by a series of overland and portable conveyors. The client hired Martin Engineering to evaluate their current system.
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Cougar® Pnuematic Piston Vibrator Eliminates Production Bottleneck
At a power plant in Vernal, Utah, coal was hanging up on the hoppers beneath the storage silos. Buildup on the walls of the hopper was an ongoing headache for operating personnel and a consistent production bottleneck. The plant resorted to climbing ladders and scaffolding and using sledge hammers to knock the coal loose.
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Martin® Hurricane Air Cannons Alleviate Ash Buildup
Koda Energy was battling significant buildup problems. Efficient material flow is a critical element of biomass-fired boilers, and accumulation or blockages can take a big bite out of a plant’s efficiency. Ash buildup on furnace walls and tubes can choke the process, degrading equipment performance and introducing the potential for safety risks during clean out.
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Innovative Utility Uses Conveyor Guards As Proactive Safety Measure
An innovative electric utility with an 80+ year history of delivering low-cost, reliable power wanted to implement measures to make its plant safer and take steps to ensure greater OSHA compliance by installing safety guards around its high-speed conveyor system. The solution needed to be in line with the company’s reputation as one of the most safety-conscious electricity providers in the nation.
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Martin® Multi Port Air Cannon Increase Productivity In Cement Plant
A cement plant was battling buildup problems in the cyclone discharge pipe following meal pipe expulsion. The buildup of sticky material created blockages leading to a smaller output opening at the bottom of the cyclone discharge pipe, causing serious production loss. To prevent blockages in the Cyclone discharge pipe, Martin Engineering determined suitable places for air nozzles, and installed two Martin® Multi Port Air Cannons.
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A Vedação Martin® ApronSeal ™ contém Poeira e Derramamento de Material
Uma mina de cobre no Arizona estava com problemas na vedação existente que não estava contendo poeira e derramamento de material. Este material fugitivo levou à necessidade de limpeza manual / da passarela todos os dias. A fábrica até comprou um transportador temporário para ajudar a aliviar esta questão. A Martin instalou a nova vedação Martin® ApronSeal ™ no transportador problemático.
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Martin® Belt Cleaners Solve Spillage Issue In Copper Mine
Spillage and carryback were accumulating at the tail section of one conveyor. This area could not be cleaned without shutting down the associated ball mill (which grinds copper ore) and locking out the conveyor. Martin installed two belt cleaners. There wasn't enough room to modify the dribble chute to accomodate any secondary cleaners so two cleaners were squeezed into a very small area.
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Truck Vibrator Offers More Complete Emptying Of Dump Trucks
Humphries Haulage was experiencing incomplete emptying of their dump trucks. Even fairly dry materials can be affected by weather and other conditions, making them extremely difficult to evacuate completely. A short vibration cycle can be a very effective way to break the surface tension and allow the load to slide out.
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Industrial Waste Truck Manufacturer Increases Productivity With Truck Vibrators
Manufacturer of industrial vacuum loaders, hydroexcavators and sewer cleaners needs solution for Off-loading of industrial waste from these vehicles. It can be a difficult task as stubborn materials don't always completely empty from the load. Vactor Manufacturing uses four different models of Cougar® truck vibrators to assist in the off-loading of industrial waste.
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Belt Cleaner Minimizes Need For Difficult Manual Cleaning
This cement plant produces one million tons per year. The plant uses a total of nine weigh feeders to move the raw materials—limestone, sand, shale and iron ore—from hoppers to the belt that conveys the material to the roller mill to be ground for kiln feed. To contain the cargo, these feeders use corrugated sidewall belts. Given their wall height, these belts are difficult to clean.
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MartinPLUS® Silo Cleaning Corrects Ratholing In Cement Vessel
A cement plant was experiencing build up which was hardening on the storage vessel’s walls. This produced a hardened rat hole that slowed flow and reduced live storage capacity. A leaky roof had contributed to the problems. It was estimated that the damp cement buildup reached 20 tons of material in the bin.
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Martin® Washbox™ Offers Unique Solution To Carryback Problem
Crushed molybdenum ore is transported to the processing plant on overland belt conveyors. As the conveyor passes through a preserve, the operation was concerned about the escape of carryback. To provide effective belt cleaning in the challenges of the operation’s high altitude and cold climate conditions, Martin Engineering developed a special belt washing station.
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Deteriorating Power Plant Needed Material Handling System Redesign
The coal conveying system at the power plant needed refurbishment. Problems included fugitive material arising as dust and spillage, as well as a general deterioration of the condition and performance of the system. Complicating the project was the plant’s need to remain in operation during the work. The plant would need to run the coal handling system almost every day.
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Martin® Railcar Opener Ensures Smooth Unloading
Up to four times a week, the terminal receives unit trains of 40 railcars at a time. Unloading proceeds round the clock, one car every 40 minutes, until all cars are emptied allowing the train to return to the manufacturing plant for another load. To keep the trains in motion, and the terminal’s five silos full, it is important that unloading proceed smoothly.
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Martin® Tracker™ Corrects Conveyor Belt Mistracking
Canada Steamship Lines Inc. owns and operates the largest fleet of self-unloading vessels in the world. One of these vessels is the CSL Assiniboine, which plies the Great Lakes carrying cargos of up to 33,860 tons of coal, grain or taconite pellets. The ship’s self-unloading system consists of three conveyors belts below the vessel’s holds.
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Transportation Company Needs More Flexible, High Discharge System
To maintain leadership in self-unloading technology, CSL had set ambitious goals for the discharge systems of new ships, including simplicity, maintainability, increased load capacity, flexibility, high discharge rates and environmentally-friendly operation. In March 2001, the CSL Spirit joined sister ships Sheila Ann and Sophie Oldendorff as the newest additions to the CSL International fleet.
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Martin Vibration Products Replace Inadequate Competitor Vibrators
At a cement company in California, air powered vibrators used to boost material flow from the unloading railcars produced high noise levels. In addition, the heavy weight of these vibrators prompted concerns about injury to the operators who installed units on railcar outlets multiple times each day. Martin Engineering was asked to provide a solution.
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Coal Spillage Significantly Reduced By Martin® Transfer Chutes
All coal burned at the plant moves through a single chute. The path is at an angle of roughly 90 degrees from either of the discharging conveyors, making for a difficult transfer. A drop height of 30 feet also creates problems, including a large flow of induced air, resulting in dust escape, high levels of impact leading to idler damage and belt abrasion from poor control of the flow of coal.
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Plugged Chutes Fixed By Martin® Inertial Flow™ Transfer
Superior Midwest Energy had little opportunity for maintenance and equipment changes due to its continuous loading schedule. The plant was running into constant plugged chutes, leading to spillage and a lot of man-hours spent on cleanup. Martin Engineering designed custom-engineered chutes specifically to suit the needs of Superior Midwest Energy.
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Air Cannons Reduce Need For Manual Cleaning
A cement plant produces 1,100,000 metric tons per year of clinker from one line. However, air cannon systems supplied by competitors were not working properly, leaving material buildups in the preheater tower. The buildups required manual cleaning at least two hours every shift, and a monthly slowdown for a major cleaning.
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Cortina de Pó Mantém o Material Fugitivo Longe de Casas e Empresas
Uma planta de geração de energia de Minnesota estava tendo problemas para controlar o pó e o derramamento de material. A redução da turbulência do material durante a transferência é essencial para evitar a fuga do pó.
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Empresa de Transporte Precisa de Solução para Poeira de Carvão
A Aurora Energy Services precisava melhorar o fluxo de carvão através do carregador de navio em seu terminal. Mas os problemas nos chutes de transferência no carregador limitavam a velocidade de carregamento e atrasava o retorno do navio. Pior ainda, a fuga de poeira de carvão durante o carregamento preocupava pois nas proximidades da planta estavam as marinas, bem como grupos ambientais.
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MartinPLUS® Maintenance Services Improve Mining Operation
Located in Indonesia is a high volume operation producing gold and copper. To handle the vast quantities of ore, the mine uses large, fast, high capacity conveyors. Belts are typically 72 or 84 inches in width, and operate at 4 m/sec. To simplify supplier arrangements, PTFI sought one belt cleaner supplier who could provide both installation and service.
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Air Cannons Dramatically Improve Employee Safety
At this rail-to-barge trans-loading facility, a set of six stacker tubes connected by conveyors allows the stockpiling of coal. Coal would hang up inside the tubes, sticking to the walls, building up inside. To clean coal out of the tubes, the operation used manual labor. A man-lift would be used to raise personnel to the lowest window of a stacker tube, so they could dig out the accumulated coal.
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Coal-Fired Power Plant Experiences Dramatic Reductions In Dust And Spillage
Plant Daniel’s two 500 MW units burn 2.9 million tons of a blend of bituminous and PRB coal annually. The coal handling system had problems with dust and spillage. The plant wanted to reduce dust and spillage, and their related hazards, and at the same time control the expense for the contract labor used for clean up and wash down procedures.
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As Soluções Martin® para Auxílio de Fluxo Reduzem Interrupções de Produção em Fábrica de Cimento
Uma fábrica de cimento em Matozinhos, Minas Gerais, Brasil, é uma das principais instalações de produção de cimento do Brasil. Inaugurada em 1959, a planta produz 660 mil toneladas (600 000 toneladas métricas) de clínquer por ano. A necessidade de melhorar a eficiência e manter a produção sem interrupções levou os funcionários da empresa a considerar formas de melhorar o fluxo de materiais através da torre de pré-aquecedor da planta.
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Sistemas de Vedação Reduzem Custos com Limpeza e Manutenção
Localizado em Ohio, o terminal de Vernon movimenta cerca de 1,8 milhão de toneladas de carvão anualmente em caminhões ou vagões para barcaças para embarque para usinas de energia. O derramamento excessivo de material em um transportador aumentou os custos de limpeza e a manutenção, além das dores de cabeça. Este transportador tem 84 polegadas de largura com uma velocidade de operação de 150 fpm.
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Belt Cleaner Improves Efficiency And Extends Blade Life
At a mine in Fayette County, West Virginia, coal-carrying conveyors both above and below ground need to be cleaned to reduce operating problems and safety issues. Cleaning these belts can be difficult as the multiple mechanical splices on many belts will reduce cleaning efficiency and shorten blade life.
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Transfer Point Solutions Increase Productivity At Container Board Plant
Bark and wood waste are used as fuel to produce heat and steam for this container board plant. A series of belt conveyors 36 to 48 inches wide carry bark to the powerhouse. The Pine Hill Mill began a program to improve its materials-handling operations and eliminate fugitive materials. The bark conveying system was the first system to be upgraded.
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Impact Cradles Minimize Conveyor Belt Damage
A drop of approximately 23 feet onto the belt proved hard on conveyor components, causing excessive wear and damage to both the belt and idlers. Martin® Impact Cradles absorb the impact originating in lumps of material landing on the belt. The cradles prevent impact damage to the belt and other conveyor components and stabilize the belt line to reduce load zone spillage.
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Piston Vibrator Corrects Bottleneck And Decreases Shutdowns
The plant’s mixture of coal and shredded tires (TDF) hangs up on the feed hopper grizzley. The plant has removed several of the grizzley bars, creating a larger opening but material still hangs up. This bottleneck forces plant personnel to push the fuel mixture over the pit, and then get out of the loader to poke the pile through the grizzley with a shovel.
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Serviços de Manutenção MartinPLUS® Ajudam Planta de Aço a Superar Questões Regulatórias
Os transportadores de uma fábrica de aço sofreriam com problemas de geração de pó e derramamento de material. Este material fugitivo levou a problemas com moradores vizinhos e agências reguladoras. Para resolver estas questões, a CST de Vitoria firmou um contrato de longo prazo com a Martin Engineering no Brasil para a manutenção de seu sistema de transporte.
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Martin® Air Cannons Eliminate Dust From Refractory
This fuel-efficient kiln operates by alternating the firing of two shafts, so one shaft burns while the other acts as a fuel for exhaust gases. The heated gases leave the combustion chamber through arches opening into a crossover channel. Dust would adhere to the refractory in the arches, choking the flow of gases from one combustion chamber into the other.
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Vedação Interna Autoajustável Martin® é Rápida e Fácil de Instalar
Em uma empresa de cimento, o clínquer abrasivo desgastaria rapidamente as tiras de vedação da calha guia, criando um grave problema de derramamento de material na zona de carga do transportador. O sistema de vedação exigia a reposição a cada três semanas. A Martin Engineering forneceu "Desempenho personalizado", adaptando as vedações autoajustáveis proporcionando uma melhor resistência à corrosão enquanto os custos permanecem dentro do orçamento do cliente.
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Clientes no Peru testam raspadores Martin® - Peru - Raspadores - (conteúdo na íntegra em inglês)
At an agglomeration plant in Peru, plant management wished to compare the performance of competitive belt cleaning systems. The plant operates parallel (redundant) conveyor systems that carry approximately the same material load on the same operating schedule. Installing competing belt cleaners on the side-by-side conveyors allowed the plant to compare belt cleaning results.
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Os produtos Martin® para Pontos de Transferência reduzem o
Esta usina de energia enfrentava problemas de geração de pó e derramamento de materiais durante o manuseio de carvão. Para aumentar a eficiência do manuseio de materiais e reduzir o risco de incêndio ou explosão, a Martin instalou calhas guias novas e mais longas, novos equipamentos de suporte para a correia, revestimentos resistentes à abrasão e um sistema de vedação.
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Martin Designs Special Suspension Bracket On Suspended Conveyors
The operation uses underground conveyors suspended by cables from the mine ceiling. Keeping the belts running in the center of the suspended conveyors is a continuous challenge. Martin designed a special suspension bracket to allow installation on the suspended conveyors. Units are built with bronze bearings to avoid problems with static electricity in the underground coal mine.
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Martin® Belt Cleaner Requires Less Maintenance and Lasts Longer
QCM moves an average of 8.5 million tons of iron pellets per year through its shiploading facility. The reclaim conveyor was creating so much carryback that the workers had to wash down the structures and pivot rail system between each shipload. This could be done without problems from April to December, but was impossible during the winter months.
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Cement Company Benefits From Martin® Air Cannons
A cement plant in Florida was producing 2,500 tons per day of clinker. Air cannons were not included in the design of this new plant. Martin Engineering developed a plan for the installation of 45 Martin® Air Cannons on the new pre-heater. Crews from MartinPLUS® Services group installed the pre-heater air cannon system.
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Martin® Belt Cleaners Save Client Over $55,000 Per Year
An aluminum recycling plant was unhappy with the performance of a competitor’s belt cleaners, and thought replacement blades were too costly. As a result of poor cleaning performance, plant employees were required to vacuum fugitive material from the conveyor pits two to three times per week, at a cost of $1,500 to $2,500 per vacuuming.
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Martin® Air Cannons Maintain Boiler Feed Rate At Power Plant
A power plant uses petroleum coke - a refinery waste product - to fire its boilers. But the sticky material would build up on the walls of the chutes carrying it from the gravimetric feeders to the boiler. Instead of the 300 tph required, the feed rate would slow down to 75 to 100 tph, starving the boilers. The plant staff resorted to frequent cleaning of the chutes.
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Flow Aids Remove Sawdust At Particleboard Manufacturer
Before wood shavings can be pressed into particleboard, they are dried in a chips dryer. The plant uses a flat line, ten-zone oven. Screens form the sides of the oven to keep the chips away from the coils that heat the oven. Sawdust picked up by the oven’s circulating air would stick to the screens, clogging the openings and reducing air movement.
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Martin® Air Cannons Require Less Maintenance
To preserve the life of the air cannon’s piston and sealing o-rings, oil was added to the air supply. But as the air cannons would discharge the oil would collect on the filter, causing the filter to plug or bind. Filter efficiency would go down, which in turn reduced plant output and increased maintenance problems. The plant installed Martin® XHV Retrofit Valves on the air cannons.
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MartinPLUS® Installation Services Gets Rave Reviews From Happy Client
A power generating station needed to improve the performance of a vibratory feed chute. To improve the situation, MartinPLUS® Services installed an electric vibrator on the feeder pan. The crew also removed the existing UHMW lining and replaced the cables that suspend the vibrating pan. The new feeder and chutes work as projected.
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MartinPLUS® Service Technicians Conduct Power Plant Overhaul In Michigan
The drag chain conveyor under a slow moving feed conveyor was inoperable. Martin Engineering was called in to engineer the existing system’s tear-out and design a new dribble chute. MartinPLUS® Service Technicians prepared and sent detailed drawings with a step-by-step procedure for removal of the drag chain conveyor.
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Transfer Point Solutions Resolve Carryback At Kentucky Energy Plant
An energy company in Kentucky was having problems with carryback on their side-by-side transfer belts carrying coal from the central reclaim tunnel to the bunkers. They hired Martin Engineering to find a solution. Martin recommended a variety of belt support, belt sealing, tail protection and dust containment solutions as well as safety accessories.
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Sequencing Air Cannons Clear Kiln
This plant is a new, state-of-the-art facility, but designed without air cannons on the pre-heater tower. Consequently, material flow through the pre-heater was subject to blockages, requiring excessive (and potentially risky) labor. Martin installed air cannons, set to fire in a sequence starting from the kiln feed shelf and working up, alternating side to side, until all the cannons have fired and then starts over.
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Air Cannons Stop 60,000 Pounds Of Sugar From Sticking To Vessel Walls
Fine sugar used in a line of powdered drink mixes would build up on the walls of the storage silo. This choked the flow of sugar out of the silo leading to slowdowns in production. By the time of the annual outage, there would be between 40,000 to 60,000 pounds of sugar stuck to the vessel walls. The cost to recover and reprocess this sugar was a considerable drain on the budget.
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Planta de Geração de Energia Precisa de um Sistema de Manuseio de Materiais a Granel Mais Limpo, Mais Seguro e Mais Produtivo
A Usina de energia da Warrick é operada pela Alcoa Generating Company para fornecer eletricidade para operações de fundição nas instalações da Alcoa Warrick. O equipamento de movimentação de carvão da planta precisava de reconstrução e melhoria, incluindo sistemas aprimorados de controle de derramamento e poeira, para fornecer um sistema de manuseio de carvão mais limpo, mais seguro e mais produtivo.
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Flow Aids Return Plant To Designed Production Rate
Material would build up at the inlet to the pre-heater tower. These accumulations choked the flow of material, reducing the plant’s production from its design rate of 3,000 to 2,700 tons per day. To regain capacity, the plant would take unscheduled outages to allow manual cleaning of the ducts. After cleaning, the buildup would resume, with flow choked again within ten days.
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Air Cannons Move Sticky Coal From Bins
To keep up with the steel mill’s around the clock, seven days-per-week schedule, the railcar dump must provide 3,000 tons of coal per day, every day. But the operation was at the mercy of the handling properties of the coal. Coal with higher moisture content, material density or size ranges would hang up on the walls of the receiving bin below the car dumper.
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MidAmerican Energy (P1118) - Usina Termeletrica a Carvão - Iowa, EUA - Serviços (conteúdo na integra em inglês)
A coal-fired power plant in Iowa was ready to replace their ineffective belt cleaners and cumbersome air tensioning system. Plant officials agreed to test a Martin® QC1™ Cleaner XHD from Martin Engineering. The test installation provided a blade life of approximately one year, and its “one-pin” blade change simplified maintenance.
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Alliant Energy (P1117) - Planta Geradora de Energia - Iowa, EUA - Serviços (conteúdo na integra em inglês)
An energy company in Lansing, Iowa was facing severe spillage problems in underground loading points. The steel structure on part of conveyor feeding system was shot. It was old and worn out. There were bows and dips in the skirtboard, and it wouldn't stay sealed. This created excessive dust and spillage in the tunnel.
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Soluções em Pontos de Transferência Corrigem Problemas de Material Fugitivo em Termelétrica de Carvão (P1116) - Georgia, EUA - (conteúdo na integra em inglês)
A coal-fired power plant was suffering from extensive spillage and other problems. The plant’s coal-conveying system needed an extensive upgrade, including new belt cleaning systems and improved transfer point systems.
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Rheinbraun AG Erfstadt (P1115) - Planta de Carvão Lignite - Germany - Raspador SHD (conteúdo na integra em inglês)
A lignite mine must move over 350 million tons of overburden per year. The mining method is open cast excavation using bucket wheel excavators and high-capacity conveying systems. To control expenses, the client wanted to extend the life of belt cleaning components while reducing the maintenance these systems required.
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Canhões de Ar Martin® Eliminam Uso de Água para Remover Acúmulo de Materiais em Cimenteira (P1114) - Nebraska, USA - (conteúdo na integra em inglês)
A plant used water blasting to remove material buildups from the pre-heater tower’s riser duct. Personnel were required to open access doors into the tower twice a day to remove the accumulations with a high-pressure water spray. The water blasting caused production problems, dropping lumps into the kiln feed, downgrading kiln efficiency and clinker quality.
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U.S. Sugar Corporation (P1113) - Planta de Processamento de Açúcar - Florida , EUA - Serviços (conteúdo na integra em inglês)
The 10 conveyors in the raw sugar conveying system suffered severe spillage and carryback as well as belt wander that originated in the accumulation of fugitive material on rolling components. Plant management made a commitment to solve these problems. Martin Engineering provided a detailed engineering study that listed a number of recommendations.
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Mineração de Ouro - Newmount Mining Corporation Mineria Yanacocha Mine, Peru - Suporte da Correia (conteúdo na íntegra em ingles)
A major expansion at a gold mine included an innovative idler design developed by Martin Engineering in conveyor transfer areas. The mine’s high-capacity conveyor system faces continuous loads and heavy impact from 8-inch lumps of copper ore. To withstand this impact, Martin Engineering designed a special belt support system.
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Soluções Martin® Resolvem Problemas de Material de Retorno e Derramamento de Material em Planta de Carvão (P1111) - MA, EUA - (conteúdo na integra em inglês)
A power plant’s coal-handling system starts with a reclaim conveyor under the stockpile and makes its way to the coal gallery. There, twelve conveyors distribute the coal to six different bunkers that feed the plant’s three coal-fired boilers. The plant suffered general dust, spillage and carryback problems throughout the coal conveying system.
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Hennepin Power Station (P1110) - Planta Geradora de Energia - Illinois, EUA - Soluções para Auxílio de Fluxo (conteúdo na integra em inglês)
During the power plant’s summer outage, an independent contractor designed and installed new chutes to feed the coal mills. But at start-up, material clogged in these new chutes and closed off the flow of coal into the boilers, causing the plant to shut down. The plant needed an emergency-response “quick fix” to return to production and a solution for long-term correction.
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Entergy Operations Services (1109) - Termeletrica a Carvão - Arkansas, EUA - Serviços (conteúdo na integra em inglês)
In normal operations at a coal-fired power plant in Arkansas, a 72-inch (1800 mm) feeder belt loads coal onto another 72-inch (1800 mm) belt. Plant engineers wanted to be able to bypass the second conveyor and load material directly from the first conveyor to the last. The plant needed engineering assistance to accomplish this redesign and avoid bottlenecks and plugs in the new chute.
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Canhões de Ar Martin® Previnem Interrupções Não Programadas (P1108) - Tennessee, EUA - (conteúdo na integra em inglês)
At CEMEX in Tennessee, buildup on the walls of the pre-heater was a continuing headache for operating personnel and a consistent production bottleneck. To knock down the buildup, the plant resorted to water blasting, but the frequent water blasting proved costly, with high labor expenses, shortened refractory life and reduced kiln efficiency.
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Raspadores Martin® Melhoram as Operações em Cimenteira (P1106) - Iowa , EUA - (conteúdo na integra em inglês)
At a cement plant in Iowa, a 42-inch (1067 mm) wide belt carries material to the stockpile from the quarry’s primary crusher. But poor performance by the conveyor’s homemade “slab” belt cleaner left piles of carryback under the conveyor, interfering with its ability to move to the stockpile, while shortening component life.
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Soluções para Pontos de Transferência rezudem risco de incêndio em Planta de Carvão ( P1105) - Missouri, EUA - (conteúdo na integra em inglês)
The transfer chutes of these redundant systems would choke, cutting coal flow to 550 tph, roughly half the system's design capacity. This required the operation of both twin bunker feed conveyors on longer schedules without allowing for system maintenance. In addition, the transfer points created large quantities of coal dust, creating a fire hazard and maintenance headache.
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A Vedação Interna Autoajustável Martin® Melhora as Operações em Planta de Sal (P1101) - Ohio, EUA - (conteúdo na integra em inglês)
Uma planta de sal em Ohio estava buscando atualizar seus sistemas de vedação. A vedação existente estava em mau estado havia vazamento de material. Com menos de duas polegadas (51 mm) de área livre de correia em cada lado da zona de carga, o transportador tinha espaço muito limitado disponível para a instalação de um sistema de vedação.
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