SAVITRIBAI PHULE PUNE UNIVERSITY

Abstract

The globalization of the Indian economy has thrown a great challenge to the
Indian industries in respect of productivity, quality, cost, delivery etc. Achieving
success. The global market has required fundamental shift in the way business
is conducted and has dramatically affected virtually every aspect of process
industry. The internal manufacturing process and supporting infrastructure
should be such that it can compete successfully in global markets with better
flexibility and delivery. The paper deals with a case study of a reputed process
industry, some changes in the process has been suggested, which leads to
reduction in labor cost and production cost.

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Introduction
Conveyor belts have been used for decades to transport bulk and unit
loads. They have proved their worth everywhere because belt conveyor
installations can be adapted to meet nearly all local conditions. They are work-
safe and economical. The demand for ever increasing capacities and ever longer
conveying lengths has accelerated the development of the belt conveyor
technique, new materials are being developed, new conveying systems are being
planned and tested especially those having regard to the environmental. The
conveyor belt plays the major part in the whole system and has to
overcome the many and varied stresses. In addition to this every conveying
problem is different and needs careful planning and selection of the right
elements in order to achieve the optimum conveying capacity in an economical
way.
There are a number of practical rules, values and experiences which can
be useful during the planning stage. This manual aims to be of assistance to
operators, engineers and project people and provides a substantial amount of
elementary data. In addition there are a number of instructions and hints offered
to enable accurate calculations or checks on installation components that
impinge on the running of the belt. In future there will be more and more use of
the computer for calculations and dimensioning of belt conveyors. With this
often the correlation of the valuation criteria will no longer be recognizable.
This manual should also help to understand the background to a calculation, the
selection criteria for an optimum belt type and to recognize a special operating
case.
All new standards DIN, or ISO, have been taken into consideration as
well as the results of individual research studies. The developments continue
and we are grateful for all hints and practical experiences.

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LITERATURE REVIEW
Several definition of material handling exists. Material handling is
defined in Compton’s Interactive Encyclopedia as “The moment of raw
material, Semi-finished goods and finished article through various stages of
production and warehousing is called material handling.” Traditional view of
material handling sees material handling operation as non-value adding and
only contributing to the cost of product. The modern view recognizes the space
and time utility of material handling operation. Material handling equipment is
used to increase output, control costs,
and maximize productivity.
The various methods used for material handling in vertical direction are
inclined conveyor,lift, robots, spiral conveyors etc. The angle of inclination in
case of inclined conveyor is limited to certain value. The inclined conveyor also
consumes large amount of space. The lift is another equipment to transfer the
material from ground to first floor. The height achieved is higher compared to
others. Robots are also used to transfer precise parts from one level to other. Lift
and robot are effective but are expensive.

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Objective

Bulk material transportation requirement have continued to press the belt

conveyor industry to carry higher tonnages over longer distance &more diverse
routes .In order to keep up, significant technology advance have being required
in the field of system design, analysis and numerical simulation.
The application of traditional components in nontraditional applications
requiring horizontal curves & intermediate drives have changed & expanded
belt conveyors possibilities. Examples of complex conveying applications along
with numerical tools required to insure reliability & availability will be
reviewed. As an engineering student our objective is to learn the practical/
actual design of conveyor system.

Conveyor design METHODOLOGY

After Selection of configuration and layout of system following steps are

Followed;
1. Characteristics of material affecting design
2. Belt speed
3. Width of belt
4. Capacity of belt conveyor
5. Driving force and power calculation
6. Belt selection
7. Pulleys
8. Idler

9. Drive selection
10. Coasting

11. Structurals

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CONSTRUCTION

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Case Study On Material Handling System In Cement Industry

Objectives

➢ To study about material handling system in cement industry.

➢ To analyze the material handling equipment in cement industry.

Introduction

In the most general sense of the word, cement is a binder, a substance that
sets and hardens independently, and can bind other materials together. Cement
used in construction is characterized as hydraulic or non-hydraulic. Hydraulic
cements (e.g. Portland cement) harden because of hydration chemical reactions
that occur independently of the admixture's water content; Non-hydraulic
cements (e.g. lime and gypsum plaster) must be kept dry in order to retain its
strength.

There are 31 cement industries in Bangladesh1. Material handling is one

of the most important tasks in cement industry. Material Handling is the
movement, storage, control and protection of materials, goods and products
throughout the process of manufacturing, distribution, consumption and
disposal.

Material handling equipment

Material handling equipment (MHE) is used for the movement and storage
of material within a facility or at a site. MHE can be classified into the
following five major categories:

• Transport Equipment. Equipment used to move material from one

location to another (e.g., between workplaces, between a loading dock
and a storage area, etc.). The major subcategories of transport equipment
are conveyors, cranes, and industrial trucks. Material can also be
transported manually using no equipment.Positioning Equipment.
Equipment used to handle material at a single location so that it is in the

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correct position for subsequent handling, machining, transport, or storage.

Unlike transport equipment, positioning equipment is usually used for
handling at a single workplace. Material. Material can also be positioned
manually using no equipment.
• Unit Load Formation Equipment. Equipment used to restrict materials so
that they maintain their integrity when handled a single load during
transport and for storage. If materials are self-restraining (e.g., a single
part or interlocking parts), then they can be formed into a unit load with
no equipment.
• Storage Equipment. Equipment used for holding or buffering materials
over a period of time. Some storage equipment may include the transport
of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If
materials are block stacked directly on the floor, then no storage
equipment is required.
• Identification and Control Equipment. Equipment used to collect and
communicate the information that is used to coordinate the flow of
materials within a facility and between a facility and its suppliers and
customers. The identification of materials and associated control can be
performed manually with no specialized equipment.

Cement production process

A cement production plant consists of the following three processes.
1. Raw material process
2. Clinker burning process & 3. Finish grinding process.

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Figure: Material handling in cement industry

Material handling in cement industry

Figure shows the use of conveyor in cement industry .Following things are used for material
handling in cement industry

▪ Belt conveyor
▪ Air glide
▪ Elevator conveyor
▪ Screw conveyor

00. Limestone Quarry and Crushing plant

01. Limestone Stockpile
02. Additives Hopper

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03. Additives Storage

04. Raw Mill Building
05. Blending and Storage Silo
06. Preheater
07. Gas Conditioning Tower and ESP
08. Kiln 09. Cooler
10. Deep Bucket Conveyor
11/12. Clinker/Gypsum Storage
13. Coal Mill Building
14. Cement Mill and Bag House
15. Cement Storage Silo
16. Packing & Dispatch
17. Central Control Room

Belt conveyor:
A conveyor belt (or belt conveyor) consists of two or more pulleys, with a
continuous loop of material - the conveyor belt - that rotates about them. One or
both of the pulleys are powered, moving the belt and the material on the belt
forward. The powered pulley is called the drive pulley while the unpowered
pulley is called the idler.

Figure: belt conveyor

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Belt conveyor is very simple in design and widely used in many industries. Belt
conveyor is mostly used in cement industry to convey raw material to grinding
machine. After grinding raw material it is conveyed by belt conveyor for mixing
process. Finally when cement clinker is grinded again finished cement is
transferred for packaging through belt conveyor. Also lot of cement is
transferred in belt conveyor in silos after packaging. Belt conveyer is very basic
material handling equipment and used frequently in cement plant.

Figure : Belt conveyor

Air glide conveyor:

Air glide is a material handling equipment useful for Bulk material

handling process. Air glide conveyors are designed to be robust and reliable for
harsh environments. The Air glide Belt conveyor is a development of the
traditional type, but instead of carrying idlers it employs a cushion of air, being
the means of supporting the loaded belt between the feed and the discharge. Air
is injected at regular intervals along the "U" shaped bedplate to the underside of
the belt, generating a low friction support cushion. A small blower unit supplies
the low-pressure filtered air to the plenum, which in most instances is sufficient
to supply the total belt length.

In cement industry air glide conveyer are used when additive materials are
supplied in a mixture

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Figure: Air glide co nveyor

Elevator conveyor
Elevator conveyor is a precise solution to the vertical movement of dry
and free flowing bulk materials for the Cement Industry. The Bucket Elevator is
constructed using stainless steel or mild steel buckets attached to a belt or chain.
Encased in a steel enclosure the elevated material is protected from the
atmosphere, giving the Bucket Elevator the ability to be used internally or
externally of buildings. In cement industry processing materials are uplifted
vertically to feed in preheater. For a uplifting operation elevator conveyor are
used in cement industry. As shown in fig:

Figure: Elevator Conveyor

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Screw Conveyor

Screw Conveyors have a variety of uses. Variations in the flight design allow
Screw Conveyors to:

• Convey
• Mix
• Feed
• Elevate\

Figure: Screw Conveyor

With the bespoke construction of the screw conveyor it is possible to have

multiple in feeds and a single out feed. In cement industry tons of material are
processed the upper listed operation. When a semi liquid material is dried in a
dryer obtained clinker is stored in storage through screw conveyor.

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Conclusion
Material handling system is a basic component in cement Industry. Tons
of bulk material are conveyed , uplifted, and stored in cement Industry so
material handling equipment like Conveyor, Elevator, Silos are the essential
part of cement Industry.

In this seminar we have defined a theoretical portion of material handling

system in cement industry. We searched in internet for required information of
our topics. Finally we decided to take a “chhatak cement Industry “as a case
study in a second portion of this seminar.

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REFERENCES
[1] Company Manual.

[2] I.L.O "Introduction to work study" Oxford and IBH Ltd, New Delhi.

[3] Bawerlag Gmbh Wiensbaden and Berlin "cement data book" pp 232 to 312.

[4] Muther, R, "Systematic layout planning", Industrial Education Institute,

Boston 1961.

[5] http// www.hazemag.de/

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