BULK HANDLING
part of Valmont Industries, Inc.
VALMONT SM HANDLES THE FOLLOWING MATERIALS
BIOMASS IRON ORE, SAND, COAL, LIMESTONE, GYPSUM, FOOD STUFFS, BOTTOM ASH, FERTILIZER, AND MANY MORE
Valmont SM is ISO 9001:2015, ISO 14001 and OHSAS 18001 verified. Valmont SM will demonstrate environmental responsibility and create and maintain safe and healthy working conditions for all employees. Valmont SM will achieve continuous improvements on the environment and working environment through the involvement of our employees. The quality department of Valmont SM upholds a quality assurance system in accordance with DS/EN ISO 9001:2015. In addition, we maintain following certificates: EN ISO 3834-2, AD 2000-Merkblatt HPO, EN 1090-1/2 EXC4, GEN DIN 18800-7.
VALMONT SM PRODUCT PORTFOLIO INCLUDES ATEX CLASSIFICATION
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BELT CONVEYORS, CHAIN CONVEYORS, PIPE CONVEYORS, SCREW CONVEYORS, BUCKET ELEVATORS, SHIP LOADERS, TRUCK LOADERS, STACKERS, ROLLER SCREENS, CRUSHERS, RECLAIMERS, HOPPERS, ON LINE ANALYZERS, MATERIAL SAMPLES, STORAGES, BINS, SILOS ETC.
PERFORMANCE GUARANTEE
Valmont SM provides complete solutions and will optimize your system for performance and minimize power consumption. Further Valmont SM offers a Performance Guarantee on each system design. Valmont SM Bulk Material Handling specializes in providing complete, complex, tailor made solutions for material handling and in close cooperation with our customers. Valmont SM has a strong track record among others in the power plant industry and is well known for our commitment and professionalism. Valmont SM will always try and create added value for its customers. Valmont SM equipment is manufactured in Denmark or in cooperation with selected well known EU suppliers on the market, to the highest quality and standards in order to achieve high performance and reliability.
We design, build and install • Co-engineering and Qualified Technical Support • Fully automated systems for flexible performance and low power consumption • Project Management and one point contact • Manufacturing and Quality Control • Equipment supply with supervision • Procurement and Logistic • Installation, Commissioning and Training • Handing over to customer after successful performance guarantee • Service contracts and spare parts
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BELT CONVEYORS BELT CONVEYORS ARE THE MOST ECONOMICAL SOLUTION OF CONVEYANCE AVAILABLE FOR THE INTERNAL CARRIAGE OF BULK GOODS, SUCH AS... ASH, GYPSUM, GRAIN, FLOUR/POWDER, WOOD CHIPS, CONCRETE, FERTILISER, COKE, SAND, LIGNITE, FOODSTUFFS, COAL, CINDERS, CEMENT, LIMESTONE, IRON ORE, STONE ETC.
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TYPICAL POWER CONSUMPTION
HORIZONTAL CONVEYANCE
VERTICAL CONVEYANCE
PER TON / PER METRE
PER TON / PER METRE
0,3 W
3W
Belt conveyors are economical and easy to maintain. Many belt conveyors run without needing much repair for 10 years – and some even run for 20 years. Belt conveyors consume less power per ton per metre than any other mode of conveyance. Horizontal conveyance generally consumes 0,3 W per ton per meter and vertical conveyance 3 W per ton per metre. Belt conveyors are available in lengths ranging from only a few metres, to several kilometres. Some single conveyors can be up to 10 km long and some combined conveyor lines can be up to 100 km. The capacity of belt conveyors varies from a few tons/ hour up to 10 – 15.000 tons/hour at belt speeds of 6 - 7 m/s. Often however, the speed will be kept at 1,5 – 2,5 m/s to minimize wear, dust and noise. Generally speaking, belt conveyors have an extremely low impact on the environment. Belt conveyors can be placed on the ground, in tunnels and on bridges – either horizontally or inclined up to about +/-18°, depending on the media being carried. Belt width B (mm)
Theoretical belt-capacity in m3/h Through-shape 3x45° · Belt-speed in m/s 0,50
1,00
1,50
2,00
2,50
3,00
3,50
500
48
97
145
194
242
291
339
650
88
176
264
352
440
528
616
800
138
276
414
552
690
828
966
1000
224
449
673
898
1122
1347
1571
1200
329
658
987
1316
1645
1974
2303
1400
456
913
1369
1826
2282
2739
3195
1600
604
1208
1812
2416
3020
3624
4228
1800
772
1544
2316
3088
3860
4632
5404
2000
958
1917
2875
3834
4792
5751
6709
2200
1171
2342
3513
4684
5855
7026
8197
From top to bottom: 1. Enclosed Belt Conveyor, Palapye, Botswana. 2. Belt conveyor transporting wood chips from ship unloaders. 3. Valmont SM belt conveyor support system in galvanized steel.
Capacity factor k ɸ[°]
2
4
6
8
10
12
14
16
H/L
0,03
0,07
0,10
0,14
0,17
0,21
0,24
0,28
k
1,00
0,99
0,98
0,97
0,95
0,93
0,91
0,89
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CASE STUDY PLANT: Skærbæk Power Plant CLIENT: Ørsted PROJECT: Custom designed conveying system
From ship unloading to boiler section A complete custom designed conveying system built and installed at Skærbæk Power plant for transporting wood chips after receiving it by ship unloaders to the boiler section by Valmont SM. Valmont SM has for decades specialized in power plants and delivered numerous transport systems for coal and has used the knowledge within this area, for the successful conversion into Biomass fired power plants. The delivered conveying system includes movable unloading hoppers with de-dusting operating on rails along the wharf for flexible ship unloading of the material. After unloading the wood chips, the system is equipped with magnetic separation for removal of eventual foreign metal pieces, screening, where oversized lumps will be removed, a sampler in order to determine process numbers and moisture for an optimum burn ability process. The material after screening is transported to an 80,000 m3 open A-storage, via belt conveyors from where extraction to silos is handled via screw reclaimers from the A-storage bottom.
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- It is in our DNA to design the correct solution. Valmont SM works closely with the customer who will specify the required capacities, what the system should be able to handle, which type of equipment is necessary and what is the available space for items and buildings at the location. Valmont SM will then submit a solution based on the customers specifications and demands. Besides the technical specifications for such a system, the customer also expects user friendly operation and maintenance of the system. In that context, Valmont SM designed a fully automated solution with emission control, via nuisance dust collectors, for the entire system. So it complied with environmental regulations. Valmont SM’s manufacturing facilities allow for inspection, pre-assembly and testing, which ensure the products supplied, correspond to the customers expectations. The amount of pre-assembly can be flexible, reducing the installation time at the plant before dispatch.
THE OPEN A-STORAGE CAN STORE
80,000 m
3
WOOD CHIPS
”
We designed, manufactured and installed a 1.5 km conveying system to Skærbæk. Our competence is to provide a co-engineered solution to the end user. We were able to do this as we have more than 40 years experience in the power plant industry. Frede Holdt Jensen - Project Manager Valmont SM
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PIPE CONVEYORS WHEN WASTE AND DUST HAVE TO BE KEPT TO A MINIMUM, OR IF MOISTURE AND POLLUTION FROM THE ATMOSPHERE MUST BE PREVENTED FROM REACHING THE MEDIUM BEING CARRIED, VALMONT SM CAN SUPPLY PIPE CONVEYORS.
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ADAPTABLE TO SITE CONDITIONS
BELTS CAN CURVE UP TO
30°
HORIZONTALLY & VERTICALLY
Pipe conveyor belts look like ordinary conveyor belts, but when loaded they form a pipe which remains closed until it is unloaded. After unloading the belt forms a pipe to ensure that materials still on the return side, stay inside the closed belt and that there is no waste. In addition, pipe conveyor belts can curve up to 30° both horizontally and vertically. Powder materials such as fly ash, cement, quicklime etc. (which can be difficult to carry using traditional belt conveyors), can be carried without difficulty in pipe conveyors. Standard specifications Transportation Maximum capacity particle size [m3/h] [mm]
Minimum centre distance [m]
Tube Diameter [mm]
Cross Section [m2] (75%)
Belt speed [m/s]
100
0,006
1,7
36
30
150
0,013
2,0
95
30-50
18
200
0,023
2,2
180
50-70
20
15
250
0,040
2,3
340
70-90
23
300
0,048
2,5
430
90-100
25 30
350
0,068
2,9
710
100-120
400
0,110
3,3
1.300
120-150
35
500
0,157
3,8
2.100
150-200
40
600
0,218
4,2
3.300
200-250
50
700
0,284
4,6
4.700
250-300
60
850
0,408
5,0
7.300
300-400
70
Minimum curve Horizontal curve: R = tube diameter x 300 (in this case min. 100) Vertical curve: R = tube diameter x 300 (in this case min. 100)
From top to bottom: 1. Pipe conveyor at Flensburg, Germany, delivered by Valmont SM.
Maximum curve Normally 90° Maximum pitch angle If the pitch angle is above 30°, the belt can be delivered with guides
2. Pipe conveyor at Aalborg Portland Cement, Denmark, delivered by Valmont SM. 3. Pipe conveyor at Tyssedal, Norway, delivered by Valmont SM.
Distance for trough link T.D. = tube diameter x 25 9
BULK CONVEYORS IN SPECIAL CONDITIONS IF CONDITIONS ARE SPECIAL, VALMONT SM CAN SUPPLY CONVEYORS SUCH AS SICON CONVEYORS, SIDEWALL CONVEYORS, PNEUMATIC CONVEYORS, SCREW CONVEYORS AND BUCKET ELEVATORS.
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SYSTEM ADVANTAGES
SICON CAN CURVE
90°
EVEN IN LIMITED SPACES
SIDEWALL CAPACITY
4000 t/h LIFTING HEIGHTS UP TO 200 METRES
The Sicon-conveyor is a rubber tube belt, much like the pipe belt conveyor, but with a cross-section like that of a closed tube. The advantage of the Sicon conveyor is that it is able to curve 90°, even when the space is limited. The Sicon conveyor can be installed in buildings where the space is very limited. The Sicon conveyor is available in 2 sizes:
SICON 100
With a capacity of up to 100 m3/h
SICON 1000
With a capacity of up to 300 m3/h
The sidewall conveyor is especially useful when combined horizontal and vertical conveyance is needed in limited space. It combines the advantages of ordinary belt conveyors and bucket conveyors. Sidewall conveyors are designed with capacities of up to 4000 t/h and lifting heights of up to 200 metres. For conveyance of powder, granulate or special products like small cut straw, Valmont SM can supply pneumatic conveyors. Valmont SM’s pneumatic conveyors are completely closed to prevent any dust emissions to the environment, during both loading and unloading.
From top to bottom: 1. Sicon conveyor at Nordic Sugar. 2. Valmont SM designed vertical conveyor. 3. Flexowell type.
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SCREEN-CRUSHER FOR SCREENING & CRUSHING 200
500
100
0
0
Screen limit (mm)
Screen limit (mm) Two Roller Screen Crusher installed at Stigsnes værket, Denmark.
90-95% fines Density = 1.0 t/m3 The capacity depends on the quality/nature of the material to be screened with regards to content of moisture, particle size and stickiness.
80
1000
60
300
40
1500
20
400
80
2000
60
500
40
Capacity curve for crusher
t/h 600
2500
20
Valmont SM´s roller screen crusher is a combined main screen with a built on crushing unit ensuring all the oversized material remains in the process for optimum performance with a minimum of waste. The main roller screen can also be delivered as a standalone screen without a crusher for applications where this is required.
Capacity curve for roller screen
t/h 3000
Density = 1.0 t/m3 The capacity depends on the particle size of the coal being processed. The curve can be applied for particle sizes ≤ 3 x gap setting.
Various types of Valmont SM roller screen crushers Type
Description
SMH 24- **
Roller screen
SMHF 24- **
Roller screen + Pre-crusher
SMHK 242-**
Roller screen + Crusher
SMHFK 242-**
Roller screen + Pre-crusher + Crusher
Type Coding The identification of the type of roller screen crusher. For example: SMHFK 242-60 = Roller screen + Pre-crusher + Crusher Length Width
1
4
2
Length (Crusher)
Screening size (mm)
Screen Crusher diagram (left) 1. Main roller screen The main screen is designed as a roller screen where separation takes place in two dimensions. The process of separation is performed via rotating rollers having driving discs welded on. 2. Crushing unit The crusher is designed as a two roller crusher, depending on the bulk material to be handled. Both rollers are fixed or one of the two rollers as a floating roller. Material processed through the crusher is conveyed to the subsequent screen or directly to the underlying conveyor. 3. After screen option The after screen option is incorporated under the rollers on the crusher type with floating rollers. The screen is designed like the main screen. None crushed material is transported to the end of the screen crusher as waste.
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4. Pre-crusher option The pre-crusher is designed as a coarse crusher consisting of one roller placed above the middle of the main screen. The pre-crusher is an option where the bulk material contains large flakes and large soft pieces.
VALMONT SM DESIGN & ENGINEERING 16
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Valmont SM Design & Engineering in
B-B ( 1 : 100 )
Valmont SM can also design hoppers, chain conveyors, apron conveyors. In connection with construction projects, Valmont SM has also moved large machines such as cranes weighing up to 400 tons for customers.
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Uppsala, Sweden.
K
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In connection with our bulk handling plants, we also supply the necessary bearing steel structures for belt bridges, transfer towers, material storage, silos, buildings with facing and roofing included. I
Valmont SM will design the solution according to our customers needs. We can optimise existing systems, upgrade them or convert them into other applications.
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G
F
From left to right: 1. Valmont SM Chain Scraper. E
2. Chain conveyor for extracting wood
D-D ( 1 : 100 )
chips from crane hopper. 3. Convening bridges and steel
D
structure support.
C
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WE WORK WITH TRUSTED PARTNERS B
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OTHER MACHINES FOR BULK HANDLING Complete solutions from Valmont SM
In addition to bulk handling plants, Valmont SM supplies machines such as stackers, reclaimers, ship loaders and ship unloaders. These machines are either supplied from our own design or from well known partners.
Design & Engineering
Valmont SM can also supply belt scales and screen plant equipment, for example: magnetic separation or eddy current separation, sample test equipment, ventilation plants, de-dusting filters, fully automated systems to operator stations and PLC, electrical equipment supply and interface panels, automation, fire protection and ATEX classification.
ATEX CLASSIFICATION
From left to right: 1. Ship loader. 2. Fully automated systems. 3. Screw reclaimer with extra high wear resistance.
UNIQUE SOLUTIONS
100% PERFORMANCE
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ABOUT VALMONT SM Valmont SM is a part of Valmont Industries, Inc. Valmont Industries, Inc., has an annual revenue of more than $3B (US), Valmont Industries, Inc., is a Fortune 1000 company recognized throughout the world as an industry leader in engineered products and services for infrastructure, and water conserving irrigation equipment for agriculture. Valmont sells its products and services in more than 100 countries while operating over 100 production facilities, located on six continents. Valmont Industries, Inc. is traded on the New York Stock Exchange (VMI). Valmont SM is an order producing company with a high capacity and effective production plant. Valmont SM’s capacity and production system are suitable for heavy industrial tasks. Valmont SM is a leading supplier of heavy complex steel structures and of towers for wind turbines.
Valmont SM manufactures and co-engineers heavy complex steel structures for a diverse range of industries, including offshore oil and gas, wind energy, transmission towers, material handling systems, infrastructure, steel construction and pressure vessels. Our business is based on a unique ability to co-engineer solutions in close cooperation with our customers. Thereafter Valmont SM can implement advanced order production of complex steel constructions, combined with electronics, hydraulics and testing. Valmont SM also has an automated serial production for more mature products. Valmont SM is located in Rødekro, about 20 km from the Danish/German border within easy reach of the E45 motorway and only 10 km from Aabenraa Port or 200 km from Hamburg International Port.
Valmont SM’s production area at its Rødekro facility covers 540,000 m2, with about 69,000 m2 of indoor production facility, corresponding to 20 production areas.
CONTACT US TO DISCUSS YOUR PROJECT REQUIREMENTS
Telephone: +45 7439 3333 15
The quality department of Valmont SM upholds a quality assurance system in accordance with DS/EN ISO 9001:2015. Valmont SM is ISO 14001 and OHSAS 18001 verified. In addition, we maintain following certificates: EN ISO 3834-2, AD 2000-Merkblatt HPO, EN 1090-1/2 EXC4, GEN DIN 18800-7
Valmont SM A/S Vaerksvej 5 DK-6230 Rødekro Denmark Telephone: +45 7439 3333 Fax: +45 7439 3339 valmontsm@valmontsm.dk www.valmontsm.dk www.valmontsm.com www.valmontsm.de VAT No.: DK 88374614
Š 2018 Valmont SM A/S - Bulk Handling brochure v1 - Design www.reklamehuset.dk
Valmont SM has a group of 30-40 skilled and experienced supervisors/specialists, to support our customers with maintenance and operation or service contracts. They can normally be requested at short notice for emergency cases and as a supporting function during installation of new projects.