1. PAINPOINT DRIVEN OPENING

Managing a cement plant’s material handling system is a constant balance between throughput, reliability, and cost. Inefficient or unreliable equipment in this critical path directly impacts your bottom line. Are you facing these persistent challenges?

Unplanned Downtime: Catastrophic failures in key components like idlers or belts can halt your entire production line, costing tens of thousands per hour in lost clinker.
Excessive Maintenance Costs: Frequent bearing replacements, misalignment corrections, and spillage cleanup require significant labor hours and parts inventory, diverting resources from proactive improvements.
High Energy Consumption: Inefficient drives, poorly sealed transfer points, and suboptimal conveyor design contribute to inflated power bills, a major operational expense.
Material Spillage & Dust Emission: Poorly sealed systems create housekeeping hazards, product loss, environmental noncompliance risks, and increased wear on adjacent equipment.
Inconsistent Feed Rates: Unreliable feeding to the raw mill or kiln leads to process instability, affecting burn quality and final product consistency.

The question for plant managers is clear: how do you achieve maximum availability with predictable operating costs? The solution lies in specifying heavyduty equipment engineered for the cement industry’s abrasive, highvolume demands.

2. PRODUCT OVERVIEW

Our engineered class of Cement Plant Conveyor Systems is designed for continuous, heavyduty transport of bulk materials such as limestone, clay, shale, clinker, and gypsum. These are not generic industrial conveyors but systems built specifically for cement plant environments.

Operational Workflow:
1. Controlled Loading: Material is fed onto the belt via a regulated chute system at the transfer point (e.g., from crusher to prehomogenization stockpile).
2. AbrasionResistant Transport: The reinforced belt carries the material over a series of impactresistant idlers along the designed incline and distance.
3. DustContained Transfer: At intermediate points or the head pulley, material is discharged through sealed hoods into the next process stage (e.g., raw mill feed bin).
4. SelfCleaning Return: The empty belt returns on troughing idlers while cleaners remove carryback material at the tail pulley.

Application Scope: Ideal for longdistance overland conveying from quarry to plant, highincline conveying to preheater towers, and hot clinker transport from cooler to storage.
Limitations: Not suitable for pneumatic conveying of fine powders or vertical lifting outside of specified incline angles. Maximum lump size and material temperature are defined by specific component selections.

3. CORE FEATURES

HEAVYDUTY IMPACT ZONES | Technical Basis: Multilayer rubber sheeting with energyabsorbing bars mounted on garlandstyle idlers | Operational Benefit: Absorbs the force of large lumps (up to 150mm) at loading points, protecting the belt carcass from premature damage | ROI Impact: Extends belt life by up to 40%, reducing replacement costs and associated downtime.

ENCLOSED TRANSFER POINTS | Technical Basis: Gasketed steel housing with internal wear liners and adjustable dust curtains | Operational Benefit: Contains dust emissions to below 20 mg/Nm³ and minimizes material spillage along the conveyor path | ROI Impact: Reduces cleanup labor by approximately 15 hours per week per transfer point and mitigates environmental penalty risks.

HIGHEFFICIENCY DRIVE ASSEMBLY | Technical Basis: Fluid couplings or variable frequency drives (VFDs) paired with CEMArated gear reducers | Operational Benefit: Provides smooth startup under full load reduces peak current draw (inrush) by up to 60% compared to directonline starters | ROI Impact: Lowers energy consumption during operation and reduces mechanical stress on drive components for longer service intervals.

ADVANCED BELT CLEANING SYSTEM | Technical Basis: Primary tungsten carbide scraper followed by secondary dualspline cleaners and return side Vploughs | Operational Benefit: Removes over 99% of carryback material from both sides of the belt before it reaches the tail pulley | ROI Impact: Prevents material buildup that causes misalignment and bearing failure cutting idler replacement frequency significantly.

REMOTE MONITORING COMPATIBILITY | Technical Basis: Integrated sensor mounts for belt alignment (switches), bearing temperature (RTDs), and speed monitoring (encoders) with standard 420mA output | Operational Benefit: Provides realtime data on system health allowing for conditionbased maintenance rather than scheduled intervals | ROI Impact Enables early fault detection preventing catastrophic failures reducing unplanned downtime by an average of 30%.

CORROSIONPROTECTED COMPONENTS | Technical Basis: Idler frames and rollers with epoxy coating bearings featuring triplelabyrinth seals filled with hightemperature grease | Operational Benefit Withstands exposure to cement dust moisture and temperature fluctuations without performance degradation | ROI Impact Ensures consistent operation in harsh plant environments extending mean time between failures (MTBF).

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Cement Plant Conveyor Solution | Advantage (% Improvement) |
|||||
| Belt Life (Abrasive Material)| 2436 months | 3648 months | +33% |
| Idler Bearing Life (L10) | 40 000 hours | 60 000 hours | +50% |
| System Availability | ~92% |>96% | +4 percentage points |
| Energy Consumption Baseline Incorporates lowrollingresistance idlers & optimized drives |12% to 18% |
| Dust Emission at Transfer Point <50 mg/Nm³ <20 mg/Nm³ 60% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: From 500 TPH for raw materials to 2 500 TPH for clinker conveying systems.
Belt Width & Speed: Standard widths from 800mm to 2 000mm operating speeds up to m/s tailored to volumetric requirements
Power Requirements: Drive motors from kW up kW voltage V/50Hz or as per client specification
Material Specifications: Belt carcass EP fabric or steel cord ST ratings; impact bars natural rubber; idler tubes precision ERW steel; seals CR/ NBR compound
Physical Dimensions: Customdesigned length incline angle (°) & transfer heights based on plant layout
Environmental Operating Range Ambient temperature °C to +°C; material temperature up °C (clinker) with specialized components

6. APPLICATION SCENARIOS

INTEGRATED CEMENT PLANT CLINKER COOLER DISCHARGE CONVEYOR Challenge A Middle Eastern plant faced chronic breakdowns on its hot clinker conveyor leading weekly unplanned stops severe roller seizure Solution We supplied a hot clinker conveyor system featuring heatresistant belts spaced garland idlers heat shields on return rollers Results System operates continuously between planned maintenance stops Material spillage reduced by % achieving months without failure

LIMESTONE QUARRY TO PLANT OVERLAND CONVEYOR Challenge A Southeast Asian plant sought reduce trucking costs km distance between quarry crusher preblending yard Solution Engineering design installation km overland conveyor rugged terrain variable frequency drive controlled acceleration Results Eliminated diesel truck fleet reducing transport cost tonne Achieved consistent feed rate improving raw mill stability

7 COMMERCIAL CONSIDERATIONS

Equipment pricing structured around system complexity capacity length

Standard Tier Includes core conveyor structure heavyduty idlers basic drives guards Meets essential performance requirements
Enhanced Tier Adds advanced dust containment premium cleaning systems integrated monitoring sensors predictive maintenance capability
Custom Engineered Tier Full design service for complex layouts special materials high inclines explosionproof requirements

Optional Features include ceramic lagging on pulleys fire suppression systems rip detection systems automated lubrication units

Service Packages available from basic commissioning operator training comprehensive multiyear maintenance agreements including scheduled inspections parts supply

Financing Options We work with international export credit agencies project finance partners offer leasing structures ease capital expenditure support turnkey project development

8 FAQ

What information required provide preliminary quotation {{keyword}}?
We require basic data material type bulk density capacity lift height overall length layout constraints This allows preliminary sizing pricing

How ensure {{keyword}} will interface existing plant equipment?
Our engineering team conducts dimensional audits existing transfer points can design adapter chutes structural supports ensure integration

What typical lead time fabrication delivery {{keyword}}?
Lead times vary scope For standard configuration conveyors expect weeks Custom engineered systems require weeks based complexity

Do provide operational manuals spare parts recommendations?
Yes comprehensive documentation provided digital print format We also recommend initial critical spares kit minimize future logistics delays

What warranty coverage offered?
We offer year warranty against manufacturing defects core equipment Extended warranty available service packages Terms clearly defined contract