17 October 2018

Industry Focus Bulk MHE

Bulk Ready

 

Aided by technology & innovation, Bulk material handling segment has been growing immensely on the back of growing industrialisation, urbanisation and automation. With a view to leverage such promising aspects, companies as well as component suppliers have been readying themselves to serve the growing demand with their innovative products & services. Keeping quality, cost & environment in mind, companies areall set to roll out new age tech-enabled equipment to aid growth of the industry reports Prerna Sharma.

 

Increase in the demand for different types of bulk material handling products such as conveyor belts, stackers, reclaimers, and spreaders for process automation across various industries has fuelled the growth of the bulk material handling products and technologies market in the recent years, reveals a recent report. Growing demand for bulk material handling products & technologies in the mining and chemical sectors globally has further accentuated growth. Additionally, they are also used in the agricultural farms for the storage and movement of crops and powder bulk materials. Modernised, automated machineries for handling bulk materials are largely being used in the chemical industry to carefully handle the hazardous chemical wastes. Added to that, the need of assembly line in the manufacturing sector is also driving the bulk material handling products and technologies market. In addition, pharmaceutical industry needs bulk material handling products for product containment, feeding reactors and stirrer containers with basic chemicals. Moreover, with the growing need for automation in manufacturing industry, it creates a huge demand for material handling equipment.

 

 

REGIONS GAINING MOMENTUM

 

North America, Asia Pacific, Europe, and the Rest of the World that includes the Middle East, Africa, and South America are the main geographical segments of the worldwide bulk material handling products and technologies market, reveals the report. Europe, which has been leading this market for quite some time, is expected to remain seated in this position over the period of forecast. It acquired a share of nearly 35 per cent in the overall market in 2015. Germany has taken the lead among all the European markets for bulk material handling products and technologies and is expected to maintain its dominance in the near future on account of the extensive utilisation of bulk material handling equipment, propelled by the rising demand for industrial automation, the increase in mass production methods, such as assembly line production, and the augmenting requirement for bulk equipment in the construction industry.

 

Asia Pacific, among others, is also exhibiting considerable scope for the future growth of the market for bulk material handling products and technologies, thanks to the rise in infrastructural advancements, boosted by the rise in urbanisation in emerging Asian economies, such as India, China, and Japan. The Asia pacific bulk material handling products and technologies market is heavily driven by China, which is also one of the most prominent domestic markets across the world. The ongoing expansion in the China market points towards a thriving future for the overall market in Asia Pacific. North America, on the other hand, is likely to witness a sluggish progress in its market for bulk material handling products and technologies over the forecast period, states the report.

 

 

 

APPLICATION AREAS

 

Transport by bulk is now becoming increasingly the primary mode of cement distribution. Cement at the plant is generally stored in silos from where the cement leaves the plant either in bags or in bulk. Bagged movement will require bagging machines, truck loading conveyors, etc. while bulk movement is generally done through enclosed bulk tankers, which are pressure vessels. Currently, a number of cement companies are moving cement in bulk through such bulk tankers but the costs are not working out to be economical considering the low unit volumes due to poor road conditions and empty returns.

 

Many cement companies are concerned about the unviable cost of transportation of cement in bulk tankers on Indian roads because of these reasons.

 

One low cost option lies in the use of linered containers. This involves the use of standard 20-foot containers available from container leasing companies or from private operators. A heavy-duty fluidizable polythene liner is inserted into these containers.These liners have their own bulkhead fillings which enable filling and unloading of the cement into the linered container through suitable spouts.

 

At the destination, the container has to be tilted for the cement to flow out of another spout at the bottom of the bulkhead.The cement is then pumped pneumatically in a closed environment to adjoining silos. This system is also applicable to all dry free flowing bulk powders.

 

In addition to such container movement, Scorpio also offers retrofits of barges to convert them to self-unloaders using aerated holds and dense phase pneumatic evacuation to far silos at the port.The company offers total solutions in dry bulk logistics where dry bulk material can be transported in standard 20’ or 40’ containers with liners. The liner is installed in container prior to loading and loading is accomplished with the aid of conveyor belt, densifier conveyor, pneumatic conveying or by gravity feeding methods. Linered container transportation gives customers the most economical solution to their transport needs. The solution is an end-to-end solution and is a silo-to-silo concept. Scorpio has tied up with leading transporters in India who can move the containers most optimally using road, rail, coastal and inland waterway modes. The filling and unloading technologies adopted by Scorpio ensure dust free operation and high rates of loading and unloading.

 

DCL’s heavy duty loading spouts are designed to load dry bulk materials from conveyors and other discharge points into open barges, ships and onto stockpiles.These rugged heavy duty spouts are available in retracted lengths as low as 10 feet (3 m) and travels up to 100 feet (30.5 m). Loading rates can vary up to 2700 cubic feet per minute (76.5 m³/min) depending on product being loaded.DCL heavy duty loading spouts utilise the latest technological advancements inthe industry, providing dust free loading of a wide range of dry dusty materials atloading rates up to 6,000 STPH.A wide variety of accessories are offered to fit the automation needs of the user,such as; auto raise tilt probes, slack cable and full up limit switches, the ‘deadfall’,cord reels, brake motors, and remote control just to name a few. Installation costs have shown to be recouped within ayear of operation in product recovery as well as inreduced maintenance and service costs.

 

TRF impact crushers are ideal processing machines forprimary and secondary crushing of raw materials for the steeland iron industry, hard coal and lignite, limestone, gypsum orminerals. These are also extensively used for the tertiarycrushing of limestone, dolomite, dunite for the bedding and blending plant for sinter preparation and coal for coking plant. Its sturdy and proven design offers advantages such as increased throughput capacity, maximum possible operating reliability, mainly unaffected by foreign bodies as well as low maintenance cost. A high crushing efficiency reduces the powerconsumption.Selective crushing can be made with ease. It is lighter in machine weight as against capacity, thereby saving installation cost.

 

 

 

BELT CONVEYORS

 

Belt Conveyors are the most commonly used conveyors as they are the most versatile conveying equipment. Belt conveyors can be used to transport product in a straight line, horizontal or inclined paths from one spot of operation to another. Bevcon Wayors is specialised in design, manufacturing, erection and commissioning of wide range of conveyors having experience of installing thousands of belt conveyors for various applications.

 

Belt conveyors are commonly used for conveying items with irregular surfaces and for small items that would fall in between rollers or bags of product that would sag between rollers. Material is conveyed directly on the belt so both regular and irregular shaped objects, large or small, light and heavy, can be transported successfully. Belt conveyors are made of a metal frame consists of two pulleys at either end with an endless loop of conveyor belt with carrying / support idlers below makes belt rotates and moves forward. Today there are different types of conveyor belts that have been created for conveying different kinds of material. Bevcon Telescopic Chute is used for abrasive or large particle size material in stockyard systems and high tonnage loading applications. Dry bulk material contains dust and fines. When a material is laid on a stockpile, it is probable that dust particles will rise and spread around, resulting in pollution of working environment and surrounding area. Telescopic chute prevents the emission of dust and loss of material as vacuum gets created inside the chute by the material flow, resulting in easy maintenance and saves operational costs. Bevcon telescopic chute is designed for loading bulk material on trucks, trains, ships and inside storages. It is provided with inner cones or tubes to contain the flow of material and an outer flexible bellow to limit the propagation of dusts.

 

Belt conveyors complement machines from Tekraf are used in bulk material handling and mining systems. They are used as the main component in bulk materials transport systems. The conveyor length can vary between short distances up to approximately 20 km in single flights. Typical belt conveyors application fields include boom conveyors/intermediate conveyors in yard machines, in mining machines and in ship loading facilities; belt feeders / feeder conveyors for hopper discharge; in-plant conveyors; overland conveyors (stationary and shiftable) with or without horizontal curves. The conveying capacity can vary between some 100 t/h in bulk materials handling up to 50,000 t/h for overburden handling in mining.

 

The belt conveyors consist of parts like pulleys (drive, tail, snub), rollers (troughing, impact, return), belt, cleaners (external/internal), take up unit, etc. These can be advanced or simple in structure based on system requirement. They can be used to transport bulk materials and packaged bags in a straight line or through changes in elevation or direction. They are widely used in cement, mining, sugar, power, and other engineering industries. According to different transferring equipment, the transfer system can consist of one independent or multiple conveyors. It can be even combined with other transfer equipment. The belt conveyer can be installed horizontally or aslope to meet the needs of different transfer lines. Conveyor has many kinds of belts with them, such as rubber belt, canvas belt, PVC belt, etc. It also has low maintenance frequency, which decreases the maintenance cost.

 

Teknik has supplied independent belt conveyors that are more than one kilometre long for clients like Manikgarh Cement (Bagalkot, Karnataka), Satna Cement (M.P), etc. It has also supplied for port automation in Ennore Port (Chennai, Tamil Nadu) that includes multiple belt conveyors having total length of more than 6 kms and carrying capacity of 5000 tonne per hour for iron ore handling. The single longest conveyor supplied there is 1.8 km long. To offer you a case study, during the execution of the project for Bajaj Hindustan, Gola, Uttar Pradesh, there was an issue related to bagasse spillage. This meant that the client had to employ additional 40 labourers for clearing the spilled bagasse. Limited space meant that there was no possibility of installing regular belt conveyors having around 18-20 degrees inclination. In order to overcome this problem, Teknik developed the 'U' Trough Cleated Belt Conveyor with an inclination of 30° to carry the bagasse. This solved their spillage problem and also significantly reduced the overheads of the client for their bagasse handling section.

 

Teknik has also supplied the innovative double deck belt conveyor in India at Dalmia Bharat, Renuka and Abroad like Kakira, Uganda and Asaliya, Sudan where in both carrying and return side of conveyor is used to carry material. This is normally used where in both stacking and reclaiming happens simultaneously.The primary purpose of the stacking conveyor is commonly for stockpile material and bags, generally aggregate that will be used at a later stage. Mobile stacker conveyors provide our clients with an efficient, flexible means of conveying material. They are not only able to save vast volumes of time, but they also significantly cut down labor costs for our clients. They have the lowest average cost per tonne of any stacking method and enable stacking in advance and retreat configurations as well as the ability to stack radially and laterally.

 

Similarly, Rollwell has specialised in manufacturing shuttle conveyors suitable for various applications and industries. The company’s plant is equipped with special test beds to undertake complete assembly and trial run for the shuttle conveyor assembly. As in other conveyors, idlers, pulleys, and all fabrication work is in-house, which ensures a quality product at most reasonable cost. Rollwell manufactures a range of chain and belt types bucket elevators. These can be used for handling coal, limestone, or any other bulk material for cement/steel/fertiliser industries. Rollwell bucket elevators are self-supported structure design for heights upto 30m with a maximum capacity of 600TPH. Bucket profiles are uniquely designed depending on the material characteristics, which ensures very low spillage of material. Reliability, efficiency and performance are the key differentiators of Rollwell bucket elevators.Idlers are the heart of a conveyor, since reliability and longer life can reduce down time for the conveyors, effect reduction in power consumption and increase belt life. Rollwell idlers operate with very low coefficient of friction and are designed for reliable and guaranteed performance of upto 60,000 hours.

 

In line with this, thyssenkrupp Industries India, (tkII) offers the widest range of equipment for material handling systems.Overland conveyors provide the most effective way of transporting bulk materials over long distances. thyssenkrupp belt conveyor systems are custom-designed to meet the specific demands of the client’s needs, for the type and volume of material to be handled, the existing topography of the route, and prevailing climatic conditions. The company’s efficient and reliable curved belt conveyor technology follows the contours of the terrain with horizontal and vertical curves.Conveyor systems for open pit mines are available in stationary, shiftable and relocatable designs. Belt widths up to 3,200 mm and maximum capacities of 25,000 m³/h, including drive and transfer stations, have already been realised.

 

IVA Bulk Handling Equipment Pvt Ltd., offers screw conveyors having features such as external tubular body with ball & socket type inlet spout and outlet spout.This type of spout allows a choice of angles from 0° to 45°. Continuous flights are welded onto the internal rotating pipe.Aluminium die casting hanger bearing comes with special type of hardened rings. Similarly, Somi Conveyor is capable to produce new generation (Somiflex) conveyor belts upto 2600mm width with the installed capacity of above 12,00,000 mtrs per annum.It is suitable for conveying in normal temperature various non-corrosive pointless lumps, granular or powders such as coal, coke, sand and cement in bulk or packaged.

 

 

COMPONENT SUPPLIERS AND THEIR INNOVATION EXPANSE

 

Rossi is 65-year old company that specialises in heavy duty applications. Rossi products are gearboxes and gear motors. Rossi is Part of Habasit AG, a company based out of Switzerland. Globally, Rossi is a name to recon with in Bulk material handling, Mining and Mineral processing, Steel plant and construction segments. Rossi is globally known for its sturdy products and depth of application knowledge.

 

Rossi Gearmotors India, Coimbatore started assembly operations in India in 2008 by importing parts from its mother plants. Over the period, Rossi India has made its name in the medium and heavy duty markets as a value supplier. In India Rossi assembles products from 75 Nm to 125000 Nm torque. Although, these are highly engineered products, the standardisation processes implemented, enables the company to deliver gearboxes quickly. Rossi products offer higher power-to-weight ratio, higher shock loading capacity, longer service life and this adds a lot of value to the customer equipment. Its evident from the fact that some customers have come back for spares after 30 years of product installation. This speaks very high about technical superiority of Rossi products

 

The warranty cost of Rossi is less than 0.05 per cent and this shows the product reliablity. Rossi pioneered upto 3 years’ warranty in the global market and win customer's faith in its capabilities.

 

Cement based materials are essential for sustainable building. However, cement manufacture is a sophisticated process whose individual stages require a great deal of energy. This makes energy costs one of the largest cost factors for the industry.Because of this, cement production requires drive units which can stand up to harsh conditions and are also especially energy-efficient.
For more than 45 years, Nord Drivesystems has been at home in almost every branch of industry where conveying solutions are used. Its drive components and systems are essential wherever things need to be moved, because all movement needs drive as efficiently and safely as possible. Because of this, the company provides an entire spectrum of mechanical, electrical and electronic drive technology from a single source, from energy-efficient motors and low-loss gear units to centralised and decentralised control technology.

 

For short and long-distance conveyor systems, mill and rotary kiln drives, as well as silo operation, Nord Drivesystems provides the very latest, energy-efficient drive solutions for every process stage in the cement industry. Nord industrial gear units can master any challenge. Nord Drivesystems plans and delivers reliable, low maintenance drive components for the entire drive chain, including electric motors, motor rockers, couplings, brakes, back stops and Taconite seals as well as heating and/or cooling.

 

WAM Group’s modular CX Trough Screw Conveyor system offers a variety of solutions for conveying or feeding powdery or granular materials. Designed for application in the food industry and in environmental technology, they are suitable for applications in which any contamination of the material handled has to be strictly avoided and where absolute cleanliness and perfect resistance to corrosion are required. CX Trough Screw Conveyors are also used in flour and animal feed milling, in plastics and chemicals, as well as in the pharmaceutical industry. The modular CX trough screw conveyor system is highly versatile. CX screw conveyors are manufactured from stainless steel with surface finishing grade suitable for the application. Fabrication of the troughs is carried out on machines ensuring perfectly smooth surfaces which is why material residue is reduced to the minimum. Furthermore, CX Trough Screw Conveyors are equipped with a gear motor appropriate for the application.

 

Cosben Equipments specialises in design, manufacture and supply of high efficiency screw feeders & conveyors for conveying/feeding various powders like cement, fly ash, micro silica, ice flakes and other dry powders.The vertical screw assembly consists of the horizontal screw feeder, which is installed below a silo or a hopper. This horizontal screw feeder feeds the powder to a vertical screw conveyor. The vertical screw assembly system is a mechanical powder loading system, which is preferred & recommended over the pneumatic loading systems and or bucket elevators due to its ease of use, lesser maintenance & compact size.Also in a lot of rural parts of India where the raw material is sourced in HDPE bags and the facilities are not equipped for pneumatic loading, the company’s efficient & compact sized mechanical loading system, which consists of the vertical screw assembly & the automatic bag slitting machine serves as the perfect solution.

 

 

 

GROWTH HAVENS

 

Sea ports and cargo terminals are likely to play a pivotal role in the development of the global bulk material handling systems market as international sea trade takes a hike. Regional ports will play a crucial role in trading across international borders and also leveraging exchange of commodities. Even after facing an economic slowdown, the global seaborne trade crossed approximately 10 billion tons in 2015 and is also expected to foresee exceptional growth in the coming years. The rising demand for liquid bulk and minor commodities is expected to emerge as a core factor driving the progress of the global bulk material handling systems market over the course of the forecast period. Moreover, activities pertaining to mining in developed as well as developed regions and the proliferating number of construction activities, mostly in Gulf Cooperation Council countries are likely to prove to be fruitful for the growth of the country in the coming years.

 

The growth of the manufacturing sector is driven by the growing global population. Moreover, the development of the mining industry is anticipated to speed up, as the need for natural resources and minerals is growing with every passing day. The growth of the manufacturing and mining industries at a global level is expected to create significant opportunities for the bulk material handling systems market and in turn fuel the production as well as the sales of such systems which are further used in these applications. The mining application segment in the bulk material handling systems market is expected to account for a share of 28.4 per cent in the global market in 2017 and is projected to reach approximately 29.3 per cent by the end of 2027.

 

 

 

Fast facts
  • In 2016, the market was valued at about $ 3,500 Mn.
  • It is projected to reach a value around $5,600 Mn by the end of 2027.
  • The global bulk material handling systems market is expected to register a CAGR of 4.3 per cent between 2017 and 2027.

 

 

 

Construction and infrastructure along with manufacturing and mining activities have become dynamic sectors, which are expected to contribute in the growth of the market for bulk material handling systems. The demand for some of the bulk material handling systems such as stackers, band conveyors, bucket elevators, and ship loaders and unloaders is increasing in manufacturing, construction, maritime and mining sectors in emerging economies of Asia Pacific. The rental services for heavy, gigantic and costly bulk material handling systems such as bucket wheel excavators, stacker cum reclaimers, and shovel, among others are expected to remain a precedence for many end users over the years.

 

 




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