STEEL BELT CONVEYORS FOR SEVERE CONDITIONS since 1929

ALAMO CEMENT

THE CHALLENGE

In 1995 Alamo Cement Co. awarded Magaldi with a contract to replace an existing rubber belt conveyor with the Magaldi Superbelt® in its cement manufacturing plant. The rubber belt conveyor had been designed to convey around 120 tons per hour H24 of clinker. It had been placed, together with other equipment, between the air quenching cooler and the final silo. For this reason, the reliability of the equipment was a key-factor to ensure the highest productivity. However, upon frequent and sudden failures of the rubber belt with relevant production losses, Alamo Cement Co. performed a detailed failure analysis to identify the reasons for these problems. From this analysis it clearly resulted that, regularly, the combination of uncontrolled high temperatures and abrasiveness of the clinker led to the failures encountered by the rubber belt.
All problems were overcome in 1995 by replacing the rubber belt conveyor with the Magaldi Superbelt®. The installation was carried out using the existing frame of the rubber belt conveyor with minor modifications in order to reduce both the project CAPEX and the rotary kiln outage.

 

THE CUSTOMER

Headquartered in San Antonio (TX - USA), Alamo Cement Co. is wholly controlled by Buzzi Unicem S.p.A..
The Company operates with a remarkable vertical integration in the ready-mix concrete and natural aggregates sector through 78 batching plants and 4 aggregates quarries.

 

THE SOLUTION

In 1995, Magaldi supplied the Alamo Cement plant with a “N” type Superbelt® conveyor, suitable for applications with an inclination of up to 28°. Both the mesh and the pans of the conveyor are made of carbon steel since the clinker temperature is 250 °C on average, with peaks of up to 300 °C. Its length is 90 meters approx. with a useful width of 650 mm. The rated power of the Magaldi Superbelt® at the Alamo Cement plant is only 22 kW, while the power demand is even lower. The set speed is 0.25 m/s to ensure a capacity above the design prototype of 120 tons per hour.

The Magaldi Superbelt® was replaced in 2010 after 15 years of service. Assuming a 95% capacity factor of the rotary kiln, the Magaldi Superbelt® had covered more than 112,000 km since 1995. Over the years, it had transported more than 15 million tons of clinker without any sudden failure.

 

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