conveytech | we manufacturer and supply of belt conveyors,cement feeding system etc
We do design, Manufacture ans supply of various type like compartment, Aggregate feeding belt conveyor for redmix concrete batching plants / Cement plants / Cement / Flyash block making plants, etc.,
In order to cater to the requirements of redmix concrete batching plant storages, cement plants / cement / flyash block making plants we are offering various ranges of silos cement, flyash Lime stone storages from 50 ton 500 tone of welded / bolted type.
For Feeding of Cement,Fly ash from Bunker to silo we are offering Twin Lobe Air Blower / Compressor, Pneumatic/ Manual Bag Feeding Machine,Twin Cement Feeding System from 500m3 / per hour to 1500m3 / per hour.
In Order to handle Cement, Flyash from storage silos to readymix concrete Batching plant / Cement plant / Cement Flyash making plant of various types.
We Design, Manufacturer,Supply and Erection of Aggregate Feeding Belt Conveyors,(Sand, Jally,Stones), Cement, Flyash, Storage Silos, Pneumatic Cement Feeding System(Air Compressor), Imported Silo Accessories, Readymix Concrete Conveyors on turnkey basis.
aggregate & cement | conveyor belt solution | cement conveyor product | asgco
Our Mid Atlantic division is the leading supplier of conveyors and bulk material handling products & services in the Mid-Atlantic region. From conveyor belting, idlers, pulleys, power transmission products, wear parts and screens to complete turnekey systems, ASGCO will handle any of your conveying and bulk material handling needs.
Our Complete Conveyor Solutions division is a manufacturer of conveyor products and equipment, along with conveyor engineering services, provided through our partnered network of servicing distributors and original equipment manufacturers (oems) around the globe.
ASGCO Steel Fabrication division is a full-service steel fabrication, contract manufacturing, machining, welding and finishing facility that has the ability to manufacture simple parts to complete assemblies to complex print-to-build projects for Original Equipment Manufacturers (OEMs) and industrial customers.
The cement industry forms an important part of our economy. The continued anticipated growth of the cement market this year will place more demands on cement facilities to meet higher industry standards. New technologies and industry innovations are being introduced every day.
Cement plants take pride in an exceptional record of efficiency, safety and productivity while always seeking the newest techniques, systems and equipment. ASGCOstrives to help your plant meet those goals through the development of high-quality products and services.
The most common way to manufacture cement is through the dry method. Although the dry process is the most modern and popular way to manufacture cement, some kilns in the United States use a wet process. The two processes are essentially alike except in the wet process, the raw materials are ground with water before being fed into the kiln.
Precast concrete products are cast in a factory setting. These products are best known for their conventional 8-by-8-by-16-inch block but can be molded into a wealth of shapes, configurations, colors, and textures.
Cement-based materials in this category include mortar, grout, and terrazzo, soil-cement and roller-compacted concrete for use in pavements and dams. Also included in this category are flowable fill and cement-treated bases.
Aggregates are building materials used in construction, including sand, gravel, crushed stone, and recycled concrete. Aggregates are mined and either used in their raw form (for example, as foundations) or serve as composite materials in the production of concrete and asphalt. End markets for aggregates include private residential construction, commercial construction, and publicly-funded infrastructure projects, with the latter consuming the most aggregates, usually for use in highway and road construction.
Aggregates are used as base materials in foundations, or as components in the production of concrete and asphalt. The diagram to the left demonstrates how aggregates are used in road construction; aggregates are clearly essential not only as a foundation for the roadbed, but also go into the cement that makes the road itself. When aggregates are used, they are an important part of the construction process.
Quarries are obviously essential to aggregates producers business; without quarries and the reserves they provide, there is no source of raw materials. Aggregates are usually shipped from quarries or production areas close to their end market. This is because even a relatively small amount of aggregates, in terms of value, can weigh several tons. Because most aggregates are transported by truck, transport over 50 miles is thus cost-prohibitive and infeasible. However, this can be circumvented to an extent by alternative modes of transport, specifically by rail or by water. For those aggregates producers with proper facilities, rail transportation provides a cheaper alternative to shipments by truck. Transport by barge is even cheaper, but is only available to those producers with access to coastal waterways.
Aggregates are not just for construction, a vast array of other products, many of which are taken for granted, are manufactured using materials derived from quarrying. These include: paper, glass, cosmetics and toothpaste to name but a few. Aggregates are also used in agriculture, food manufacture and water & sewage purification.
Challenge: The customer did not have easy access to the splicing area on this conveyor system. The tail pulley was obstructed by both the equipment and the surrounding structure. In order to string the belt on such an elevated, inclined
Challenge: The customer did not have easy access to the splicing area on this conveyor system. The tail pulley was obstructed by both the equipment and the surrounding structure. In order to string the belt on such an elevated, inclined conveyor, the belt would need to be held over top of the system with a crane, which would bring up safety concerns, posing an additional challenge for the installation. The elevation and incline also made transporting the vulcanizing equipment much more difficult.
Solutions: ASGCO recommended using the Quarry-Duty 3 ply 600 PIW 3/8 x 3/32, 42 wide by 700 long textile reinforced conveyor belt which is highly engineered for steep-incline conveying. The extra strength meets the grueling demands of this heavy-duty quarry conveyor system. A crane was needed to hold the belt over the system during the stringing and a man lift was needed for the non-catwalk side. The product was also installed with AR1 covers for added protection.
Results: The high adhesion, lower elongation and superior field performance of the Quarry-Duty conveyor belting is engineered to protect the belt from wear and tear. The vulcanized splice is much stronger than a mechanical splice and makes for a smooth transition as the belt travels through the belt scrapers. This long-life conveyor belting met the customers needs and provided a long-lasting, quality solution.
Objective:Solve belt mis-tracking and off center load issues Challenge:An aggregate quarry had multiple issues that were keeping the conveyor belt off-track. They were experiencing severe off-center loading issues, along with belt tracking and alignment problems. The conveyor itself was racked
Challenge:An aggregate quarry had multiple issues that were keeping the conveyor belt off-track. They were experiencing severe off-center loading issues, along with belt tracking and alignment problems. The conveyor itself was racked and not straight which meant it was not receiving its load uniformly. The mis-tracking was causing the belt edges to become frayed and worn, chewing up the sides of the belt. On several occasions, the belt became so severely mis-aligned, that it came in contact with the idler brackets and was sawing through them, leading to catastrophic damage to the belt, and causing extended downtime for the plants operations.
Recommendations:After ASGCOs technicians performed a complete survey of the conveyor system, the problem issues were identified. It was recommended that the Tru-Trainer Flat Return Troughing Idler be installed on the return side of the conveyor. The Tru-Trainers internal pivot triggers continuous alignment by always tracking the belt to the center of the conveyor, reducing edge damage, spillage and overall better conveyor belt tracking performance.
Results:The customer had purchased Tru-Trainers from us before and knew how reliable and re-active they were. After installing the Tru-Trainer Flat Return Troughing Idler, the belt is continually running straight in the frame. Because it reacts immediately if the belt begins to steer off center, the belt edge damage has been greatly reduced and the off-center loading issue has been minimized. The customer was very pleased and will continue to order Tru-Trainers to keep the belt aligned.
Objective: To eliminate belt slippage problems while minimizing belt wear. Challenge:This cement plants stacker conveyor was experiencing tremendous belt slippage problems that the conventional rubber lagging they were using failed to correct. The harsh wet and cold environmental conditions were
Challenge:This cement plants stacker conveyor was experiencing tremendous belt slippage problems that the conventional rubber lagging they were using failed to correct. The harsh wet and cold environmental conditions were tough on the belts and caused the rubber lagged pulleys to wear out quickly. The customer had been adamantly opposed to the use of ceramic pulley lagging, feeling it was too tough on the conveyor belts. A solution was needed that would correct the belt slippage and wear problems while addressing these concerns at the same time.
Recommendations/Solutions:After careful consideration it was recommended to use ASGCOs NEW Semi-Ceramic Pulley
Lagging to correct the slippage and premature wear. This lagging product line features 40% ceramic coverage which addresses
the customers concern about the use of ceramic lagging on the belt, while also providing the solution for the slippage that can
tear at the back of the belt. This new, improved lagging is excellent in wet or muddy conditions, such as those present at this
cement plant. The increased traction delivered by the ceramic allows for lower belt tension and less downtime caused by the
excessive wear of the rubber lagging. ASGCOs Semi-Ceramic Lagging was a win-win scenario for the customer.
Results:After 6 months of use there has been zero (0) wear on the belt and zero (0) wear on the lagging. The condition of the belt
continues to look as good as the day the newly lagged pulleys were installed. Since the ceramic strips are wider than the competitors
strips, there are less seams and less chances for fugitive material to get under those seams and break it down. The customer is very
satisfied with this new product!
Objective: Bypass the dryer by redirecting product from an incline conveyor onto an adjacent steep incline conveyor. Challenge:The customer first came to ASGCO with the question how can we eliminate ourdryer and the conveyor that feeds it cost effectively. The
Challenge:The customer first came to ASGCO with the question how can we eliminate ourdryer and the conveyor that feeds it cost effectively. The largest challenge of this project wasthe relationship of these two conveyors. They were not exactly perpendicular to each other whichmade the design of the chute difficult.
Solution:ASGCO used a Cloud Point Laser Scanner to scan the area instead of taking field dimensions with hand tools, minimizing the margin for error and increasing accuracy. Then ASGCO engineers used our 3-DEM chute analysis program to model a chute which would effectively transfer material between the two conveyors, while ensuring there would be no heavy impact or abrasion areas in the new chute. A Flo-Control chute was then fabricated at our Fabrication facility and then installed to transfer the material onto a cleated belt, eliminating the dryer completely. UHMW lining was placed inside of the chute to gave the chute better sliding capabilities and to prevent material from sticking to the chute and causing plugging.
Results:The result of this project are a fully functioning transition including an ASGCO engineered and fabricated flow control chute and load zone that exceeded the customers expectations in regards to quality, workmanship, and functionality. The customer was able to run product without any delays and it made for a seamless transition to their goal of bypassing a dryer with their product.
Objective: Solve belt mis-tracking and off center load issues Challenge: A major cement processing facility in was experiencing severe belt tracking and alignment problems leading to regular costly repairs and maintenance. This plant was using traditional training idlers in an
Challenge: A major cement processing facility in was experiencing severe belt tracking and alignment problems leading to regular costly repairs and maintenance. This plant was using traditional training idlers in an attempt to control the mis-tracking, however the nature of the aggregate material on the belt lead to continual build up around the pivot point, yielding it ineffective. In addition, the rubber disk return idlers were preventing the belt from re-centering, defeating their purpose.
On several occasions, the belt became so severely mis-aligned, that it came in contact with the tail section of the
support structure, leading to catastrophic damage to the belt, and causing extended downtime for the
plants operations. The problem persisted upon installation of a new belt, and within 12 months, it needed
to be completely replaced a second time.
After ASGCOs technicians performed a complete survey of the conveyor system, the problem issues were identified.
It was recommended that ASGCO Tru-Trainer was to be installed on the return side of the conveyor, 30 feet
before the tail pulley. This position would allow the belt to run straight around the tail pulley and also be centered on
the conveyor in the load point, reducing spillage and costly material loss. In addition, the rubber disk return idlers
were replaced with flat return idlers, eliminating resistance to centering.
After installing the ASGCO Tru-Trainer on return side of the conveyor, the belt is continually running straight
in the frame of the conveyor. Due to the sealed design, interference from material buildup has been eliminated.
The plants output has greatly increased due to the greatly reduced maintenance and repair issues and productivity
is at an all time high.and reacts immediately if the belt begins to steer off center. Because it does not rely on
contact with the belt edge in order to guide the belt, belt edge damage which frequently occurs with conventional
tracking systems, is avoided.
Objective: To design a new self-contained material load zone that would eliminate costly spillage and expensive clean up. Challenge:This customer receives barges several times a month, and sometimes more frequently depending on the demand. The raw material travels on top
Challenge:This customer receives barges several times a month, and sometimes more frequently depending on the demand. The raw material travels on top to feed the silos. This powder has extremely fine properties that were escaping and filling the structure surrounding the conveyor with thick dust and debris that would settle throughout the room, sometimes in upwards of several feet. The floor would become lined with this expensive material, that once exposed, became useless in the cement process.
The challenge was to eliminate the fugitive dust and spillage and the additional costs incurred for the time and effort taken
in the removal of the material, plus any disposal fees. Access will also need to be provided to insure proper operation and
allow for serviceability of the load zone.
Solution:It was recommended that they install the Pro-Zone modular conveyor belt load zone system to optimize the
air/dust sealing of the receiving conveyor belt. ASGCO engineers worked closely with our trained servicing distributor
and designed a specific, self-contained system based on the parameters of this particular conveyor. Belt speed, material
weight, size and air flow, were among the many factors that were taken into consideration when designing the system.
CEMA design standards of 20 transition idlers before and 35 troughing idlers after the Pro-Zone were also addressed.
The Pro-Zone was designed around the existing chute and dust collection system. It creates a sealed belt support
system with quick access for monitoring and easy adjustments. The placement of the new custom designed baffles and
expansion pieces tied the new load zone system all together.
Results:The powdered material no longer plumes into the room. The workers used to kick up this material and breathe
the fugitive dust, just to provide basic maintenance. So the improved efficiency has also lifted the morale of the maintenance
staff as well. The cost of removing the wasted product has been virtually eliminated by the cement facility. The ASGCO
Pro-Zone System removed a costly obstacle in the companys procedure and has allowed for greatly increased
A ready-mix plant had difficulty properly tracking the vital conveyor belt that feeds the mixer. The problem was essentially that the conveyor belt was difficult to keep in alignment, which caused serious belt edge damage, and in turn de-lamination and
A ready-mix plant had difficulty properly tracking the vital conveyor belt that feeds the mixer. The problem was essentially that the conveyor belt was difficult to keep in alignment, which caused serious belt edge damage, and in turn de-lamination and spillage in the conveyor load zone.
ASGCO has successfully reduced the carry back to levels that far exceed the expectations of the customer. The customer has now installed several other ASGCO cleaners to attack carry back problems throughout the plant. (more)
ASGCO has successfully reduced the carry back to levels that far exceed the expectations of the customer. The customer has now installed several other ASGCO cleaners to attack carry back problems throughout the plant.
Todays aggregate industry is filled with challenges. Foremost, to produce enough aggregate for cement, asphalt and other products for homes, businesses, schools, hospitals, and infrastructures. Also, operators must address environmental responsibility concerns that dictate the use of best practices to
Todays aggregate industry is filled with challenges. Foremost, to produce enough aggregate for cement, asphalt and other products for homes, businesses, schools, hospitals, and infrastructures. Also, operators must address environmental responsibility concerns that dictate the use of best practices to protect both natural resources and future generations of citizens.
cement manufacturing belt conveyor solutions | flexco
At Flexco, we pride ourselves on helping you - and your belt conveyor system work better than ever before. Thats why we dont just sell products. We partner with you to enhance productivity. And even after your belt is up and running, Flexco stays involved. Its all part of our commitment to being your most valued partner on the job.
As the worlds urban population grows from 54.5% in 2016 to 60% in 2030, infrastructure spending and construction activity will increase the demand for cement. In order to succeed in an industry that plays a critical support role in global development, the drive toward efficiency and innovation has to be your focus.
Flexco understands the cement industry and that sets us apart. We are genuinely invested in the success of the cement industry, and well work side-by-side with you to address any obstacles that stand in the way of optimal belt conveyor performance. With a team of field representatives and global distributor partners, Flexco is grounded in real people who are dedicated to the future of cement manufacturing.
Flexco has spent countless hours working alongside cement customers to understand the realities of your everyday challenges and we have a comprehensive range of belt conveyor products to address your pain points at every step of the cement manufacturing process from the Quarry to the Finish Mill.
Chinas cement industry is shifting from a higher number of small cement plants to a fewer number of large cement plants. As of 2014, the top 10 cement producers in the country held a 52% market share.