Structure and Function

1.1
Raw material handling and transport
Calcination
Stucco silo
Blending plant (Mixing plant)
Homogenizer ventilation
Packing plant
 Designation of Items
Designation of Items
1G 08 CM11
Raw material silo
= 1G 08 CM12
1G 07 CL01 Feed bin
1G 08 GL01
= 1G 08 GL31 1G 07 GL01
= 1G 28 GL01 Belt conveyor
Bucket elevator 1G 08 GL21
= 2M 01 GL01
= 2M 30 GL01 1G 07 GL04
= 3P 10 GL01 1G 08 GL11 Vibrating trough
1G 08 GL12
1G 08 GL02 Reversible belt conveyor
1G 07 GL05 Magnetic separator
1G 08 HQ01 Raw material central filter
1G 07 GP01 Screw conveyor
1G 08 WZ11.QM01
Needle pin gate
= 1G 08 WZ12.QM01 1G 07 HU11 Crusher
1G 10 CM11 Raw material bin
1G 07 QR01
1G 11 GL01 Belt weigher 1G 11 QR01 Cellular wheel
1G 13 HU01 Mill 1G 22 QR21 sluice
3P 11 QR01
1G 15 TL01 Mill gear box
 Designation of Items Designation of Items
1G 17 WZ52 1G 16 CM01 Hydraulic aggregate
1G 25 WZ51
1G 28 WZ01 .WM01 Lubricating system for
1G 28 WZ02 .WM01 1G 16 GP11
clamping piston bearing
1G 28 WZ03 .WM01
1G 28 WZ04 .WM01 1G 17 GP41
1G 28 WZ05 .WM01 1G 22 GP21 Sampler
2M 01 WZ02 1G 25 GP41
Aeroslide
2M 01 WZ03
2M 02 WZ02
2M 05 WZ02 .WM01 1G 17 GQ01
2M 25 WZ01 1G 25 GQ02
2M 26 WZ01 1G 28 GQ01
2M 26 WZ02 2M 02 GQ02
Aeroslide fan
3P 10 WZ01 2M 25 GQ01
3P 10 WZ02 2M 26 GQ01
2M 26 GQ01
1G 18 BF01 Pitot tube 2M 26 GQ01
1G 18 GQ01 Main fan
1G 18 QM41 Purge air flap 1G 17 HQ01 System filter
1G 17 QM11 Emergency cooling flap
 Designation of Items Designation of Items
1G 18 QN21 Exhaust control flap 1G 22 QN21
1G 17 WZ52 Recirculation gas flow control = 2M 01 QN01
1G 22 QN31 flap = 2M 01 QN02 Flow control gate PCD
1G 18 WZ01 .WP01 Stack = 2M 02 QN01
= 2M 05 QN02
1G 19 EM01 Hot gas generator
1G 22 VP01 Homogenizer
1G 19 GQ01 Combustion air fan
1G 25 GQ01 Suction cooling fan
1G 19 GQ02 Dilution air fan
1G 25 HQ01 Suction cooling filter
1G 19 QN11 Dilution air adjusting flap
1G 28 QM01
1G 22 EB11 = 1G 28 QM02 Aeroslide two-way gate
1G 22 EB12 = 3P 10 QM01
1G 22 EB13
HOM trace heater 2M 01 CM01
1G 22 EB14 Silo
1G 22 EB15 = 2M 02 CM01
1G 22 EB16 2M 01 HQ01
1G 22 GQ01 = 2M 02 HQ01
Filter
1G 22 GQ02 HOM aeration blower = 2M 04 HQ01
1G 22 GQ03 = 2M 05 HQ01
 Designation of Items Designation of Items
2M 01 GQ01 2M 04 HQ05
Aeration blower
2M 01 GQ01 = 2M 11 HQ11 Passive filter
2M 04 CM01 Hydrated lime silo = 2M 12 HQ11

2M 04 CM05 Hydrated lime weighing vessel 2M 05 CM01 Waste material silo

2M 04 EP01 Heat exchanger 2M 05 GQ01 Side channel blower
2M 04 GP01 2M 05 VL01 Bulk loading device
2M 11 GP01 Metering screw 2M 11 CM11
2M 11 GP02 Weighing vessel
= 2M 12 CM11
2M 04 GQ01 Screw compressor 2M 11 HQ01
Dedusting filter
2M 04 HN01 = 2M 21 HQ01
2M 04 VL05
2M 11 VL00 Big bag loading
2M 05 HN01
2M 11 VL11 2M 11 VL01
Additive silo
2M 11 VL12 Vibrator = 2M 11 VL02
2M 11 VL31 2M 11 WQ01 Big bag hoisting device
2M 11 VL32
2M 12 VL11 2M 21 CL11 Manual metering vessel
2M 21 VL01
2M 21 CM01 Mixing vessel
 Designation of Items
2M 21 CM04 Designation of Items
2M 21 CM06
3P 10 GP11
Screw conveyor 3P 40 GL04 Bag deflecting station
3P 55 GP01 Bag discharge belt with
3P 40 VQ01
2M 21 GP41 cleaning
Pneumatic sampler
2M 21 GP42 3P 41 UQ01 Bag charging device
2M 21 HW01 Mixer
Low voltage main
2M 26 QN01 1G 94 UC01
distribution (LVMD)
2M 26 QN02 Flow control gate PP
3P 22 QN01 Uninterruptible power supply
1G 94 UC02
(UPS)
3P 10 HQ01 Shaking screen
1G 94 UC03
3P 11 HQ01 Collecting hopper filter
1G 94 UC04 Motor control center (MCC)
3P 22 CM01 Bin 1G 94 UC05
3P 30 VL01 4/6 round packer muff 1G 94 UH01
3P 40 GL01 Bag alignment belt 3P 30 UH01 PLC switchboard (PLC)
3P 94 UH01
3P 40 GL02 Check weigher
1G 94 UH10 Remote I/O switchboard (RIO)
3P 40 GL03 Belt conveyor
 Feed hopper (= 1G 07 CL01)

The raw material is supplied to the plant via a feed hopper. The feed hopper is filled with raw material by a
wheel loader.
 Belt conveyor (= 1G 07 GL01,= 1G 08 GL21)
The belt conveyor is used to convey the raw
material. The raw material is transported
from the feeding point to the next plant
component by means of a belt. The conveyor
drive station serves as means of propulsion
for the belt conveyor. The belt is operated as
a head drive.
The reversing station contains a deflection
drum mounted on both sides of the base
frame. Via the tensioning station, the belt
tension can be set in such a way that the
friction between the belt and drum is
. It also compensates any elongation of the belt resulting from
sufficient to transfer the requisite drive operation. The belt frame acts as a holder for the loadbearing
torques rollers or sliding elements for lower and upper run.
The feeding box is mounted on the belt frame on the material feed side. It prevents the
material from falling off the belt during feeding. Head and lamellar separators are used to
remove any adhering material to be conveyed from the conveyor belt. Pressure roller
stations are used to regulate the belt in the lower run. The press down the conveyor belt
between two lower belt rollers. The misalignment switch prevents damage and destruction
of the conveyor belts in the event of belt drift.
The simultaneous deactivation of upstream plant parts prevents contamination and damage
caused by overfilling at the feed point, for example. Belt guide rollers prevent sudden belt
deviation. These rollers must not be subjected to continuous loading, as such loading will
damage the belt edges.
 Mechanical Details

Motor
Unit Code Name Dimensions Capacity Features Parts
Power

2 inlet point Belt covers, platforms,

RGT 1G 07 GL01 Belt conveyor 800x11520 75 t/h 7,5 kW 2 dedustion point handrails, chutes
Sensors and support
2 inlet point Belt covers, platforms,
RGT 1G 08 GL02 Belt conveyor 800x12270 75 t/h 7,5 kW 2 dedustion point handrails, chutes
Sensors and support
2 inlet point Belt covers, platforms,
Belt conveyor
RGT 1G 08 GL21 650x8150 35 t/h 5,5 kW 2 dedustion point handrails, chutes
Sensors and support
Design

Impact roller
Return roller
TECHICAL DATA SHEET OF BELT CONVEYORS
(1G_07_GL01)
TECHICAL DATA SHEET OF BELT CONVEYORS
(1G_08_GL02)
General Machine Description
The belt conveyor is used for conveying different kind of materials
in horizontal or inclined way on a certain angle positions.
Belt conveyors with the high reliability and low energy
consumption are preferred to be used in every area where
different materials are being conveyed.
Types of the belt conveyor;
• Flat type,
• Trough type
• V type
The basic elements of the belt conveyor are: support frame, drive
and tensioning stations, carrying idlers, conveyor belt, inlet and
outlet, ladder and platform. The elements of the tensioning
station are: tensioning drum and bearings. The elements of the
drive unite are: drive drum, bearings, geared motor.
In addition, there are maintenance hatches that enable an easy
intervention in cases of breakdown.
Main Parts

Basic Construction of Belt Conveyor Main Parts of Drive Station

Main Parts of Tension Station Sectional Drawing of Drive Drum
Tensioning System
Two tensioning systems are used in belt conveyors.
• Threaded tensioning system
• Gravitational tensioning system

Threaded Tensioning System Photo of Gravitational Tensioning

 Pre Scraper

Pre- scraper is made of polyurethane segment. It is

designed for high scraping performance for all heavy
working conditions.
Since the system is supported from both sides with springs,
it prevents the leakage of material via long and continuous
pressure.
Polyurethane segment has A80 hardness, working
temperature range is -40°C, +90°C. The suitable scraper is
chosen according to conveyor design parameters.

Pre-Scraper
Seconder Scraper
Seconder Scraper is used especially in the case of appearance
of inconveniences such as material spill that appears during
the transfer from one conveyor to another and proximity of
the belt and chute gate.
It has a very high cleaning performance in cleaning belt
surface from fine-dusty or damp-adhesive materials.
Solid rubber provides high performance in scrapping by
absorbing loads. Seconder scrapper is recommended for
conveyor systems with a belt width up to 2000 mm and a
speed of 3 m/s.
Due to its special design and tensioning system seconder
scrapper is used in both reversible and single direction belt
conveyors

Seconder Scraper
Plough Scrapper (V-Type
Scrapper)
Plough scraper with replaceable polyurethane strip is used for the
cleaning of the inner side (inside) of the belt and to prevent material
jamming to drums,. Amount of applied pressure can be easily
adjustable.
Side Sealing Rubber Tape

Side sealing tape is used to prevent material passage

through the belt edge.

Side Sealing Rubber Tape

 Replacement of Wear Parts

The following sequence must be observed:

1. Shut down the entire plant and secure against unintended restarting.
2. Clean the inner side of the machine.
3. Before exchanging the spare part weared, it should be cleaned with the compressed air.
4. Switch off the (auxiliary or machine own) control unit
5. Open the cover or connection of the machine parts in order to remove the spare part.
6. Remove the weared part.
7. Insert new part and install the other parts/components of machine
8. Close the head cover and all connection parts.
9. Put the machine into operation.
Replacement of Drive
Drum
Process sequence is as follows;

❖ Remove the material inlet port and suction throttling

by unscrewing the bolt connections.
❖ Remove the gear unit by removing the gear unit
connecting bolts.
❖ Disassemble the bearing connections on both sides of
the drum and remove the bearings.
❖ Loose the studs on tensioning station and slide the
tension drum with belt to the drive side.
❖ Pull the drive drum with the belt and remove.
❖ Drive drum is free to remove, take it out.
Replacement of Tension
Drum
Process sequence is as follows;
❖ Drive drum must be removed to remove tension
drum. Follow the steps in “Replacement of Drive
Drum” section
remove the drive drum.
❖ Take the tension drum through the end with
conveyor belt.
❖ Remove easily the drum between the conveyor
belt.
Replacement of Conveyor
Belt
Process sequence is as follows;
❖ Firstly upper covers of the conveyor must be removed.
Remove the bolts and take all upper covers, dedusting chute
and material inlet.
❖ As described above, drive and tension drum must be
removed.
❖ Each roller stations positioned between conveyor belt
must be removed. Remove all roller stations by taking
upwards
as shown in images.
❖ Follow the same process for the chassis support profiles.
❖ Scraper mounted on tension unit must be removed to
remove the conveyor belt. Take out scraper by removing the
detent pin.
❖ Take out the conveyor belt.