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01 The

01 The pipe conveyor transports the alternative fuels from the storage area to the pre-heater LOGISTICS Beumer Group. This system has been running since January 2017 at the Denizli Çimento plant and has proved to be a particularly efficient and economical solution. The AFR system from Beumer, stores, mixes and conveys differently composed materials such as the residue-derived fuels (RDF), as well as shredded waste tires whose size usually does not exceed 120 x 120 mm. These differently composed materials comprise of fuels for the pre-heater, calciner and the main burner. The core of Beumer’s AFR solution is represented by the two pipe conveyors used in this project. This completely enclosed conveying system ensures an environmentally safe, dust-free and low-energy consuming transport mechanism of raw materials to make alternative fuels and requires – and this is one of the most important factor – a minimum level of personnel. A lot of challenges arose in creating a conveying system for raw materials and alternative fuels at the Denizli plant. As the existing plant had not been designed for this kind of systems. “We needed a partner who supplies and installs a single-source solution” explains Güngör Aydin, Project Manager at Denizli. In their search, the cement manufacturer looked to Beumer Group. “In the past, the system supplier Beumer had installed a bucket elevator in the plant for a different project. We are very satisfied with it and have made only good experience so far.” The contract was signed only one month after Beumer Group had received the customer’s inquiry in October 2015. Entire system solution from a single source In order to support producers of cement in the alternative fuels and raw materials field, the German company Beumer Group has developed a complete business segment dedicated to AFR systems. “Our technical know-how and tailor-made systems permit us to offer optimum support to our customers,” says Michal Hrala, Managing Director at Beumer Group Czech Republic. Founded in 1935, as a manufacturer of conveying equipment, Beumer has enough expertise when it comes to conveying application in the cement industry, as some of its first orders were placed by local cement, lime and mining companies. As a system provider, the company is able to supply and install the entire eco-system of the application from aligning and unloading of the delivery vehicle, to the storing, conveying and feeding process of the alternative fuels. On remembering his experience the deputy factory manager at Oyak Denizli, Berkan Fidan explains, “We evaluated different variants of mechanical transport systems, but in the end, opted for a single-source solution from Beumer Group based on the innovative pipe conveyor technology.” In May 2016, CTN Makina, an authorized supplier of Beumer, manufactured all of the steel components for the system and started assembling both the imported components and those manufactured on site. Beumer installed two conveyors, one was 206 meters long and the other one was 190 meters, 42 WORLD OF INDUSTRIES 2018

02 With its ability to navigate horizontal and vertical curves, the conveyor can be optimally adapted to the terrain 03 Two pipe conveyors, 206 and 190 metres long, each with a capacity of 15 tonnes per hour 02 03 as well as the corresponding equipment for the two lines. Each pipe conveyor reaches a capacity of 15 tons per hour. “This conveying technology is not only eco-friendly but requires low maintenance,” describes Michal Hrala of Beumer Group. “Its enclosed type of construction protects the environment from any material falling down and from emissions. Another advantage is the lack of dust development on the running line”. With its ability to navigate horizontal and vertical curves, the pipe conveyor can be optimally adapted to the terrain. In comparison to other belt conveyors, the number of required transfer towers is considerably lower. This allows for substantial capital cost savings for the customer. The specialists from Beumer also took care of the project planning for the storage area and the required equipment as well as numerous conveyors and supply lines. The company also handled the supply of mechanical equipment and the steel structure, the assembly and commissioning. The delivery of the residue-derived fuel material is carried out in moving-floor trailers. The alternative fuels are unloaded and stored at the receiving station. All four containers of the arriving material are fed with material from the storage area by a grab crane. These different fuels are then burnt in the calciner and the main burner of the kiln. On top of that, Beumer installed two containers with discharge devices in front of each pipe conveyor ensuring an optimum mixture of the fuels. A container for distribution is also installed at the end of each conveyor. Sharing her experience Michal Hrala explains “During the construction dimensioning of this system we were faced with a particular challenge. Since the cement plant is located in an earthquake-prone area, we had to develop the system accordingly.” That means: the design of the pipe conveyor had to ensure that the conveyors withstand not only the dynamic load of an earthquake but also the repercussions. The existing pre-heater towers represented another hurdle. As they offered very little space, the designers at Beumer Group adapted the required equipment to the narrow conditions. In October 2016, barely one year after the contract was signed, the commissioning of the system took place. “We are very satisfied with the single-source system of Beumer Group,” Güngör Aydin, Project Manager at Denizli, sums up. All transport systems supplied and the accompanying equipment are intertwined to ensure steady fuel feeding. “Not only do we save costs by requiring a smaller amount of expensive primary fuels, we also work much more energy-efficiently,” he declares. “This means that our capital costs will have paid for themselves in a short amount of time.” Photographs: Beumer Group WORLD OF INDUSTRIES 2018 43