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IBAU HAMBURGCentral Cone

THE ORIGINAL

I BAU HAMBURG

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The I BAU HAMBURG Central Cone – THE ORIGINALRaw meal blending silo, made by IBAU:• High blending efficiency• Low power consumption• High availability

The IBAU centralcone system

The blending silo is simul-taneously used for a contin-uous blending process aswell as for raw mix storage.The feeding of the silotakes place via a novel typeof parallel distributor ensur-ing a controlled build-upof the different materiallayers.

Homogenizing the rawmeal is achieved by causingthe layers of differentCaCO3 content (1) to flowtogether by funnelling (2)action and thus mergingwith one another. The grav-ity flow in the funnels pro-duces the blending effect.

The bottom of the silo isdivided into aeration sec-tions (4). Each section hasa flow control gate (5) andan air valve (6) assigned toit. Three blowers (8) areavailable for aerating thesilo bottom. The sectionsare aerated three at a timefor varying periods. Asa result, three funnels areformed simultaneouslydeveloping relativelyslowly from the silo bottomto the upper surface of thestored material. The funnelformation process is socontrolled, that the freshraw meal which has justbeen fed into the silo can-not rush straight through tothe silo outlet. This beingprevented by first closingthe three gates of theaerated sections and thuscausing three new funnelsto develop in three othersections. This ensures con-trolled flow behaviour ofthe blending funnels. Thepower consumption amountsto 0.1 – 0.3 KWh/h t(metric) of raw mix.

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1 Parallel distributor

2 Material layers

3 Funnel

4 Central cone

5 Flow control gate

6 Annular aerationbottom

7 Metering Bin

8 Flow control gate

9 Aeration sectionswith open-typefluidslides

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Storage silo, made by IBAU:• High recovery up to more than 99%• Self cleaning of coating material at the silo wall• No blockages of outlets

Description of thestorage siloWith the progressivelyincreasing size of the pro-duction units in the cementindustry there has been acorresponding increase insize of the silo units for sto-ring the cement. Silos withdiameter of 20 m and moreand with individual storagecapacities ranging up to30,000 t must be capable ofefficient and trouble-freeemptying.

The IBAU central cone silois today’s answer to thistask. Several dischargegates placed at the circum-ference of the silo openedone after the other make thecement flow downwardsnear the outer shell. Thissystem has been proved tobe extraordinarily success-full in more than 5000 unitsbeing in operation. Morethan 99% recovery is repor-ted by the users.

Only a small ring of thesilo bottom is covered withfluidizing units and dividedinto several sections. Onesection only after the otheris activated by means of alow capacity blower.

In other words a smallamount of compressed airrequiring only little powermakes the cement moveabove one defined section.The cement moves down-wards at the silo wall avoi-ding the formation of incru-stations and dead zones onthe silo wall.

When discharging throughtwo or more gates parallel,any desired discharge capa-city can be achieved.

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The I BAU HAMBURG Central Cone – THE ORIGINALAdvantages of the IBAU central cone silo:• Optimised material aeration and discharge technology• High operating reliability• Total control and maintenance of all parts even inside

View into the central cone

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silo with aeration sections

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The I BAU HAMBURG Central Cone – THE ORIGINALDyckerhoff Zement’s raw meal silo at Lengerich:• Most modern state of the art raw meal blending silo• Separate levels for storing and blending• Low specific power consumption

View of the Lengerich works with

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the raw meal silo at the right

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The I BAU HAMBURG Central Cone – THE ORIGINALHolcim, Lägerdorf dispatch terminal, in operation since 1977:• Fully automatic bulk terminal• Integrated mixing plant in steel construction• High degree of flexibility

The cement terminal with 3 cone

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silos and the new mixing plant

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The ring silo having a total capacity of

The I BAU HAMBURG Central Cone – THE ORIGINALThe first cement ring silo:• Bulk dispatch at the RKW-WÜLFRATH terminal

on the territory of the THYSSEN AGsteel plant in Duisburg-Schwelgern.

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13.000 tons. In operation since August 1979.

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The I BAU HAMBURG Central Cone – THE ORIGINALOne of the largest cone silos in the world at Queensland Cement, Australia:• Cement storage silo and bulk loading into trucks and rail wagons• Silo diameter of 29,3 m, silo capacity 36.000 tons• Highly efficient and reliable discharge process

Queensland Cements large volume

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cone silo in operation since 1993

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The I BAU HAMBURG Central Cone – THE ORIGINALAdvanced mixing plants for special cement:• Biggest multicompartment silo with 22 chambers,

a total height of 71 m and 26 m in diameter.• Silo technology, material transport, mixing, bulk loading as well as plant automation - all from a single source.

Mixing tower of Lafarge Cement, Karsdorf works

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Cross-section of the mixing plant

Dedusting

Feeding pipesfrom the mills

Fluidslides tolarge-size silos

Large-size silos

Dischargelarge-size silos

Weighing andmetering binProduct andloading silos

Thrust collar

Bag andbig-bag feeding

Weighing andmetering bin

Simplexloaders

Mixer

Bulk loading

Control room

Screw pump

Weighing bridge

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This system with a blending efficiency of more than 10:1 is in operation for many years.

The I BAU HAMBURG Central Cone – THE ORIGINALThe drawing shows a raw meal blending silowith an integrated kiln feeding systemwith weigh bin, flow meter,IBAU pumps – one as stand-by.

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Hundreds of this silo type are in operation for many years.

The drawing shows a typical central cone silowith 2 SIMPLEX loaders for truck loading.All the equipment is located under the cone.There are no openings in the wall for the mobile loaders.

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Modern design of a rail terminal.

The I BAU HAMBURG Central Cone – THE ORIGINALThe drawing shows a central cone silowith SIMPLEX loaders for rail car loading.2 moveable SIMPLEX loaders are installed in each rail line.There is no opening in the silo wall.

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Since 1979 ring silos for cement in operation in many countries.

The first cement ring silo is in operation since 1979.The drawing shows an integrated cement terminal for 2 types of cement,saving investment costs compared with traditional plants.All the handling equipment is installed under the cone.

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Aeration section and silo outlet

The I BAU HAMBURG Central Cone – THE ORIGINALA silo bottom covered with fluidising units,divided into several sections. One section after the other is activatedby means of a low capacity blower.

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The recovery of the silo is more than 99 %

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The I BAU HAMBURG Central Cone – THE ORIGINALDischarging and blending by alternatingfunnel flows due to stop and go discharge,controlled by flow control gatesand connected fluidising sections.

Aeration sections and silo outlet

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Funnel creation during the discharge process

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The I BAU HAMBURG Central Cone – THE ORIGINALAll handling equipment, including silo discharge, truck and train loadingas well as complete packing plants, are installed underneath the cone.Silos with a diameter of up to 30m and with storage capacities of ranging up to 40.000 tonsensure an economical material handling due to silo technology for a complete discharge.

Cone silo discharge sections with flow control gate

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Bulk loading with mobile loader

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The I BAU HAMBURG Central Cone – THE ORIGINALIn case precasting is not possible, the segmentscan also be manufactured directly at site.The use of precast concrete elements resultsin reduced construction costs and time.

Cone after placing the segments

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Cone silos during construction, in situ version

05/0

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I BAU HAMBURG

Marine Terminals, Shiploaders and -unloaders,Cement Carriers, Equipment for Power Plants,

Special Applications

I BAU HAMBURG · Rödingsmarkt 35 · D-20459 Hamburg · PHONE +49 (0) 40 36 13 090FAX +49 (0) 40 36 39 83 · Email: info@ibauhamburg.de · Internet: www.ibauhamburg.de

Mixing plant for RÜDERSDORFERZEMENT, Eisenhüttenstadt, Germany

High-Capacity mixing plant for HOLCIM,Antwerp, Belgium

Shiploading station for CIVIL AND MARINESLAG CEMENT, Port Talbot, UK

Mobile Shipunloader alonga river in Germany