samson bulk material receiving unit feeder.pdf · the samson™ bulk material receiving unit truck...

SAMSON™

BULK MATERIAL

RECEIVING UNIT

W E C O N V E Y Q U A L I T Y

CONTENTS

3 Surface Installation

4 The Samson™ Solution

5 Universal Application

6 Operational Concept

7 Discharge Rate Control

8 Body & Entry Designs

9 Samson™ Construction

10 Dust & Fume Control

11 Enclosure Systems

12 Discharge Interface

13 Feeder Options

14 Hydraulic Drive

15 Mechanical Drive

16 Instrumentation

17 Electrical Controls

18 Sizing and Screening

19 Storage Solutions

20 Under Floor Options

21 Railcar Discharge

22 Related Products

23 After Sales & Service

A UNIQUE CONCEPT

B&W Mechanical Handling Ltd. developed the Samson™ surfacefeeder concept to satisfy the demands of clients requiring a mobilesolution to receive general bulk materials such as coal and aggre-gates direct from tipping trucks in mainly Ship Loading applicationswhere fixed plant was not a viable option.

The Samson™ concept eliminated the need for any truck ramps orfixed civil work and was rapidly extended to fixed plant projectswhere the flexibility of surface installation was a clear benefit.

Mobile Samson™ Feeder receives Kaolin for Ship Loading (Truck to Ship Concept)

Mobile Samson™ in Quarry with Integral Sizer receives from Dump Trucks


2

SURFACE INSTALLATION

The Samson™ provides a com-pact solution for this new Mortarplant and by combining a crossmounted transfer conveyor witha vertical bucket elevator to raisethe sand to storage silos thecomplete equipment could thenbe surface mounted avoiding thecost and complication of under-ground pits and hoppers.

• No Deep Pits.

• No Underground Hoppers.

• No Expensive Civil Works.

• Flexibility of Location.

• One Piece Integrated Machine.

• Receives Direct from Trucks.

• Receives Direct from Shovels.

• Buffer Holding Capacity.

• Fast Truck Discharge.

• Controlled Rate Feeding.

• Handles Dry and Dusty Materials.

• Reduced Dust Generation.

• Handles Wet and Sticky Materials.

• No Risk of Bridging or Blockage.

• Reduced Energy Consumption.

• Easy Maintenance Access.

• Easy Housekeeping Access.

• Reliable in Service.

• Proven References Worldwide.

The Samson™ Receives Coal for the Coking Plant at a major UK steel works operating continuously 24/7

The Samson™ receives Sand for a Mortar Plant discharging to Belt Transfer Conveyor


3


AN ECONOMICAL SOLUTION

Illustrated above a conventionalunderground truck tipping hop-per with deep pit and feederdischarging to an inclined beltconveyor to raise the materialout of the pit and to the associ-ated process plant.

Requires permanent and expen-sive civil works and cannot berelocated to accommodate plantdevelopment.

The Samson™ Bulk Material Receiving Unit Truck Dump Station

In this Cement Grinding Plant three Samson™ Bulk Material Receiving Units intake Cement Clinker plus other additives for the whole plant

4


CONSTRUCTION CONCEPT

The wide Apron-Belt designpermits a very low loadingheight allowing the trucks todischarge direct to the entrysection with only a small accessramp.

Trapezoidal shaped apron barsat every chain pitch providemaximum support and allowminimum sprocket diameter.

The wide Apron-Belt design com-bines the strength of a Steel ApronFeeder with the cleanliness of aBelt Feeder. Since the materialdepth is less than the belt width thebridging and blockages associatedwith conventional tapered hoppersis completely eliminated guarantee-ing reliable discharge.

Highly developed over manyyears the Samson™ side sealcontains the material within thebody preventing spillage.

Wide Belt Design Eliminates Bridging

External Chains Outside the Material Flow

Steel Apron Bars Support the Load

Flexible Side Seal with outer Belt Ledge

Load Carried on the Chain RollersConveyor Belt Aligned with the Chain Pin Centre and Rivetted to the Steel Apron Bars

5

Flexible side sealscontain the largermaterial whilst theraised belt edge

contains any finespassing the mainseal to prevent

chain contamination

OPERATIONAL CONCEPT

Material is drawn from the tip-ping truck into the Samson™body by the forward movingapron-belt conveyor. The operat-ing concept can be divided intothree stages as illustrated.

Stage A:

The first truck arrives and dis-charges its material on to theforward moving Samson™apron-belt. As the Samson™ beltmoves forward so the material isdrawn from the truck body.

Stage B:

When the truck is empty itdeparts the Samson™ and thematerial contained within theSamson™ is continually dis-charged to the following convey-or system. The material movesforward and the Samson™ entrysection is exposed.

Stage C:

After the first truck has depart-ed the following truck reversesinto position. During this timeperiod the forward movingSamson™ apron-belt hasexposed the entry section readyto accept the next truck con-tents.

And so it goes on...

A

B

C

Broken Glass is received by the Samson™ at a Recycling Operation

Material is drawn into the empty Samson™ body by the forward moving Apron-Belt

The Complete Truck Contents transferred to the Samson™ body

During the Truck Manoeuvring Cycle the Samson™ Entry empties ready to accept the next load


6

DISCHARGE RATE CONTROL

As material is transferred fromthe truck or shovel to theSamson™ the load level variesfrom zero to 100 % along themachine length.

Since the output rate is propor-tional to the material bed depthand belt speed it is necessary toregulate the bed depth suchthat the output rate may be con-trolled by varying only the beltspeed.

The Levelling Blade solution main-tains a constant bed depth at thedischarge by cutting the peaks intothe troughs and enables the finaloutput rate to be closely regulated.

For extremely cohesive materialsthe rotating Teaser shown right per-forms the same task by cutting theflow into manageable pieces.

Levelling Blade controls the material bed depth at the Samson™ Discharge

Material Stored within the Samson™ body may be at various Load Levels along the length of the Samson™


7

BODY AND ENTRY DESIGNS

A B

The Samson™ with Deflected Chassis and Parallel Entry (width 3.0 m) receives Broken Glass from both Tipping Trucks and Shovels

The Samson™ with Straight Chassis and Flared Entry(width 4.5 m) receives Sandy Clay from Shovels

Flare Entry width from 4.0 to 6.0 m.

Universal Truck Entry for All Truck Types

Standard Ramp Raised Ramp for Greater Entry Volume

The Samson™ Deflected Chassisdesign provides a near horizon-tal loading section to receivematerial from tipping trucks tomaximise the entry volume andeliminate any risk of the trucktailgate fouling the apron-belt.

For use only with Shovels theStraight Chassis design isadequate to maintain theSamson™holding volume.

For operation with trucks theaccess ramp height directly con-trols the Samson™ entry volumeand therefore the time requiredto discharge the truck.

Illustration A shows a standardramp giving a reasonable entrycapacity of say 10 tons.

Illustration B shows a raisedramp height giving an increasedentry volume to reduce the trucktipping time and increase theoverall average handling rate.

For operation with multiple truckdesigns the Universal TruckEntry provides total flexibility.


8

SAMSON™ CONSTRUCTION

The Samson™ is available in fivebasic design ranges each signi-fied by the chain tension ratingknown as.

Samson™ 380 for light materi-als and low duty applications.

Samson™ 450 with its shortpitch chain design ideal formedium duty mobile applica-tions where the lowest entryheight is required.

Samson™ 450 Super for medi-um duty continuous processapplications typically handlingfuels, crushed stone, clinker andsimilar graded materials.

Samson™ 800 for continuousduty applications handing heav-ier mineral ores and where con-tinuous availability is mandatory.

Samson™ 1600 for extremeduty applications includingROM material sizes and for themost arduous operating condi-tions.

Samson™ 380

Samson™ 800 Samson™ 1600

Samson™ 450

The Samson™ construction expands in strength as the chain specification increases

The Massive Samson™ 1600 receives Gabbros Rock from Shovels for Barge Loading at 1,000 t.p.h.


9


DUST AND FUME CONTROL

The Samson™ with Deflected Chassis and Full Enclosure including Dust Filter receives Cement Clinker

Flow into the Samson™ in a Controlled Stream

Conventional Underground Hopper

Resultant Dust Pollution

With a conventional undergroundhopper the material falls free allow-ing particulate separation and gen-erating high velocity displaced air.

The displaced air ejects the dustparticles from the hopper at highspeed causing extreme fugitive dustpollution with both environmentaland health and safety implications.

The Samson™ Surface Feeder isthe ideal solution for the intakeof dry and dusty materials wheredust pollution is a real hazard.

Material free fall is near zeroand the bulk of the truck con-tents is drawn into the Samson™body in a controlled streameliminating particulate separa-tion and therefore virtually elimi-nating dust pollution at source.

Only when handling the mostdusty materials (Cement Clinkerfor example) is it necessary toprovide dust extraction and thenonly a relatively small air volumeis required. Typically only 25% ofthe rate required for extractionon conventional deep hoppersthus saving not only on capitalcost but also on long term oper-ational costs also.

DisplacedAir

Free FallingMaterials

Separate intoParticles

Generating...Dust...

Expelled by theDisplaced Air

10


ENCLOSURE SYSTEMS

Mobile Samson™ with Flexible PVC Sheet Partial EnclosureEnclosure with Fume Extraction for Odious Materials

Enclosure with Extended Flared Entry for large Mining Dump Trucks

Full Enclosure with Flexible Entry Curtain but without Dust Extraction

The Samson™ enclosure integrated to a complete coal preparation plant handling ROM material direct from the adjacent open cast mine

Full Enclosure with Ducted Dust Extraction

Fixed enclosures clad in Profiled Steel sheeting overa fabricated steel frame made integral to the bodyof the Samson™ eliminating the need for additionalor separate buildings... less cost... greater flexibility...

The enclosure may be supplied complete in flat-packed components for site assembly or may bemanufactured locally with an engineering onlypackage by B&W.

11


DISCHARGE INTERFACE

Twin Samson™ Surface Feeders discharge to a Common Belt Conveyor at 90 degrees with Parallel Chutes

The Samson™ with a Centralising Head Chute discharges to a conveyor positioned In-Line

Parallel Head Chute for 90 degree Transfer

Centralising Head Chute

Standard Samson™body will be termi-nated to an outletflange at this level

The Parallel Head Chute eliminates risk of bridging and blockagewhen handling cohesive materials and is always the preferred solu-tion where the plant arrangement permits.

Where the ongoing conveyor is in-line or at an angle to the Samson™then the centralising chute is the only option but generally this solu-tion is less compact and requires an increased discharge height.

12


FEEDER OPTIONS

Single Screw Feeder provides metered output to a Bucket Elevator Kleen-Line Belt Feeder transfer to Bucket Elevator

Vibro-Feeder with Reject Grill to remove over size materialTwin Screws meter output to Progressive Cavity Pump

Vibratory Feeder provides regulated output to an inclined belt conveyor

Vibro-Feeder controlling feed rate to a Steep Angle Belt Conveyor

For closely controlled discharge rate down to a fewcubic metres per hour a suitable feeder device atthe Samson™ discharge is required.

Using the Samson™ head chute as a small bufferhopper the output of the Samson™ is regulatedusing high a level detector to stop/start the driveand maintain a constant level in the head chute.

Generally not used with a Levelling Blade except inspecial conditions.

13


HYDRAULIC DRIVE

A - Suction Strainer.

B - Hydraulic Pump.

C - Pressure Filter.

D - Relief Valve.

E - Solenoid Control Valve.

F - Speed Control Valve.

G - Hydraulic Motor.

H - Reduction Gear.

J - Oil Cooler (where required).

K - Return Line Filter.

L - Reservoir Instrumentation.

M- Reservoir Heater.

A

B

CD

E

F

G

H

JK

L

M

Hydraulic Drive comprising Variable Displacement Hydraulic Pump providing local or remote belt speed control

Comprehensive protection and oil filtration systems guarantee long life and reliable operation

Axial Piston Hydraulic Pump Set

Radial Piston Hydraulic Motor

14


MECHANICAL DRIVE

All Samson™ Feeders are supplied as standard with a shaft mounted reduction gear

Worm main gear unit with helical primary reduction to achieve the required overall gear ratio

High efficiency Helical/Bevel main reduction gear with helical primary

Hydraulic drives are available forall machines but are preferredunder the following conditions:

Very high torque demand orwhen dual gear drives arerequired to equalise the loadshare on each side of thedrive shaft.

Compact high power trans-mission capacity generallyfor drives over 55 kW..

Rapid drive cycling whenused with a level detectorcontrol in the head chute.

Mechanical Drives provide aless complex alternative and arethe preferred solution for:

Continuous output using theLevelling Blade solution thusavoiding rapid drive cycling.

Remotely controlled variablespeed is required interfacedto a central process control.

Where there may be a prob-lem with maintenance facili-ties for hydraulic equipment.

15


INSTRUMENTATION

A

B

C

D

EF

G

H

For the safe operation and pro-tection of the Samson™ feedervarious items of field instrumen-tation are available:

A - Rotating Warning Beaconlinked to a drive torque monitor-ing system to warn of impend-ing overload and indicate to theoperator to cease filling.

B - Ultrasonic Detector to signalthe presence of a vehicle at theSamson™ entry and initiate acontrolled startup sequence forthe Samson™ and the ongoingplant.

C - When the Samson™ headchutes forms a buffer hopper foran ongoing feeder this LevelDetector is linked to the drivecontrol to start the Samson™ onlow level and stop on high level,see the diagram or the right.

D - Blocked Chute detectorarranged to stop the Samson™drive if the head chute is over filledor blocked with material.

E - Hydraulic Fluid Reservoir pro-tection systems to inhibit the elec-tric motor in the event of high fluidtemperature or low fluid level.

F - Tail shaft Rotation Sensor toinhibit the drive system in the eventrotation is lost in normal operation.

G - Traffic Lamp linked to the ongo-ing process control to signal eitherthe machine readiness or the gradeor type of material required.

H - Local control cabinet plus safe-ty stop system.

Instruments are generally suppliedloose but with mounting brackets tofix to the Samson™ or Chutes.

Chute Level Detection for use withan auxiliary feeder or when theongoing conveyor acts as anextractor to control the feed rate.

Traffic Lamp Truck Management

Samson™ starts on low level stops on high level

16


CONTROLS

Blending Systems

When several different materialsmust be blended onto a commoncollecting conveyor multipleSamson™ feeders, one for eachmaterial type, may be linked to acentral controller and arranged todischarge a set blend ratio as aproportion of the total output asmeasured by a downstream beltweigh idler.

Variable Output Rate

To control the output rate of theSamson™ feeder using theLevelling Blade system it is nec-essary to provide variable speedfor the Samson™ belt drive.

For mechanical drives anInverter is required to controlthe motor speed and thereforethe belt speed. For a fixed level-ling blade height the output rateis proportional to the belt speed.

For hydraulic drives it is neces-sary to provide an electronicinterface for the pump servoallowing for remote speed con-trol using a 4-20 ma signal.

Interfaces

Invariably the Samson™ will belinked to a plant control systemfor sequencing with otherequipment.

The Samson™ may be suppliedwith a local PLC plus necessarycommunication protocol com-patible with the main plant con-trol systems. Or, supplied withinstrumentation only plus suchas Inverter unit(s) which will beconnected individually to theclients control systems locatedin the main plant control room.

Control units are supplied loosefor site installation either com-plete will all necessary motorcontrol and logic gear or as alocal control station only linkedto an existing central motor con-trol centre (MCC) perhapslocated some distance from theequipment.

Weighing Idler

Inverter Speed Control Modules located local to the Samson™ but linked to a remote control room

Local Cabinet with Motor Control Gear

17


Twin Rotor Sizer supplied with the Samson™ 1600 Series feeder receives ROM Limestone for crushing down for onward conveying

Samson™ supplied with Vibrating Screen to remove oversize material before onward conveying

SIZING AND SCREENING

The Samson™ may be suppliedcomplete with integral rotarycrusher or screening equipmentto size the raw material beforeonward conveying, either as apackage or engineered to suitclient’s free issue equipment.

18

For fixed plant the Samson™may be integrated to per-manent building structuresas illustrated right receivingLimestone from large min-ing dump trucks.


The Samson™ 800 Series provides 100 cubic metres of live storage for Alternative Fuels in a Cement Plant.

Extended Inclined Section for increased storage or discharge height

The Samson™ Horizontal Storage Bunker with Overhead Conveyor and Plough Discharger

LIVE STORAGE SOLUTIONS

For handling difficult materials that are liable tobridge and block in conventional silos the Samson™offers the ideal solution for live storage with holdingcapacities up to around 200 tons.

Illustrated above and right the conventional Samson™design with horizontal loading section and inclineddischarge, with this arrangement the storage volumeis generally limited by the increased chain tensionrequired to raise the load.

Illustrated below a specialised application for thestorage of Sewage Sludge including twin Samson™surface feeders each with belt conveyor transfer totwo Samson™ horizontal storage units within thebuilding able to store and discharge on demand.

19

SIDE LOADING andDRIVE OVER TIPPING

In confined spaces the Side Loading solution mayprovide an economical alternative allowing a simpli-fied plant layout with reduced transfer points andminimum disruption to the process operation duringthe new equipment installation.

Side loading is particularly suited to drive-over-tipapplications where the Samson™ may be mountedbelow floor level or supplied with a suitable rampallowing the trucks to drive over the Samson™ entrysection, tip and continue in the same direction, asillustrated right and below.

In drive over projects handlingfree flowing materials a simplegrill only is required to supportthe truck and allow material topass through.

However, for cohesive materialssuch a grill may blind and blockand for this condition the driveover door system was developedcomprising hydraulically operat-ed doors allowing the truck todrive over and, after the doorshave automatically opened, dis-charge direct to the Samson™below without hindrance.

The Side Loading Samson™ receives Cement Clinker for import directly to an existing conveyor installation

The wide Apron-Belt of theSamson™ concept allowsnear vertical hopper sides

permitting a very shallow pitfor economical installationand for the same reason

eliminating any risk of mate-rial bridging or blockage.


20

The Samson™ solution forRailcar discharge may be imple-mented in a shallow pit, typicallywith depth only 4.0 metres, ide-ally suited in port area with highground water level or whereworking on hard rock increasesthe cost of the excavation whichwith a conventional taperedhopper could be as much as 14metres deep to obtain the nec-essary hopper angle for reliablematerial flow handling such asindustrial coals etcetera.

With a shallow pit the materialfree fall is minimised and, sincethe Apron-Belt of the Samson™feeder is wider than the typicalrailcar, the material flows out-ward reducing the velocity ofthe displaced air and therebyreducing dust generation.

With the deflected chassisdesign the raised discharge pro-vides an ideal transfer to the fol-lowing conveyor which, thanksto the shallow pit depth, may beof reduced length and thereforereduced energy input saving oncapital and running costs.

Discharge facility for Hopper Bottom Railcars receives coal for a Cement Plant including a Samson™ feeder with 80 tons holding capacity

The Wide Apron-Belt Samson™ Concept permits a Shallow Excavation and Economical Installation

RAILCAR DISCHARGE


21


The Samson™ Feeder integrated to this Mobile Shiploader permits direct bulk export from Truck to Ship

The B&W Stormajor™ with integrated Samson™ 1600 Series Feeder and Radial Stacking Boom for Barge Loading

The B&W Stormajor™ combines the benefits of a Samson™ Surface Feeder with a Radial Stacking Boom mounted to a common mobile chassis.

22

MOBILE SHIPLOADER and STACKER withINTEGRAL SAMSON™ SURFACE FEEDERS


GERMANY

AUMUND Fördererbau GmbHSaalhoffer Str. 1747495 RheinbergPhone: +49 - 2843 - 72 0Fax: +49 - 2843 - 6 02 70e-mail: [email protected]

AUMUND Fördertechnik GmbHSaalhoffer Str. 1747495 RheinbergPhone: +49 - 2843 - 72 0Fax: +49 - 2843 - 6 02 70e-mail: [email protected]

SCHADE Lagertechnik GmbHDorstener Straße 36044653 HernePhone: +49 - 2325 - 58 74 0Fax: +49 - 2325 - 58 74 74e-mail: [email protected]

GREAT BRITAIN

B&W Mechanical Handling Ltd.Gemini House Cambridgeshire Business Park, 1 Bartholemew`s WalkEly, Cambridgeshire, CB7 4EA.Phone: +44 - 1353 - 665 001Fax: +44 - 1353 - 666 734e-mail: [email protected]

INDIA

AUMUND Engineering Private Ltd.2nd Floor, Lakshmi Neela Rite ChoiceChambers · 9, Bazulla Road,T. Nagar Chennai - 600 017Phone: +91 - 44 - 4393 63 00Fax: +91 - 44 - 2815 60 46e-mail: [email protected]

HONG KONG SAR

AUMUND Asia (H.K.) LimitedSuite 1301, Oxford House,Taikoo Place, 979 King's Road,Quarry BayHong Kong.Phone: +852 - 3695 - 43 33Fax: +852 - 3695 - 43 11e-mail: [email protected]

THE NETHERLANDS

AUMUND Holding B.V.Spoorstraat 42-525911 KJ VenloPhone: +31 - 77 - 320 01 11Fax: +31 - 77 - 320 07 28e-mail: [email protected]

SWITZERLAND

AUMUND AGArther Str. 3, 6301 ZugPhone: +41 - 41 - 710 10 82Fax: +41 - 41 - 710 42 02e-mail: [email protected]

POLANDAUMUND PolskaRepresentative Officeul. Lektorska 34 G,44-210 Rybnik.Phone: +48 - 32 - 426 32 11Fax: +48 - 32 - 426 32 01e-mail: [email protected]

FRANCEAUMUND France S.A.R.L.53, Rue d’Hauteville, 75010 ParisPhone: +33 - 1 - 42 46 72 72Fax: +33 - 1 - 42 46 72 74e-mail: [email protected]

BRAZILAUMUND Ltda.Rua Haddock Lobo, 337 - 11. andar01414-001 São Paulo, SPPhone: +55 - 11 - 3059 0160Fax: +55 - 11 - 3059 0161e-mail: [email protected]

USAAUMUND Corporation1825 Barrett Lakes BoulevardBarrett Lakes Center IISuite 520Kennesaw, GA 30144Phone: +1 - 770 - 226 - 95 78Fax: +1 - 770 - 953 - 48 44e-mail: [email protected]

P.R. CHINAAUMUND Machinery Trading(Beijing) Co. Ltd.Rm. 7-8, 22-F, East Ocean CentreNo. 24 Jianguomenwai AvenueChaoyang DistrictBeijing 100004Phone: +86 - 10 - 65 15 58 13 / 14Fax: +86 - 10 - 65 15 58 15e-mail: [email protected]

THE AUMUND GROUPAFTER SALESSERVICE

B&W Mechanical Handling Ltd., within theAumund Group, strive to deliver the higheststandards of customer support and aftersales service worldwide with the collabora-tion of the local Aumund Group daughtercompanies and representative offices andincluding: -

• Application advice.

• Conceptual Plant Layout.

• Plant Selection and Specification.

• Supervision of Installation.

• Commissioning.

• Advice on Maintenance Programmes.

• Rebuilding and Refurbishment.

• Genuine Spare Parts.

• Service Contracts.

Our engineers are highly trained and expe-rienced in the B&W products and familiarwith the demands of continuous processindustries where plant availability is critical.

Illustrated above the B&W site supervisordemonstrates the proper fitting of the con-veyor belt over the Samson™ Apron-Bars.

23


www.aumund.com

AUMUND GROUP Headquarters in Rheinberg, Germany

Products offer a unique concept in bulk materials handlingwith Surface Mounting and Mobility for maximum flexibility

in location and economy in installation and operation.Often opening new opportunities for processes on short

term contract options that with conventional fixed plant ortraditional underground hoppers and feeders would not be

economically viable.

B&W Mechanical Handling Ltd.Gemini House, Cambridgeshire Business Park, 1 Bartholomew’s Walk, Ely, Cambridgeshire, CB7 4EA, UK.

Tel: +44 - 1353 - 665001 • Fax: +44 - 1353 - 666734 • e-mail: [email protected]

B&W Mechanical Handling Ltd. UK

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samson bulk material receiving unit feeder.pdf · the samson™ bulk material receiving unit truck...

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