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Continuous loading of dry bulk cargo into ocean-going vessels – the Medcem case study: Jaber Malandi, Bedeschi (Italy)

Filmed at Cemtech MEA 2015, 8-11 February, Grand Hyatt Dubai, UAE

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Today, we are going to speak about three main subjects. First, we can start with Bedeschi group, secondly with our case study for the EREN Holding with Bedeschi profit and CTP as for the cleaning system, for the environment. As a start, Bedeschi is the mother company, more than 100 years of experience, we have five different sectors.

Our Bedeschi handling is responsible about the bulk handling and CTP is the engineering and manufacturing for more than forty years of experience for treatment and gas filtration technology. Recently, we had a new company to our group it's ONT, more than 50 years experience of designing for conveying systems for the bulk materials for sure.

This is our offices in all over the world, we have thousands of references. Our three offices, in one of them in Badawa, it's Bedeschi, and in Genoa Bedeschi Handling and our office in Miami, Bedeschi America, and Bedeschi Dubai with lot of agents. Now, we start with our case study for EREN Holding Medcem in Turkey. Bedeschi and CTP are taking part in the construction of a new Greenfield Cement Plant in Turkey for production capacity 10, 500 tonne per day clinker approximately 3.5 million of tonne of clinker.

Bedeschi will supply all the machinery for raw materials handling as outlined below. We start with the remix storage for the limestone. This is the [xx] circular storage that we have. We have two circular limestone pre-homogenization plant with luffing and slewing stacker and bridge reclaimer. Each with a total storage approximately 50,000 tonne and 2,000 t/h stacking and the 700 t/h for reclaiming capacity. The bulk density 1.4 tonne cubic meter, the grain size 95%<80-100%<300, the resting angle is 38, diameter of the rails is 90 and 50, 000 as we mentioned before. Moving to the additive storage for the raw mill, for the clay and the iron ore clay on the sand depends. An addtive storage facility here compromising, we have 4x10,000 areas will store the material and both raw mill and the cement mill, iron ore clay or sand at one side and the gypsum and the additive at the other side. Stacking will carry out via a belt stacking system with a capacity of 2,000 tonnes per hour. The iron ore clay or sand be reclaimed by 250 tonne per hour a side semi-portal claimer from the additive storage, I'm going to show the pictures later.

300 tonne
belt conveyor will transport the iron ore clay or sand to the raw mill's feeding hoppers, dust filters will be installed for sure from CTP. And this is our same photo for EREN Holding. This is the picture. And for the additive storage for the cement where the gypsum and additive are stored into multi box longitudinal sheed with 250 side semi-portal reclaimer. We transport the gypsum and the additives to the cement mills within hoppers and also for the dust filters will be installed also by CTP.

This is the picture showing on and you can see here how we use the space with the retaining wall and some heater from the inside so we increase the capacity of the storage retaining wall and [xx] And for the coal for sure everybody is going for the coal. Coal preblending storage to 25,000 tonne capacity of coal preblending. 500 tonne tripper car is installed to stack the coal and two 100 tonne per hour side semi-portal reclaimers claim the coal.

0.81 tonne cubic meter, the grain size 0.5, the anglel is 35-38 between the [xx] and the coal, the total stored volume 12,500. This is a picture showing that coal reclaimer. Right now moving to the ship loader that we have. We installed the ship loader for the cement and the clinker, the bulk density that we have for the clinker 1.5 tonne and for the clinker 1.35.

The moisture is about 5% for the clinker and the size 0-30, the capacity 4000 dead weight. The shiploaders are designed for loading, a rate up to 1400 tonnes per hour. Vessels at the capacity up to 40, 000 dead weight and the shiploaders are slewing and travelling time. So, but we have up to 6500 tonnes per hour installing in [xx] and you can see here that [xx].

Also these two pictures showing the same case. Here, we can see in these pictures how we load the material inside hoppers going to the stack up or the shiploaders. And here the picture showing how we delivered the cargo to the ship using this banana chute, and this is different between all type of material.

Each material has different type of chutes that we are using and this is how we deliver the material. From this picture you can see it's very close to the city. I think it's in Greece, it's totally closed also you install two filters here, so it's totally closed for very friendly to the environment.

For the dedusting system, CTP company is a responsible about the environmental solution that we have. We have [xx] different phares all over the world. Recently, in the Middle East area we have Lafarge, Jordan, in Saudi Arabia, in National Cement Company in Egypt and Oman Cement Company in Muscat, Oman. This is the flow sheet showing the Kiln/Raw Mill exhaust gas processing line, and this is the know how of CTP what we can put our hands in before the filter for the heat exchanger for the pre-heater and this is layout.

The technology of CTP using the swipe technology, I'm going to tell you about it later. For this case, for the Turkey project, which is the biggest filter for cement in Europe, 10, 500 as I told you before. The total capacity, 1,300,000 cubic meters per hour. The inlet gas temperature, 95, 180, the inlet dust concentration is 50 and the bag material is fiber glass and the TFE.

And we have the bags per each valve on each row is 20. So, the space opportunities for 75.4 square meter, 2,880 bags, multiply two because we have two. And the filtration surface as we can see 10, 000 square meter for two. And for the gas conditioning tower, this is the main data as you see here the gas valve flow is 1.5 million cubic meter per hour and the gas 320 and the outlet [xx] is 150. The active length is 18 meter. The shell diameter is seven meters, spray lances is by fluids. Cooling water injection is 30 cubic meters per hour. This is some picture from the site, also from other different sites. And this is for the [xx] same project. And the technology that we have is the Swap System Sonic Wave Solution Pulse.

And I call it, I have special name is triple E, low energy, high efficiency, and very economic. And this technology is using how tube are concentrating the pulse of the air. This is a different from the pulse. This is a new technology of the cleaning system that we have. We are using specific type of cellulite bulbs in a tank to concentrate the pulse up to speed one [xx].

So this speed will guarantee the cleaning, the whole length of the bag with very low pressure, and very low pressure drop. To give you small idea, this is the main features for this technology, the special powerful bulb is installed in here. The first action of this bulb is very huge and very first action of the bulb is to give you very high speed of the pulse, and the shape of the pulse will travel all over the bag with the low pressure of 2.5 [xx].

So, our goals is strictly to high cleaning efficiency and alternate concentration, what is it I'm talking about? Okay, okay. And very long bag life that we have and the lifetime is very, very long, I'm talking about five years of bags guarantee for CTP. I don't need for online cleaning, it's not the [xx] offline so no isolation is going to happen for our system.

This is a small picture showing the difference between the technology, this is the old technology plate please. This is the known technology, all the jet pass technology. Our technology it's not working, it's okay. I'm going to describe like this, I'm going to come back, it's okay leave it. This is the technology, the technology is very simple, using the jet pass this is how we clean it like that. So you're spreading the bag and consuming the life. Our technology is using our mom's technology this is how we're cleaning the laundry like that.

So the pulse will transfer from the top to the end of the bag and try to show this picture and this is how we do it. This is our mom technology, this is the best technology from the top up to the end of the back. This is the last to try if it works. This is the jet pulse high pressure cleaning system and this is our system as I told you like that.

We're talking about 6-12 meter up to 16m, by the way this technology was running in the power plants and it's not using for the cement and this is now using for the cement. Five years of the bag warranty we're talking about, very low air consumption, very high in energy, no venturi will be needed and this is the trend showing through the years with bag length withthe space that we are covering for each valve.

This is the swap technology, as you see it's in the top comparing to others. 120 square meters, our offices as you can see, this is there, this is for Bedeschi, for Bedeschi America, Bedeschi Dubai office and thank you very, very much.

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