Optimization of the Clinker Bulk Loader Discharge Structure

In the cement industry,the efficient operation of clinker bulk loader,dust collector, and related equipment is crucial. Company S operates a cement clinker production line with a capacity of 450 tons per hour, equipped with four bulk loading systems. Operators control the discharge pipe using a hoist, powered by a turbine reducer, to accommodate vehicles of different heights. However, during actual operations, the equipment faced several issues that impacted production efficiency and environmental hygiene.


Identified Problems

The clinker bulk loading discharge system consists of four sections of telescoping main pipes and four sections of telescoping dust collection pipes. When loading, the positions of the telescoping joints and hooks cause dust to escape from gaps around the discharge pipe, leading to the accumulation of dust around the equipment. This issue worsens during windy weather. Additionally, after three months of use, the walls of the telescoping pipes suffer severe wear. Operators frequently encounter problems such as pipe misalignment and hook wear. These issues complicate maintenance and increase downtime, significantly affecting clinker loading efficiency and raising maintenance costs and labor intensity.

 



Rectification Measures

To address these issues, Darko's technical team conducted a thorough analysis and proposed a series of corrective measures:

 

1) Redesigning the Discharge Device

To improve the sealing and reduce dust emissions, the technical team redesigned the clinker discharge device . The new design incorporates wear-resistant pipes made from composite steel plates. The dust collection outlets are positioned on both sides of the top of the discharge pipe. This internal loading and internal airflow design effectively reduces dust emissions.


2) Improving Sealing Performance

To address previous issues of air leakage and dust overflow, the technical team connected the main pipe with steel cables, creating a flexible structure. During installation, they added sealing gaskets between components to maximize the negative pressure of the telescoping pipe hood. This prevents external air from entering the dust collection system and enhances dust collection efficiency .





3) Regular Maintenance and Inspection

Due to the high dust concentration and large processing volume handled by the bag dust collector, and the tendency of clinker dust to form clumps, especially in wet weather, the technical team established a regular inspection plan. This ensures the dust collection system operates normally. Regular checks help identify and resolve potential problems promptly, ensuring continuous and efficient equipment operation.

 


Post-Modification Results

After the modifications, the clinker bulk loader transformed into an internal loading and dust collection system, eliminating dust emissions caused by hood blockages. Since October 2021, the problem of pipe misalignment has not recurred, effectively resolving long-standing dust overflow issues. Furthermore, the modifications significantly improved the working environment for employees and enhanced the company's economic benefits and overall environmental conditions.

 

Through this transformation, Darko not only improved equipment performance but also created a safer and cleaner working environment for employees. This showcases our ongoing commitment to environmental protection and efficiency. We will continue to focus on technological innovation, providing high-quality bulk loaders and cement equipment solutions.If you are interested in our products or solutions, please feel free to contact us. 

 

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