A Blueprint for Minimizing Downtime: Your Cement Plant Profits When You Avoid Material Transfer Disruption

When you boil it down, what is the one thing cement plants must do to be profitable?

Move material.

Specifically, move material without disruption.

There are many complicated processes in cement production. While there is a long list of equipment types at a cement plant, belt conveyors, drag chain conveyors, and bucket elevators are the pulse of the operation. Without the consistent conveyance of aggregates and bulk raw materials through the different production stages, no cement will be made.

But wear and tear on the equipment is inevitable – especially when you factor in all the abrasive and extremely hot material being handled.

So it is not surprising that many plants have to replace conveyor belts and other material transfer components far too often, racking up extensive – and in some cases, avoidable – expenses.

This is where proactive maintenance comes into play, which can keep material flowing through the plant without disruption and reduce the chances of equipment failure.

Addressing Common Conveyor Problems Before They Occur

With so many variables in cement production, it’s impossible to pinpoint every possible issue that plants may encounter. But some material transfer problems are far more common than others. Minimizing just those can make a world of difference in production uptime, output and revenue.

Start with the conveyor system itself. When you know what kind of equipment you’re getting, it’s easier to develop plans to keep it in optimal shape. When you look at your conveyors, ask yourself these questions:

● Was the conveyor built to handle cement-specific raw material like clay, gypsum, limestone or clinker?
● Are the belts heat- and abrasion-resistant?
● Is the system designed for easy adjustments?
● Does the conveyance path match the facility layout?

These considerations can mitigate many issues, and help on-site personnel establish a strategic maintenance plan to avoid problems that lead to downtime. In an operation that relies almost exclusively on moving material, some of the most common mechanical and technical issues in cement plants happen to the conveyors such as:

Bearing stress
Conveyor bearings undergo continual strain during operation. They must be consistently lubricated to handle the required – or increased – load.

Belt mistracking
If the idlers or rollers are out of alignment, or objects get stuck in the structure (both common in cement-making), mistracking will occur. This interrupts operations and can damage the belt if it wasn’t designed for the task.

Material spillage
This is a preventable issue. While cement plants are dusty and dirty, material spillage should never be ignored. It is usually caused by overloading the conveyor, improperly installed skirtboards, or relying on the conveyor to transfer material past its design or structural limits.

Jammed rollers and idlers
In addition to causing belt mistracking, jammed idlers and rollers can be a fire hazard due to the piles of extremely hot material after it leaves the kiln. This is another reason to make sure the conveyors are built for the application.

Today’s Maintenance Plan Is Tomorrow’s Payoff

When it comes to proactive maintenance on the right equipment at cement plants, it’s a pay now or pay more later kind of world.

So why wait?

Investing in modern equipment for your operation means it’s been spec’d for what you need it to do, giving you an advantage because of its consistent performance. This will minimize unplanned downtime and deliver output that equals big dollars.
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This article is part two of our three-part series, “Modernizing the Cement Plant.” Continue reading here:

• Part one
• Part two
• Part three

Learn more about the CDM manufacturing process here.
Visit this page for CDM’s conveying systems brochure, including tech specs and material and design information.

About CDM

The CDM story is about understanding that every industrial operation is different — as are their conveying challenges. A custom-engineered conveying system is a cost-effective approach to any operation willing to have a partner who is vested in your success and one who stands by their product.

CDM has earned more than 91 percent repeat business because we’re more than just a conveying systems manufacturer — we’re a business partner.

For additional information contact:

Andrew Parker, President CDM Systems, Inc.

Andrew@cdmsys.com  • cdmsys.com