ENGINEERING PROJECTS

Moving material, be it aggregate, coal, copper or other bulk material, ASGCO® has the proven engineering technology and design expertise to provide our customers with the best engineered solution to their conveyor material handling applications.

With design engineering capabilities and practical bulk material handling knowledge at our core, we understand the importance of accurately moving material from one location to the next in the most cost effective method. We have mechanical engineers on staff that can understand your application and suggest a process to make it a reality. Finally, in true turn-key fashion, we will partner with you as a single source to implement the solution.

ENGINEERING PROJECT CASE STUDIES:


ASGCO® Integrates Point Cloud Scanning Technology Into ASGCO® Conveyor Safety Product Installation at A Mid-West Coal Fired Power Plant.


Industry:
Coal Fired Power Plant

Application: (3) Coal Handling Conveyors

Product: ASGCO Point Cloud Scanning Services, ASGCO Safe-Guard Return Roller Guards, Return Roller Cages, and Flat Guard Panels.

Objective: Provide plant workers safety in the work place by the means of installing conveyor safe guard equipment. Although the plant does not fall under either MSHA or OSHA requirements, it strives for “best practice” that meets both regulations and ensures plant safety.

 

Challenge: Due to fire prevention in coal handling facilities, the plant required a turn-key installation that did not require a “burn permit”, thus all safe guarding panel railing and hardware had to be bolted onto existing conveyor structures and bolt hole patterns. The project required a very strict pre-installation measurement tolerance, that provided precise, accurate coordinates. This need for accuracy was extremely important in the prefabricating of the safe guarding fastening system onto the existing conveyor structures (such as existing holes, detouring around piping conduit and emergency stops). The plant had very limited down time and called for quick and efficient installation turnaround time.



ASGCO® Engineering Helps East Coast Silica Manufacturer Streamline Their Processes.

Industry:  Minerals

Application: Conveyor Feeding Dryers

Product: Flo-Control™ Transfer Point System

Objective: Bypass the dryer by redirecting product from an incline conveyor onto an adjacent steep incline conveyor.

 

 

Challenge: The customer first came to ASGCO with the question “how can we eliminate our dryer and the conveyor that feeds it cost effectively.” The largest challenge of this project was the relationship of these two conveyors. They were not exactly perpendicular to each other which made the design of the chute difficult.


 
ASGCO’s® Pro-Zone™ Solves Southeastern US Cement Plant’s Wasteful Dust and Spillage Problem

Industry: Cement Manufacturer Distribution Terminal Facility

Application: Calcium sulphoaluminate cement powder

Product: ASGCO®’s Pro-Zone™ Modular Conveyor Belt Load Zone System

Objective: To design a new self-contained material load zone that would eliminate costly spillage
and expensive clean up.

 

Challenge:  This customer receives barges several times a month, and sometimes more frequently depending on the demand. The raw material travels on top to feed the silos. This powder has extremely fine properties that were escaping and filling the structure surrounding the conveyor with thick dust and debris that would settle throughout the room, sometimes in upwards of several feet. The floor would become lined with this expensive material, that once exposed, became useless in the cement process.

The challenge was to eliminate the fugitive dust and spillage and the additional costs incurred for the time and effort taken in the removal of the material, plus any disposal fees. Access will also need to be provided to insure proper operation and allow for serviceability of the load zone.


 
ASGCO® Helps Northeastern US Coal Burning Power Station Improve Material Flow and Reduce Maintenance Costs

Industry: Cement Manufacturer Distribution Terminal Facility

Application: Calcium sulphoaluminate cement powder

Product: ASGCO®’s Pro-Zone™ Modular Conveyor Belt Load Zone System

Objective: To design a new self-contained material load zone that would eliminate costly spillage
and expensive clean up.

 

Challenge: Constant abrasion from high moisture bituminous coal was causing serious wear and plugging on flow chutes at a major Northeastern US coal burning power station. ASGCO® 3-DEM® Designed Flo-Control® Chutes are custom tailored to adapt to unique challenges of any material in any environment.

A major US coal burning power plant was experiencing constant chute plugging after recent upgrades to its coal yard. These issues were compounded by spillage due to holes being formed almost immediately in the new round chutes that were installed. These problems led to major maintenance down time, and the round design of the newly installed chutes proved difficult to repair. This situation prevented the silos from being stocked with coal, reducing productivity, as well as adding a significant cost for repair and maintenance from holes in the new chute after 30 days of service. Because of the round design of the chutes, repairing the holes and replacing the liners became cost and time prohibitive.


 

New Conveyor Technology Improves Environmental, Safety and Productivity for Bulk Material


Industry:
Coal Fired Power Plant

Product: ASGCO® Pro-Zone™ modular conveyor belt load zone system

Objective: Provide the latest conveyor technology and engineering to solve a coal dust and spillage environmental concerns and increase productivity.

 

 

 

Challenge: In today’s coal fired power plants, it is important to keep coal dust and coal spillage in the load zone area to a minimum. Many plants struggle to keep these areas clean, due to not having enough time or man power to properly adjust skirt rubber or fix holes in the chutes. Around many load zone areas you will usually find coal piles in between troughing idlers and on the floor. This coal spillage is expensive to remove and if not properly fixed the coal piles will reoccur again and again.

This Midwest coal fired power plant had this problem. The skirt rubber wasn’t getting adjusted or changed when needed; piles of coal all around the load zone area floor caused a safety hazard. The existing load zone was missing hoods, dust curtains and was rusting in some areas. All these problems together were causing coal to spill and coal dust to fill the air around the conveyor.


 
ASGCO® Helps Midwestern US Coal Handling Operation Reduce Combustible Dust and Spillage in High Volume Transfer Terminal


Industry:
Midwestern Coal Bulk Shipping Terminal

Application: Sub-Bituminous Coal 54” transfer point at 3000 TPH and 1000 FPM

Product: ASGCO® Designed Flo-Control® Chutes and complete transfer points

Objective: To reduce combustible dust spillage and maintenance issues

 

 

 Challenge: This underground rail car transfer point for Sub-Bituminous Coal was failing due to poor design and inferior components, leading to major dust and spillage.

The existing 54”wide conveyor transfer point located under a rail car unloader was causing excessive dust, spillage and conveyor belt cover wear due to the poor design, chute liner wear and corrosion. The extremely volatile nature of sub-bituminous coal/PRB presents a fire and explosion hazard when there is airborne dust and spilled coal in the area. The existing transfer point being located underground in a tunnel made the cleanup of spilled coal difficult as well as creating an explosion hazard due to the dusting.


 
ASGCO® – 3-DEM Analysis of Existing Bucket Reclaimer and of a New Bidirectional Design Bucket to Verify the New Design Will Achieve the Same Output as the Existing Design.


Industry:
Boron mine

Application: Bucket Wheel Reclaimer

Material: Borax Ore, Tincal Ore; 5” minus

Product: ASGCO® 3-DEM Analysis

Objective: Conduct an analysis of the existing bucket design to establish a baseline and then performed the same tests on the new bidirectional split bucket design.

Details: Bucket Wheel
Capacity: 400 STPH
Bucket Wheel Drive: 4.4 RPM
Carriage Traverse Speed: 40 FPM

Challenge: The driving force behind this project was initiated out of a safety issue. The existing bucket design would require 3 to 4 operators to manually flip the buckets which would put the operators in a dangerous position as the buckets are very heavy and could cause an injury during the process of flipping the bucket to change direction. Therefore corrective actions resulting from an incident investigation were to redesign and re-engineer the bucket to enable the bucket wheel to change direction without flipping the buckets. Due to the split design of the new bucket the challenge was to ensure the same tonnage would flow thru the bucket without any restriction.

  • Chute modeled using Flo-Control Transfer Point System.

    Chute modeled using Flo-Control Transfer Point System.

  • Point Cloud Scanning used to provide accurate coordinates in this Safe-Guard® Flat Guard installation.

    Point Cloud Scanning used to provide accurate coordinates in this Safe-Guard® Flat Guard installation.

  • ASGCO® 3-DEM designed Flo-Control® Chutes used to improve material flow at this coal burning power station.

    ASGCO® 3-DEM designed Flo-Control® Chutes used to improve material flow at this coal burning power station.

  • ASGCO® Engineering used the latest conveyor technology to solve coal and dust spillage problem in this load zone with Pro-Zone™ modular advanced dust containment system.

    ASGCO® Engineering used the latest conveyor technology to solve coal and dust spillage problem in this load zone with Pro-Zone™ modular advanced dust containment system.

  • BEFORE: Mid-west coal bulk terminal

    BEFORE: Mid-west coal bulk terminal

  • AFTER: ASGCO® designed Flo-Control Chutes and complete transfer point with Impact Cradle Beds, Slide-Lers™, Slide-N-Roll™ Load Zone Support Systems.

    AFTER: ASGCO® designed Flo-Control Chutes and complete transfer point with Impact Cradle Beds, Slide-Lers™, Slide-N-Roll™ Load Zone Support Systems.

  • BEFORE: Existing Bucket for Bucket wheel reclaimer.

    BEFORE: Existing Bucket for Bucket wheel reclaimer.

  • AFTER: Split Bucket design using ASGCO® 3-DEM® analysis.

    AFTER: Split Bucket design using ASGCO® 3-DEM® analysis.