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ASGCO® Products for the Cement Industry

03/04/2016


Cement Brohure_Download img
ASGCO® “Complete Conveyor Solutions” Offers the Cement Industry
High Quality Products and Services with Proven Success.

Our modern world is inconceivable without cement. It is the basic building material
for the most varied construction tasks and is the most important component for manu-
facturing concrete.

The cement industry forms an important part of our economy. The continued
anticipated growth of the cement market this year will place more demands on cement
facilities to meet higher industry standards. New technologies and industry innovations
are being introduced every day.

Cement plants take pride in an exceptional record of efficiency, safety and productivity
while always seeking the newest techniques, systems and equipment. ASGCO® strives
to help your plant meet those goals through the development of high-quality products and
services.

 

 

An Overview of the Cement Manufacturing Process

Production of cement by the dry process.

The most common way to manufacture cement is through the dry method. Although the dry process is the most modern and
popular way to manufacture cement, some kilns in the United States use a wet process. The two processes are essentially alike
except in the wet process, the raw materials are ground with water before being fed into the kiln.

Cement Brochure_cement process illustration

Production is completed after the passing of raw material from the following stages:
  1. Raw material extraction/ Quarry
  2. Grinding, Proportioning and Blending
  3. Pre-heater Phase
  4. Kiln Phase
  5. Cooling and Final Grinding
  6. Packing & Shipping
Concrete is produced in four basic forms:

Ready-mixed concrete – the most common form, accounts for nearly three-fourths of all concrete. It’s batched at local plants for
delivery in the familiar trucks with revolving drums.

Precast concrete products – are cast in a factory setting. These products are best known for their conventional 8-by-8-by-16-inch
block but can be molded into a wealth of shapes, configurations, colors, and textures.

Cement-based materials – in this category include mortar, grout, and terrazzo, soil-cement and roller-compacted concrete for
use in pavements and dams. Also included in this category are flowable fill and cement-treated bases.

A new generation of advanced products – incorporates fibers and special aggregate to create roofing tiles, shake shingles,
lap siding, and countertops.

 

Solving a Dust and Spillage Problem at a Major Cement Plant

This customer receives barges several times a month of raw material that travelled on top to feed the silos. This extremely
fine powder was 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 and also lining the floor. 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.

The ASGCO® Pro-Zone™ modular conveyor belt load zone system was designed and installed around the existing chute and
dust collection system. It creates a sealed belt support system with quick access for monitoring and easy adjustments. Belt speed,
material weight, size and air flow, were among the many factors that were taken into consideration when designing the system.

As a result the powdered material no longer plumes into the room and the cost of removing the wasted product has been virtually
eliminated by the cement facility. The ASGCO® Pro-Zone™ System removed a costly obstacle in the company’s procedure and
has allowed for greatly increased production throughout.

Cement Brochure_ProZone Before and After        Cement Brochure_Solutions

 

Efficient, Reliable Equipment is an Important Requirement for Cost-Effective
Cement Production

Primary & Secondary Belt Cleaners

ASGCO®’s belt cleaners are specifically designed for long lasting removal of the toughest materials on the planet.
Belt cleaners help remove the cement material carry-back and prevent it from falling off at various points of the
conveyor along the return side of the system causing a multitude of major problems including premature wear on
conveyor belt idlers and pulleys, belt misalignment, and an unsafe working environment.

CEMENT PRODUCT PICS_belt cleaners
Primary Belt Cleaners:
Skalper®, Super-Skalper®, Skalper MDX®, E-Z Skalper®, Saklper III®, Mini-Skalper®
Secondary Belt Cleaners: Razor-Back®, Razor-Back® Retractable System, Razor-Back MDX®, TORO Reverse Belt Cleaner,
Chevron,
V-Plow XD, Hinged V-Plow, Reversible Diagonal Plow, Dry Wipe, Vibra-Clean, Vibrating Dribble Chute

 
Belt Tracking Idlers

ASGCO®’s line of Tru-Trainer® conveyor belt trackers don’t rely on contact with the belt edge in order to guide it.
This means that conveyor belt edge damage is avoided. Its sealed design makes it a perfect choice for highly abrasive
environments under both wet or dry conditions.

CEMENT PRODUCT PICS_tru-trainers

Conveyor Idlers: Tru-Trainer® Series of Flat Return, Dual Return, Dual V-Return, Dual Return Urethane, Tapered Troughing and
Reverse Troughing Idlers; Dura-Sleeve, Slide-lers

 
Skirting & Dust Control

ASGCO® has many solutions for both controlling dust and eliminating spillage in the load zone. ASGCO®’s
Skirt Sealing systems provide a highly reliable, positive seal in the load zone.

CEMENT PRODUCT PICS_skirting

Skirt Sealing Systems & Dust Control Products: Standard Double Clamp-Mount®, Clamp-Mount MDX®, Single Clamp-Mount®,
E-Z Mount,
Conveyor Dust Curtains, Chute Tail Box, External Skirtboard/Wear Liner System
Skirting: Tri-Seal, Multi-Seal, Dura-Seal, B&R Dura-Seal, Dura-Tuff

 
Conveyor Safety Products

The safety of workers is the most critical objective of any facility, and delivering products to improve safety and reduce
injury is a major focus at ASGCO®. As a result we have developed the Safe-Guard® line of conveyor safety products
to provide barriers to moving conveyor equipment and protect workers from injury.

CEMENT PRODUCT PICS_conveyor safety

Conveyor Safety Products: Safe-Guard® Series of Modular Flat Guards, Return Idler Guards, Heavy Duty Return Idler Guards,
V-Return Idler Guard, Return Idler Cage, Return Roll Changer and Chute Inspection Doors; Sure-Grip Belt Clamps, Conveyor Belt Lifter

 
ASGCO® Pro-Zone®

A patented modular, self-contained material load zone system is the world’s first advanced containment and dust control
solution for conveyed bulk material products. The ultimate addition for maximum load zone efficiency is a conveyor belt
load-zone system that optimizes the sealing for air/dust tightness of the receiving conveyor belt. This self-contained system
requires no additional skirting.

CEMENT PRODUCT PICS_ProZone

Load Zone Support Products: Slide-N-Roll, 3 Roll Slide-N-Roll, Impact Cradle Bed, Quarry Duty Impact Beds, Roller Cassette, Pro-Zone®

 
Transfer Point Design

ASGCO®’s 3-DEM™ design, fabrication and installation techniques for handling material flow, are easily applied to both
existing and new installations, for significant cost improvements and system efficiency. 3-DEM® (Discrete Element Methods)
chute analysis program is a virtual modeling technology that can determine optimal chute design to maximize material flow
and reduce impact in the load zone.

CEMENT PRODUCT PICS_transfer design point

 
Conveyor Training and Services

At ASGCO® our coordinated Service team has the capabilities to fabricate, implement, and service your equipment, always
focusing on insuring your success. Routine scheduled maintenance programs are available and provide major cost savings
by addressing issues as they arise, instead of fixing more significant problems due to failure.

The ASGCO® Conveyor Training School (ACT™) offers classes created to provide your team with the highest quality training
to solve ongoing conveyor problems and maintain key components. In addition, a custom curriculum can be developed to
provide specific instructions to meet your needs.

CEMENT PRODUCT PICS_training