Martin Engineering Upgrades GCC Conveyor Systems

 For Grupo Cementos de Chihuahua (GCC), a cement manufacturer, Martin Engineering was tasked with preparing a proposal for a significant upgrade to the conveyor systems in their facility.

Cement, ready-mixed concrete, aggregates, and other products related to them are produced worldwide by the GCC. In the beginning of 2013, company officials carried out an extensive evaluation of the extensive conveyor system that US Butadiene Market uses to handle raw materials and move finished goods.

Martin Engineering was contacted after it was determined that upgrades to conveyor transfer points could reduce dust emissions and spillage.

Dan Marshall, a product engineer at Martin Engineering, stated: Dust can be produced and released virtually any time bulk materials are moved, particularly at high speeds or in large quantities."

"Dust accumulation has an impact on both productivity and safety, so it's more than just a cleaning problem. The fact that bulk handling systems frequently have to adjust to changing weather and material conditions makes dust management even more difficult."

The project's scope included upgrading six transfer points on four late-70s-constructed conveyors as part of the upgrade. The belts had widths of 24 inches and lengths of 40 to 110 feet each. They move between 200 and 250 tons per hour between the storage building and the bins that feed the finish mills during normal operation.

Ralph Denoski, manager of maintenance for the GCC, said: The majority of this plant's material handling system was fairly standard for its time, but some of its components were getting old.

"We wanted to take advantage of the newest technologies, and we were also aware that significant advancements had been made in some areas of bulk handling."

Martin Engineering was scheduled to carry out the upgrade works during GCC's scheduled shutdown in March. Martin Engineering was in charge of planning and supervising the project, in addition to providing the components. A mechanical contracting firm assisted with the installation.

Upgrade of the system for the conveyors On each of the four conveyors, the material inlet chutes were disconnected from the skirtboard system, and the deteriorated rubber skirt seals, clamps, supports, skirtboard chute walls, and tail boxes were taken out. Idlers from the past were also taken out.

Each conveyor had three Martin® Trac-MountTM Idlers installed. The distinctive idler design ensures proper belt carriage and stabilizes the belt line to enhance sealing. Its slide-in/slide-out frames enable service without raising the belt or removing adjacent idlers, and its slim profile requires only 8 inches of space for 6 inches of idlers.

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Two new belt support cradles and an impact cradle were added to each transfer point. Martin® Impact Cradles, which are installed beneath the loading zone, stabilize the belt line and absorb the force of falling material on a transfer point to prevent the escape of dust and fines. A top layer of low-friction, ultra-high molecular weight (UHMW) polymer and a lower layer of energy-absorbing styrene butadiene rubber (SBR) make up rugged impact bars.

In addition to the impact cradles, each conveyor received two Martin® Slider Cradles. To support the edges of the belt, eliminate sagging, increase sealing efficiency, and extend the life of the belt, the cradles were positioned beneath the skirtboard of the transfer point. The bars can be flipped over to provide a second wear surface when the top eventually wears out.

On each transfer point, new side/center supports and covers were attached to sections of 16-foot skirt board. To contain fugitive dust, Martin® ApronSealTM Skirting was installed at each transfer point. This is a dual design with a primary seal that is clamped to the steel skirt board and a secondary seal that is designed to catch any dust or fines that get under the primary seal.

A Martin® TrackerTM was installed on the return sides of the conveyor, approximately 10 feet in front of the tail pulley. By ensuring that the belts are continuously adjusted precisely, the Tracker helps to reduce edge damage, prevent spillage, and extend the life of the belt.

At long last, each belt got a Martin® QC1™ Cleaner HD and one Martin® SQC2S More clean. The QC1 has a tungsten carbide tip and a polyurethane blend that are designed to maintain consistent tension without frequently being adjusted.

Conveyor results The entire upgrade was finished in 11 days, and the crews worked 12 hours a day to take advantage of the planned shutdown. Denoski stated that the difference is obvious.

Denoski stated, "The production team responsible for that area has received nothing but positive feedback regarding the upgrades." Because we are not losing product to dust and spills, material can be sold rather than cleaned up from the floor. Now, the resources used for cleanup can be put toward more important business functions.

Denoski came to the conclusion, "Our experience with Martin Engineering has been very positive." The best solutions for bulk material handling issues and the company's knowledge of them are its greatest strengths. Additionally, the company's unconditional guarantee gives us assurance that it will stand behind its products.