CEE Oct-Dec 2012

of material movement and have been successfully employed by the Holtec in cement as well as other industries. New concepts in material handling The paper covers the following four concepts: In Motion Loading of clinker in Railway Rakes For the clinkerization units, having split located grinding units and transport connectivity through railways, clinker loading is usually done through overland hoppers, constructed on top of the railway tracks and clinker is being loaded through telescopic chutes. This paper suggest loading of rail rakes in motion (Rapid loading Rapid Loading System system). With Rapid loading system rake 0.6 to 0.7 km/hr below loading hopper that means a full rake of clinker (about 650 m in length) is likely to get loaded in about 1hr of time as compared to conventional system of rail loading, required 3 to 6 hrs. Lower investment cost, less number of operations and less drivers make thi s system more advantageous as compared to the conventional systems. For the hauling of railway rake at a constant speed of 0.6 to 0. 7 km/hr, creep drive need to be installed in the locomotive as a prerequisite of this system. Use of bottom discharge wagons for coal and clinker transport and its easy unloading Traditionally, cement industry has been using normal BOX/BOXN type of wagons for the transportation of coal and clinker. For the unloading of these wagons, wagon tipplers are installed, through which these wagons are unloaded. A full rake of 58 wagons need 3 - 4 hrs Track Hopper Unloading System of time (i.e. 15 -18 wagons unloading per hour) for unloading. Holtec designed a simple but effective system of lignite unloading, which is running successfully since last 10 years. One more system is under execution for other materials such as coal , copper concentrated and rock phosphate . If the industry insists for bottom discharge wagons from railways, similar systems could be used in the industry, for coal and clinker unloading. The system proposed is quite simple , effective, fast and economical more reliable and less prone to dust nuisance as compared to the conventional systems. Initially could be difficult for the industry to switch over to bottom discharge wagons, as railways have limited quantity of such wagons, but gradually they need to switch over. Use of wagon traverser Nowadays the trend is to go for large capacity clinkerization units, located close to the limestone deposit and construct split located grinding units 12