Large quantities of sulphur are transported, stored, handled & comsumed as an additive in cement industry. Various storage methods are required to ensure that the sulphur is not contaminated & it doesn’t damage equipment from corrosion, fires, etc. The stored sulphur usually exist in larger pieces & posses many sharp edges due to irregularity in shapes which can be easily broken into its smaller particles.
Factors affecting losses of sulphur during its storage & handling:
Sulphur storage sheds
Being a brittle material, sulphur is easily degraded during its handling procedures. Minimum Losses will occur during the loading/unloading, transportation of sulphur due to the creation of airborne dust. The losses that occurs during its handling depends upon the following factors:
Form of sulphur being handled
Ambient Environmental conditions (i.e. wind speed and direction)
Handling procedures/methods
Exposure to air, sunlight and rain
Indoor bulk storage of sulphur is recommeded in order to minimize losses and contamination of sulphur. One of the premier and well-versed entity as sulphur storage shed manufacturer in india, Hindustan Alcox Limited has a vast experience of 30 years in creating sulphur dome & suphur storage shed. Providing storage & handling of sulphur storage, these world-class structures minimizes the issues to be faced in storage & handling of its bulk storage.
The prime use of additive is to enhance the properties of mortar that has taken place for many centuries. In big cement plants, Additive storage(like Sulphur, Phosphorus etc) in bulk is carried out and added to subject material to improve its inherit properties, performance, efficiency and reduce cost.
Sulphur Storage:
For Industrial Purpose, Large quantities of sulphur are stored, transported, handled, melted and comsumed annually. Sulphur storage can be done in many forms which vary in their friability and mechanical strength. If required, the Sulphur is then crushed from larger pieces, producing smaller particles and dust.
Best preventive measures for sustainance of energy efficiency for sulphur storage:
Energy Efficiency plays a significant role in meeting the challenges by improving the operating capabilities and also augment the performance of existing transmission and distribution materials. Preventive measures which can be realised at best for sustaining overall energy efficiency are as follows:
Implementation of an energy efficiency management system
Benchmarking
Energy efficient design (EED)
Process integration
Expertise and know-how gains on energy efficiency
Effective control, maintenance and monitoring of installations
Sulphur storage shed, engineered by Hindustan Alcox Limited is a practically feasible and turnkey solution to cover stockpile for the most challenging environment. In addition to barrel vault structure, Sulphur Dome is also an appropriate choice for storing additives and covers large span to facilitate the storage of various other additives under same shed. Hindustan Alcox Limited has expertise in customizing the Sulphur Stockpile Shed after practically emphasizing the durability, strength and technical feasibility of structure with optimum space utilization.
A finely grounded inorganic material that may be added to mortar in order to improve or achieve special properties, are Additives. The use of additives to enhance the properties of mortar or renders has taken place for many centuries. In big cement plants,Additive storage in bulk is carried out and added to subject material to improve its inherit properties, performance, efficiency and reduce cost.
Additive storage
The potential hazards due to additive storage concerning efficiency and production in the cement plant, varies according to the nature and the concentration of the different chemical components present, are as follows:
Moisture problem due to high reactive tendency
Particle Segregation Problem
Caking Problem by virtue of crystallization, adsorption
Chemical oxidation under high temperature
Flow problem in handling equipments
Preventive Measures to avoid on-site hazards
In order to avoid on-site hazards concerning efficiency and production in the cement plant, the recommended preventive measures are as follows:
‘Using moisture barrier process’, ’open space & air circulation’, ‘water leak elimination’ are some of the techniques that can be used in purpose to prevent additive storage not only from moisture problem and particle segregation problem but also from flow problem in handling equipments.
Caking problem is complete or partial solidification of additives by virtue of crystallization, adsorption after a long storage time. Additive Storagestockpiles should be monitored at regular intervals to prevent this caking problem.
Keeping the additive stockpile under extremely dry and cool additive storage sheds not only retards the chemical oxidation reaction but also maintain their resistive nature against oxidizing components for the long duration.
Additive storage shed, engineered by Hindustan Alcox Limited is advisable to cover stockpile for the most challenging environment. In addition to barrel vault structure, Additive Dome is also an appropriate choice for storing additives and covers large span to facilitate the storage of various additives under same shed. Hindustan Alcox Limited customizes additive dome after practically emphasizing the durability, strength and technical feasibility of structure with optimum space utilization.
Dome structure is a hemi-spherical hollow structure, used as roofing/ ceiling. Earlier Domes were only used in constructing Architectural buildings, but with the passage of time their importance to endure under adverse climatic conditions is understood and now domes can be seen in almost every sphere of construction industry. In other words, a semi-spherical structure with the curvature on top, when usually created to cover a sufficient room for bulk storage like cement, limestone, coal, lignite, gypsum, additives and many more. Depending upon the material used for storage, followings are the storage domes with their usage in industry:
a) Slag Dome:
Slag is metal-separated stony waste material in form of their metal oxides mixed with silicon di-oxides. Industrially, its storage in Slag dome is generally carried for Metal ore smelting process to serve some useful purpose like ‘temperature control in Smelting’, ‘preventing re-oxidation of molten metal’, ‘removing waste from smelting process’.
Usages:
Slag dome is useful in sustenance of its compaction characteristics of slag.
Slag dome is also useful in keeping low risk of breakability and maintenance of maximum strength.
b) Additive Dome:
Additives are organic material added to subject material in purpose to improve its inherit properties, performance, efficiency and reduce cost. Industrially, Additive storage covers a wide range of additives like antifoams, organic additives and other performance enhancement additives. Some well-known examples of additives are ‘fly ash’, ‘GGBFS’, and ‘silica fume’.
Usages:
Additive dome covers large span to facilitate the storage of various additives under same shed.
Storing Additives under domes facilitates maximum utilization of space in plant which may be used for other industrial purpose too.
Ventilation facility and prevention from adverse conditions of environment under additive dome will eliminate the problem of oxidation, which causes clinical effects in labor.
c) Gypsum Dome:
Gypsum storage
Gypsum is fine-grained calcium sulphate (CuSo4) material industrially used as fertilizer/enhancer in subject material to improve its inherit qualities, performance, efficiency and reduce cost.
Usages:
Gypsum storage is very useful in controlling fugitive emission of gypsum.
Storing Gypsum under domes facilitates maximum utilization of space in plant.
Gypsum dome also helpful in prevention from vulnerability caused by adverse environmental conditions and rainfall.
d) Clinker Dome:
At sintering stage in cement manufacturing process, a nodular material is formed known as Clinker. In the Cement plant, Clinker is prepared by fusing various clays and limestone with additives by melting them below to the point of liquidation. ‘Silica fume cement clinker’, ’pozzolana cement clinker’, ‘ground granulated blast furnace slag cement clinker’ are most commonly formed Clinkers.
Usages:
Clinker dome has a benefit of facilitating no spillage and zero dust pollution. This will not only prevent wastage of resources but also create health friendly environment for labor.
Clinker storage under dome also help in prevention from heat which further facilitates setting up hot clinker to its favorable temperature before being converted into its grinded form, known as cement.
Clinker storage protects clinker from being affected by Rainfall or heavy thunderstorms, which can harm the quality of clinker.
e) Cement Dome:
Bulk Storage Dome
The grinded form of clinker is cement. Cement is used as binding material that combines with water and other additives and sets to bind two other materials together. That is why it also called as Hydraulic binder. White cement, pozzolana cement, acid resistant cement, blast furnace cement, sulphate resistant cement, rapid hardening cement, quick-setting cement, high alumina cement, colored cement are some common types of cements in construction industry.
Usages:
Cement dome are highly non-vulnerable to maintain moisture and water resistance in heavy rainfall areas.
Maintenance of temperature and adequate ventilation system is recommended for large scale storage, which can be fulfilled under cement dome.
Cement storageare useful in providing maximum utilization of space in plant, which fulfills need of efficient loading and unloading of cement in order to feed power stations continuously.
f) Limestone dome:
Limestone is composition of calcium carbonate, CaCo3 with other minerals, generally found in organic sedimentary rocks formed from accumulation of shell, forms, coral etc. In clinker/cement formation, limestone is used as one of the major component. Moreover, In precious Architectural works, limestone is also used neutralize the effect of acidity caused by acid rain.
Usages:
Limestone storage costs less as compared to reinforced concrete silo for storage. Therefore limestone dome gives you economical storage solution.
Limestone dome provide best protection against moisture and rainy weather, as limestone is highly susceptible to moisture.
f) Coal/Lignite dome:
Extracted from the ground by coal mining, coal is the biggest source of energy for the worldwide electricity generation. In simple terms, there exist four types of coal – peat, lignite (brown coal), bituminous, and anthracite(highest quality coal). Coal/Lignite storage is done in large quantities and requires stacking in open areas. ‘Production in mild climatic condition and market it in winter season’, ‘Feed the thermal power stations continuously’ are some of the key reasons for coal storage, which we understand the most.
Usages:
Coal/lignite dome are made in such way to prevail cross ventilation at very corner inside it which can be done to prevent heat accumulation.
Coal domeprovide best protection against moisture and rainy weather since coal is vulnerable to moisture.
The storage of (Cement, Clinker, Slag, Limestone, Additives, Gypsum and other industrial materials) in large quantities is reffered as bulk storage. Handling of bulk storage is process of movement, storage, control and protection of industrial material throughout the process of manufacturing, distribution, consumption and disposal. Followings are the major issues to be faced in storage, handling and transport of bulk solids powders and other dry material:
Additive storage
Emission from storage:: The storage, and transport of Industrial Material like limestone storage, gypsum storage, cement storage for long duration produces emissions of volatile organic compounds (VOCs), nitrogen oxides (NO), carbon monoxide (CO) and other toxic air pollutants. These toxic emission are not only threat to lives of labour, but also harmful for our ecosystem.
Moisture problem: Increase in moisture content in bulk storage not only affects the intrinsic properties of material but also gives rise to its reactive tendency with other chemicals.
Flow problem: The most common problem in operating bulk storage is flow blockage. It largely depends upon bulk density, particle size and moisture content in the material.
Particle Segregation Problem: Existence of moisture content in material for a long time causeserratic feed & variation in particle size (segregation) which leads to increased energy consumption and reduced mill performance.
Caking Problem : Fully or partial solidification of bulk solids like (cement, limestone) by virtue of adsorption, crystallisation, adsorption after a long storage time. Heat and exposure to dry air will exacerbate caking. Persistence of such problem increases the manpower and time needed for disaggregation of unwanted aggregated material.
Chemical oxidation : Some of the industrial material are oxidative in nature and their chemical oxidation rises with the rise in temperature, which causes loss in the intrinsic properties of material.
Storage is meant to be of two types: Low-capacity bin storages and High-capacity bulk storage. Unlike bin storages, Bulk storage is storage of (Cement, Clinker, Slag, Limestone, Additives, Gypsum and other industrial materials) in large quantities. Followings are the various types of bulk storage depending on the material to be stored for industrial purpose:
a) Slag Storage:
Slag is metal-separated stony waste material in form of their metal oxides mixed with silicon di-oxides. Industrially, Slag storage is generally done for Metal ore smelting process for serving various useful purpose such as ‘temperature control in Smelting’, ‘removing waste from smelting process’, ‘preventing re-oxidation of molten metal’.
Few facts:
Each year, more than 400 million tonnes of iron and steel slag is produced.
In some countries, up to 80% of the cement contains granulated slag, as it helps to bring down the cost of cement.
According to the Slag Cement Association, 59% of the embodied CO2 emissions can be saved by replacing Portland cement with slag cement in concrete.
Advantages:
In most Countries, Slag Storage is used as energy saving material. Therefore, It mainly helps in reducing heating and cooling cost in industries.
Slag storage is helpful in improving compaction characteristics of cement placement.
Slag Storage under sheds is also helpful in keeping low risk of breakability and maintenance of maximum strength.
Additive storage
b) Additive Storage:
Additives are the organic material added to subject material in order to improve its inherit qualities, performance, efficiency and reduce cost. Industrially, Additive storage covers a wide range of antifoams, organic additives and other performance enhancement additives. Some well-known examples of additives are ‘fly ash’, ‘GGBFS’, and ‘silica fume’.
Few facts:
In the United States, 95% of the masonry cement is made by adding additives to subject material like clinker , cement etc
In some countries, up to 80% of the cement contains granulated slag, as it helps to bring down the cost of cement.
Advantages:
Achieve high sustainability of plant by virtue of ‘less electrical consumptions’ and ‘natural resources preservation’.
Storing Additives like fly ash under shed do not require grinding and mixing, thereby nullify grinding cost to plant.
Some Additives like Sulphites are not only highly oxidant in nature, but also causes clinical effects in sensitive individuals. Cross ventilation quality and prevention from adverse conditions of environment across the Additive storage sheds will eliminate such difficulties.
c) Gypsum Storage:
One of the additives, called Gypsum is fine grained calcium sulphate material industrially used as fertilizer/enhancer in subject material to improve its inherit qualities, performance, efficiency and reduce cost. ‘Calcium sulphate di-hydrate’, ‘alabaster’, ‘plaster of paris’, selenite, rock gypsum, and gypsite are some well known gypsum examples used for gypsum storage.
Few facts:
Being the main ingredient in plaster of Paris (PoP), it is useful in making casts and sculptures.
90% of Gypsum is very soft that it could be scratch with our fingernail.
Most of the Gypsum often found in the mines of Australia, Mexico, US. Out of these three countries, largest ever gypsum crystals were found in Mexico, weighing 55 ton.
Advantages:
Gypsum storage sheds is very effective for prevention and control of fugitive emission.
Less operation and maintenance cost is required.
Prevention from vulnerability caused by adverse environmental conditions.
d) Clinker Storage:
Clinker is nodular material formed at sintering stage in cement manufacturing process. In the Cement plant, Clinker is prepared by fusing various clays and limestone with additives by melting them below to the point of liquidation. Most commonly formed Clinkers are ‘silica fume cement clinker’, ’pozzolana cement clinker’, ‘ground granulated blast furnace slag cement clinker’.
Advantages:
Clinker storage has an advantage of no spillage of clinker and no dust pollution. This will not only prevent wastage of resources but also create heath friendly environment.
Clinker storage also help in setting up hot clinker to its favorable temperature before being converted into its grinded form, called as cement.
Clinker has quality of moisture proof. The only thing can harm clinker is Rainfall or heavy thunder-storms, which can be easily prevented by clinker storage sheds.
e) Cement Storage:
Cement is grinded form of clinker. In construction, Cement is used as binder material that combines with water and other ingredients and sets to bind two other materials together. That is why it also called as Hydraulic binder. Various types of cements are pozzolana cement, blast furnace cement, rapid hardening cement, quick-setting cement, acid resistant cement, sulphate resistant cement, high alumina cement, white cement, colored cement.
Advantages:
Due to its high water resistant nature of cement, cement storage under sheds are highly non-vulnerable to maintain moisture and water resistance in heavy rainfall areas.
Large scale Cement storage are recommended to maintain temperature as well as ventilation system, which can be fulfilled under cement storage sheds
To feed power stations continuously, we need efficient loading and unloading of cement, which can be done though Stacker/reclaimer under cement storage sheds.
f) Limestone Storage:
Limestone (a composition of calcium carbonate, CaCo3 with other minerals) generally found in most organic sedimentary rocks formed from accumulation of coral, shell, forams etc. In construction Industry, limestone is used as one of the major components in clinker/cement formation. Moreover, In precious Architectural works, limestone is also used neutralize the effect of acidity caused by acid rain .
Advantages:
Limestone storage under steel sheds will cost about 40% less as compared to reinforced concrete silos. Therefore helps in overall cost cutting.
Steel used in limestone storage sheds is highly corrosion proof as well as water proof. Therefore operation process will be more reliable, long lasting and anti-corrosion.
Limestone storage under storage shed also provide best protection against adverse weather conditions.
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