Thin Shells – Geodesic Domes

A geodesic dome is a thin shelled arrangements made out of triangles connected together to form a true sphere. The triangles are architecturally firm and distribute the stress throughout the dome, allowing the structure to bear heavy loads for their size. Space frame is the three dimensional framework that makes the dome structure stable.

These Geodesic Domes are the strongest, lightest and cost-effective building since it can cover space without any interior supports that usually cover up space in an interior. Not only it is cost effective but it is also easy to construct.

Things to keep in mind while Planning the construction of Geodesic Dome:-

• Designing the dome structure is the first step to start with. The size and the amount of triangles and their calculations to form the dome structure are needed.
• Struts: these are the framework for the dome which are made up of rods. Usually geodesic domes comprise of struts of different sizes.
• There are various cladding options which can be used based on the intended use of the building.
• Finalizing the structure: several things should be kept in mind while putting all the pieces together such as the struts and their dimensions, their edges flattered so that they fall on the same plane when attached, and to make sure the flattened edges bend slightly (found by calculation).

These types of dome structures are famous for their vast usage in, because the materials required are all environment friendly and the structure itself is very safe and creates spacious interior.

About Hindustan Alcox

We at Hindustan Alcox limited, one of the modern dome structure manufacturers use the combination of its basic features and latest technology to make dome structure more appealing and highly versatile in installation as well as in maintenance.

Read More – Role of space frame in Conventional Center & Exhibition Hall

Structural Benefits of Geodesic Dome

Dome is a hemispherical structure evolved from the arch, usually forming a ceiling or roof. It is a closed structure; a sphere made up of a Network of circles lying on the surface of the sphere.

Geodesic domes are the segmented portion of geodesic spheres. They are composed of frame work of triangles in a polyhedron pattern and these structures are based upon octahedrons or tetrahedrons. Such bulk storage dome can be created using a limited number of simple elements and joints which efficiently resolve a dome’s internal force.

Benefits of Geodesic Dome:-

1. Stronger structure: These bulk storage domes are much stronger than any conventional buildings. The nature of the spherical design provides strength because all the points of the structure share the applied stress evenly as opposed to the right angles of typical box structures.
2. Energy efficient: These Dome structure has much more bulk storage than a box shape building because of the lack of corners, this leads to lighter buildings, thereby reducing the steel consumption in the building.
3. Eco-friendly: These bulk storage domes are extremely “Green” in terms of cost, building materials, and future maintenance. The environmental benefits of domes also play an important role, as its proven to have a lesser footprint and negative impact that that of conventional type structures.
4. Weather Resistant: Due to their high structural integrity, they perform extremely well in such natural disasters like earthquakes, floods and severe wind storms. They are mostly suitable for disaster prone climates.
5. Fireproof: After getting practical data of decades and performing the firelighter test, it is concluded that domes have excellent fire proofing capability than other similar structures.

About Hindustan Alcox

We, At Hindustan Alcox limited, one of the modern dome manufacturers use the combination of its basic features and latest technology to make dome structure more appealing and highly versatile in installation as well as in maintenance.

Read Also – Advantages of Space Frame

Petcoke Storage: Best Practices to Control Petcoke Emissions & Spontaneous Combustion

Petcoke storage:

Similar to coal, Petcoke (a by-product of the oil refining process) is widely used in thermal power plants for power generation due to its higher carbon emissions than already carbon-intensive coal. Petcoke is also used as a complementary fuel in cement industries.

Many concerns about possible public health consequences by petcoke emission have been raised due to the establishment of large outdoor petcoke storage. Moreover during its bulk storage, many problems like spontaneous combustion, fugitive emission etc can occur at any stage of transport, storage & handling which is also a reason for the inefficient power generation at captive thermal power plant.

 

Best Practices to Control Petcoke Emissions & Spontaneous combustion:

Petcoke Storage Shed

To control Petcoke emission, a variety of procedures & techniques should be followed based on knowledge of specific facility and product conditions. Followings are the best practices that should be adopted to control petcoke emission:-

• Stockpile Handling & Maintenance: Following the “first in, first out” rule in petcoke stocking and stacking under petcoke dome or petcoke storage shed reduces the chances for hot spots in stockpiles by dissuading heat build up for portions of petcoke stockpiles so that the handling procedure may remain undisturbed for a long term. Moreover, proper maintenance of petcoke stockpiles like ‘piles compaction’, ‘piles stacking with minimum drop height’ etc will help to reduce petcoke fugitive emission.

 

• Wetting with water: The systematic application of water to petcoke helps to control fugitive dust emissions and maintain product moisture content. This periodic reapplication of water is generally needed to overcome the hydrophobic nature of petroleum coke.

 

• Maintenance of Temperature: It is better to maintain the ambient temperature near a specific threshold during plant operation not only for avoiding the problems of spontaneous combustion & fugitive emission but also for obtaining efficient power output.

 

• Electronic controls & self-checking systems: Automatic calibration with electronic equipments as well as manual calibration and checking should also be performed at regular basis to avoid Spontaneous Combustion in petcoke storage plants.

 

 

 –  Hindustan Alcox Limited, New Delhi

(Petcoke storage shed Manufacturers)

Sulphur Storage: Factors affecting losses during its storage & handling

Sulphur Storage:

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.

– Hindustan Alcox Limited

(Sulphur storage Sheds Manufacturer in India)

Flue gas de-sulphurized (FGD) gypsum – An Important By-product of cement industry

Role of gypsum in cement Industry:

Limestone, gypsum, slag & other additives are the most common raw materials used in cement production. Gypsum is a soft, transparent or translucent mineral composed of crystallised calcium sulphate (CaSO4), found naturally in sedimentary deposits. Gypsum is added to cement to regulate the extreme setting reaction which occurs in the presence of water. Besides influencing the setting time, gypsum also has an influence on other properties of cement such as strength development, volume stability etc.  

FGD storage sheds

Flue gas de-sulphurized (FGD) gypsum (An Important By-product of cement industry):

FGD gypsum results from the emissions cleaning process known as flue gas desulphurisation (FGD), at coal fired electricity generating stations. The cleaning of flue gases is carried out when finely ground limestone (or lime) reacts with sulphur dioxide emissions to produce a pure gypsum. In some cement industries, a multistep manufacturing process with electric utilities are carried out to meet precise product specifications for FGD gypsum. Followings are the importance of FGD gypsum, as by-product of cement industry:

• Contribution as an end product
• Environment Friendly
• Highly Economic
• Higher Purity Than Natural resources

 

Hindustan Alcox Limited take pride to be one of the top gypsum storage shed manufacturer  in India by offering world-class sheds in form of barrel vault structural sheds or gypsum domes. The Company has wide experience of about 30 years in building FGD sheds  with long span steel structure having span of up to 150 m & height of up to 40 m.

 

– Hindustan Alcox Limited, New delhi

(FGD Shed – Specialist)

 

 

Cement Industry Impacts & Management for Limestone and Clinker Storage

Limestone storage:

In cement plant, one of the major component for clinker or cement formation is limestone. Dispatch, storage and processing of limestone can be divided into five main operations: i.e. crushing/grinding, sizing, benefication, storage/loading-out & transport. For cement production, limestone is first reduced in size by processing through a series of crushers and grinders and then limestone storage is done under covered sheds to get rid of cement industry impacts such as environmental Issues, health & safety issues and many more.

Clinker Storage:

Clinker storage

After limestone is reduced in size by processing, the stored limestone is then mixed with some mineral aggregates (siliceous, aluminous, and ferrous materials) and water in high temperature kiln to form clinker. After cooling, clinker storage is done under covered sheds or clinker dome. The nodules of cement clinker are then ground to the consistency of face powder to produce powdered cement.

Cement Industry Impacts & Management for Limestone & Clinker Storage:

The cement maufacturing industry exhibits various issues associated with cement and lime manufacturing, which occur during the operational phase. Emissions associated with intermediate and final materials handling and storage are responsible for the followings industrial Impacts :

• Environmental issues

  • Air Emissions

  • Energy consumption and fuels

  • Wastewater

  • Solid waste generation

  • Noise

• Labor Health & Safety

  • Safety from Dust

  • Safety from Heat

  • Safety from Noise & vibrations

  • Physical Hazards

  • Safety from Radiation

• Environmetal Health & Safety

Hindustan Alcox Limited specializes in providing storage solution for limestone with long span steel structure to get rid of above-mentioned cement industry impacts. Limestone storage shed, engineered by the Hindustan Alcox Limited is the best available choice to cover limestone stockpiles for the most challenging environment. Clinker storage sheds or Limestone storage sheds are often built over operating stockpiles so that construction may proceed efficiently without interrupting operational work. 

• Hindustan Alcox Limited, New Delhi

  (Limestone Storage Shed Specialist)

Coal Storage Domes integrated with Coal Gasification: An Ideal Storage Solution

Coal Storage:

Spontaneous Combustion

For a fruitful outcome of thermal Power Plants, the business of industrial coal storage for large quantities is on top priority for maintaining the product Integrity. Open stockpiles leave materials subject to degradation during storage. In addition, there are environmental concerns with controlling dust and runoff from these coal stockpiles.

Coal Storage Domes integrated with Coal Gasification:

Coal storage

Conversion of coal by the chemical processes to produce a mixture of combustible gas or fuel gas or syngas is termed coal gasification Coal Gasifiers generally entails the controlled oxidation of the coal to convert it into desired gaseous products. The emphasis of coal gasification is to meet stringent emission control requirements.

Bulk storage dome structures are highly durable and strong. If we talk about strength and average building life of dome structures, then their life is longer and strength is more than any other type of stacker reclaimer sheds in Space frame industry. Coal storage domes with coal gasification has its own advantages. These include:

• Simple foundation requirements.

• Rapid construction regardless of weather.

• Condensation is virtually eliminated.

• Better environmental and fugitive dust control.

• Environment Friendly.

Dome Structural system provides a unique solution to the bulk storage industry. Remained committed towards sustainability and improving the local economies, the coal dome manufactured by Hindustan Alcox Limited are strong, durable, environmentally sound and adaptable. Over Last 20 Years, Our capabilities as a “prime industrial shed manufacturer” include building the Bulk storage dome shell for providing turnkey solutions all over the world.

• Hindustan Alcox Limited, New Delhi

  (Coal Storage Sheds Manufacturer in India)

Best preventive measures for sustaining energy efficiency for sulphur storage

Additive storage:

Additive 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.

• Hindustan Alcox Limited, New Delhi

  (Additive storage shed manufacturer in India)

Coal Storage: Performance Requirements for Maximum efficiency

Coal Storage:

Spontaneous Combustion in Coal storage Plants

Coal is a fossil fuel just like oil and natural gas. In thermal power plants, coal storage or petcoke storage (as the most exploited solid fuel) at large scale is preferred for the production of electric energy. A good preparation of coal before its combustion increases the homogeneity and efficiency of the fuel, reduces transportation costs and its displacement inside the plant produces less dust and reduces the emission of sulphur oxides. Besides, Preventive measures should be taken at every stage during the transport and bulk storage, in order to reduce any environmental impact, so that it became easier to maximize plant efficiency without any interference of any outside or environmental effects.

 

Performance Requirements for Maximum efficiency:

The large investment in a thermal power plant should be protected in best pos­sible way by maintaining the quality of resources (like coal, petcoke, lignite etc) and by uplifting the performance of their handling system. The coal handling system and equipment should perform satisfactorily to meet the guaranteed performance for maximum efficiency as stated here under:

1. Efficient operation in thermal power plants means the careful use of fuels and other consumables resources includ­ing in-house consumption of electricity. High availability requires strong focus on maintenance, which in turns contribute as one of the factors in producing maximum efficiency.

 

2. Stacker or reclaimer should be stable under a specified design condition and meet all the specified requirements. During unfavorable environmental conditions, the stacker or reclaimer should reclaim the coal in a way to avoid generation of well compacted, damp and sticky coal.

 

3. Sulphur content in fuel always had an adverse effect on overall plant efficiency. ‘Corrosive acids formation’ and ‘heat loss in boiler’ can be evaded by properly supervising and removing the sulphur content in coal.

 

4. Condition based maintenance uses intelligent measurements and assessments. These can include oil quality, differential pressure measure­ments, vibration readings and many more. By such applications, maintenance and renewal of plant components can be done exactly when needed.

 

5. Fuel quality of coal, which is generally quoted in terms of its gross calorific value (GCV) along with its moisture and ash content impacts on whole plant operational efficiency. Assessing fuel quality and choosing fuel of maximum gross calorific value and less moisture & ash content improves combustion and power generation as well.

 

6. Variation in the ambient temperature tends to affect plant performance and load capability of gas turbines along with the performance of cooling system. Hence, it is better to maintain the ambient temperature near a specific threshold during plant operation for maximum power output.

 

Using long-time experience of 30 years, It has been challenge for Hindustan Alcox Limited to identify and eliminate unnecessary energy losses from the processes by providing the best choice for covering coal stockpiles under Coal storage shed. Alternatively, Coal Storage and handling can be done under dome structure sheds (like Coal dome, petcoke dome).

 

– Hindustan Alcox Limited, New Delhi

(Coal storage shed manufacturer)

Role of Gypsum storage in FGD/Flue gas desulphurization unit

Gypsum storage:

gypsum storage

Finely grinded form of calcium sulphate / CuSo₄.2H₂O material industrially used for enhancing adhesive strength of the cement, called as gypsum. Gypsum Storage at large scale is needed since it is one of the prime resources in the cement industry. In purpose to improve cement’s inherit qualities, performance and efficiency, a composite gypsum storage solution needs to be followed systematically:

Gypsum Handling System:

Gypsum handling includes bunkering of gypsum, along with its stacking & reclaiming in a very cautious way. Large Stackers are used to form two different patterns- ‘cone’ , ‘chevron’ either on one or both sides of stacker. Stacking & reclaiming of coal is not only limited to avoid risks (such as spontaneous combustion, self oxidation, caking problem) to coal stockpiles but it must be carried out in such a way to keep coal effective. Gypsum is usually stored under well-constructed sheds ensuring its storage without deterioration and without contact to ground and structural members, without exposure to moisture and heat, and away from direct sun.

For environmental friendly gypsum storage and production of an best outcome in cement industry, today almost all out-performing cement plants use to store gypsum stockpiles under a strong, durable, eco-friendly and solution-rich gypsum storage shed and gypsum dome.

 

Role of gypsum storage system in FGD/ Flue gas desulphurization unit:

The resources like coal, petcoke, limestone contain a significant amount of sulphur into them. In many large scale power plants and cement plant (where the resource is Coal, petcoke, limestone etc), the problems arises from boiler or furnace where large volumes of So₂ accumulation not only deteriorates air quality of environment but also highly corrosive for handling equipments like stacks, fans etc.

In order to extract So₂ from flue gas, the mechanism of extraction employed is known as FGD or Flue Gas Desulphurization. In Flue Gas Desulphurization, the chemical Techniques are used to exclude sulphur di-oxide (So₂) in exhausted flue gasses from the Furnace/boiler. Some of the Chemical techniques used for FGD are ‘Wet Scrubing’, ‘Dry Scrubing’, ‘SNOX FGD’ etc.

The output from flue gas desulphurization is synthetic gypsum, which is carried out under FGD shed. For cement manufacturing, this FGD storage product or synthetic gypsum is supplied in crushed form for further fine grinding with cement clinker and has many other commercial applications in cement industry, bricks manufacturing etc.

 

– Hindustan Alcox Limited, New Delhi

(Gypsum storage shed manufacturer In India)