CORN STORAGE SILOS & ELEVATORS
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CORN STORAGE SILOS & ELEVATORS HO Scale Structure Kit 933-2975 Thanks for purchasing this Cornerstone Series ® kit. All parts are made of plastic, so use only compatible paints and glues. Please read these instructions and study the drawings before starting. Since the 1970s ethanol, or grain alco- hol, has been promoted as a clean- burning, renewable alternative to gaso- line. As the push toward reduced emis- sions, cleaner air and lower depend- ence on imported oil increases, ethanol has found favor as a gasoline additive. About 70% of the gasoline sold in the U.S. in 2007/08 contained some ethanol, mostly in a 10% blend. With over six million flexible fuel vehicles on the highways in 2007/08, an 85% ethanol-15% gasoline blend called E85 is becoming widely available at gas stations. Ethanol is big business—especially for railroads. Raw materials, or feedstocks, for ethanol production can come from many sources as diverse as sugar cane, municipal solid waste, wood, kudzu and various grains, but corn is most com- mon, with about 70% of new plants pro- posed in 2009 using corn or other mate- rials in combination with corn. With plenty of rail-served grain handling and petroleum infrastructure already in place across the continent, railroads are perfectly poised to handle inbound and outbound traffic. The process begins with unloading corn in a shed that accommodates hoppers and trucks. Railroads haul it in from rural elevators in covered hoppers. Carload lots and entire unit trains move to ethanol plants—how much each receives is dependent on plant size and location. For example, a 100 million gallon per year plant (typical sizes range from 50 to 110 million gallons) that receives 60% of its corn by rail gets about 17 cars per day, the rest arrives by truck from local producers. Inside the unloading shed corn is dumped into below-ground bins and augers and an elevator conveyor leg move it to storage silos. In many cases, a 10-day supply of corn is kept at the plant. A second, smaller grain conveyor moves corn into the processing center where it’s ground and mixed with water to make mash. Enzymes are added to convert the starch to simple sugars such as dextrose. Ammonia is added to con- trol pH and to feed the yeast in fermen- tation. The mash is cooked to reduce bacteria levels. After cooling, the mash is piped to fermentation tanks where yeast is added. In 40 to 50 hours, the yeast has convert- ed sugars to ethanol and carbon dioxide. The mixture of alcohol and solids, now called beer (but not the kind you would drink!) is piped to distillation towers where ethanol is concentrated to 190 proof (95 percent by volume) and solids, called stillage, are removed for process- ing. Further dehydration in molecular sieve tanks yields 200 proof ethanol. Ethanol is piped to storage tanks. On the way, 5% gasoline is added to make it unfit for human consumption (drinkable ethanol is subject to beverage taxes). At this point, it’s ready to ship in tank cars. Stillage, the left over corn solids minus the starch, is processed into distillers dried grains with solubles (DDGS), a protein-rich byproduct used in animal feed. In the energy center building, DDGS is dried and pelletized. Augers and conveyors move the pellets into the DDGS storage shed, adjacent to the loading/unloading shed, prior to loading in covered hoppers. A 100 million gallon per year plant ships 10 cars of ethanol and nine hoppers of DDGS pellets daily. On Your Layout The Corn Storage Silos & Elevators kit is an essential part of the complex—it’s where incoming corn is stored for even- tual conversion to ethanol and DDGS. The kit includes a concrete structure encompassing two cylindrical silos, very typical of 1980s and later installations. Also included is a tall grain conveyor leg identical to those used by modern trackside grain handling facilities. This conveyor moves grain from the corn unloading shed to the top of the silos where piping routes it into the desired silo. A shorter grain conveyor routes grain from an underground base auger into the processing center. The silos and elevators are usually near the corn unloading shed. This structure kit is the second in the North American Ethanol series. The rest of the kits in the series make it easy to simulate an entire ethanol plant. Ethanol plants rely heavily on rail serv- ice. Inbound traffic includes covered hoppers of corn and tank cars of gaso- line. Outbound loads include ethanol tank cars and covered hoppers of DDGS pellets. A steady flow of empty cars doubles the volume of cars, so plants often have their own switcher. The PROTO 2000 ® EMD SW9/1200 is ideal for your ethanol facility. Cars serving the facility are easily mod- eled with Platinum Line ™ PS2-CD 4427 High-Side Covered Hoppers, Gold Line ™ Evans 4780 Cubic Foot Covered Hoppers, Trinity 6351 4-Bay Covered Hoppers and Trinity 30,145-Gallon Tank Cars. The Corn Storage Silos & Elevators kit also makes a great stand alone trackside grain elevator for modern grain handling scenes with the addition of your own hopper car loading chute attached to one of the conveyor legs (chute available separately, see prototype photos for modeling ideas). It’s also a realistic addition to a milling or malting plant, or additional storage for a waterfront grain terminal. ©2009 Wm. K. Walthers, Inc. Milwaukee WI, 53218
Transcript of CORN STORAGE SILOS & ELEVATORS
CORN STORAGE SILOS & ELEVATORS
HO ScaleStructure Kit
933-2975
Thanks for purchasing this CornerstoneSeries® kit. All parts are made of plastic,so use only compatible paints and glues.Please read these instructions and studythe drawings before starting.
Since the 1970s ethanol, or grain alco-hol, has been promoted as a clean-burning, renewable alternative to gaso-line. As the push toward reduced emis-sions, cleaner air and lower depend-ence on imported oil increases, ethanolhas found favor as a gasoline additive.About 70% of the gasoline sold in theU.S. in 2007/08 contained someethanol, mostly in a 10% blend. Withover six million flexible fuel vehicleson the highways in 2007/08, an 85%ethanol-15% gasoline blend calledE85 is becoming widely available atgas stations.
Ethanol is big business—especially forrailroads. Raw materials, or feedstocks,for ethanol production can come frommany sources as diverse as sugar cane,municipal solid waste, wood, kudzu andvarious grains, but corn is most com-mon, with about 70% of new plants pro-posed in 2009 using corn or other mate-rials in combination with corn. Withplenty of rail-served grain handling andpetroleum infrastructure already inplace across the continent, railroads areperfectly poised to handle inbound andoutbound traffic.
The process begins with unloading cornin a shed that accommodates hoppersand trucks. Railroads haul it in fromrural elevators in covered hoppers.Carload lots and entire unit trains moveto ethanol plants—how much eachreceives is dependent on plant size andlocation. For example, a 100 milliongallon per year plant (typical sizes rangefrom 50 to 110 million gallons) thatreceives 60% of its corn by rail getsabout 17 cars per day, the rest arrives bytruck from local producers. Inside theunloading shed corn is dumped into
below-ground bins and augers and anelevator conveyor leg move it to storagesilos. In many cases, a 10-day supply ofcorn is kept at the plant.
A second, smaller grain conveyormoves corn into the processing centerwhere it’s ground and mixed with waterto make mash. Enzymes are added toconvert the starch to simple sugars suchas dextrose. Ammonia is added to con-trol pH and to feed the yeast in fermen-tation. The mash is cooked to reducebacteria levels. After cooling, the mashis piped to fermentation tanks whereyeast is added.
In 40 to 50 hours, the yeast has convert-ed sugars to ethanol and carbon dioxide.The mixture of alcohol and solids, nowcalled beer (but not the kind you woulddrink!) is piped to distillation towerswhere ethanol is concentrated to 190proof (95 percent by volume) and solids,called stillage, are removed for process-ing. Further dehydration in molecularsieve tanks yields 200 proof ethanol.
Ethanol is piped to storage tanks. On theway, 5% gasoline is added to make itunfit for human consumption (drinkableethanol is subject to beverage taxes). Atthis point, it’s ready to ship in tank cars.
Stillage, the left over corn solids minusthe starch, is processed into distillersdried grains with solubles (DDGS), aprotein-rich byproduct used in animalfeed. In the energy center building,DDGS is dried and pelletized. Augersand conveyors move the pellets into theDDGS storage shed, adjacent to theloading/unloading shed, prior to loadingin covered hoppers. A 100 million gallonper year plant ships 10 cars of ethanoland nine hoppers of DDGS pellets daily.
On Your Layout
The Corn Storage Silos & Elevators kitis an essential part of the complex—it’swhere incoming corn is stored for even-tual conversion to ethanol and DDGS.
The kit includes a concrete structureencompassing two cylindrical silos, verytypical of 1980s and later installations.Also included is a tall grain conveyorleg identical to those used by moderntrackside grain handling facilities. Thisconveyor moves grain from the cornunloading shed to the top of the siloswhere piping routes it into the desiredsilo. A shorter grain conveyor routesgrain from an underground base augerinto the processing center. The silos andelevators are usually near the cornunloading shed. This structure kit is thesecond in the North American Ethanolseries. The rest of the kits in the seriesmake it easy to simulate an entireethanol plant.
Ethanol plants rely heavily on rail serv-ice. Inbound traffic includes coveredhoppers of corn and tank cars of gaso-line. Outbound loads include ethanoltank cars and covered hoppers of DDGSpellets. A steady flow of empty carsdoubles the volume of cars, so plantsoften have their own switcher. ThePROTO 2000® EMD SW9/1200 is idealfor your ethanol facility.
Cars serving the facility are easily mod-eled with Platinum Line™ PS2-CD 4427High-Side Covered Hoppers, GoldLine™ Evans 4780 Cubic Foot CoveredHoppers, Trinity 6351 4-Bay CoveredHoppers and Trinity 30,145-GallonTank Cars.
The Corn Storage Silos & Elevators kitalso makes a great stand alone tracksidegrain elevator for modern grain handlingscenes with the addition of your ownhopper car loading chute attached to oneof the conveyor legs (chute availableseparately, see prototype photos formodeling ideas). It’s also a realisticaddition to a milling or malting plant, oradditional storage for a waterfront grainterminal.
©2009 Wm. K. Walthers, Inc. Milwaukee WI, 53218
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1. Glue two sets of nine silosections (2) together.
2. Glue the two assembled silosonto the base (1). 3. Then glue onthe top (5).
4. Glue the front (3) and rear (4)face in place.
5. Glue the pads (32) onto the top.
6. Glue the connector (21) to theend of the base pipe (33). Thenplace, do not glue, these into theholes in the pads.
7. Glue the railings (11, 12) intothe holes around the top.
SILOSParts found on the following sprues:7002936/A; 7002975/A; 7002975/B;7002975/C; 7003089/B; 7003124/B
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1. Glue the center housing (2) to the inside of the right outersupport (7). Then glue the vertical beams (3, 4, 5) to theinside of the outer supports (7, 11). Next glue on left outersupport (6) as well as the other supports (11) on that side.Note: Always put beams #3 at the top and #5 at the bottomwith #4 in the middle. Glue the right side outer supports inplace as illustrated..
2. Glue motor (10) to the motor plat-form (9) and the in turn glue this tothe top end of the rails as shown. Gluethe drive belt cover (8) to the motor and the side of the top.
3. Glue the top platform (12, 13, 14, 15,16) together and then onto the railsdirectly below the motor platform.Note: The railings go on the outsideedges of the platform base.
4. Glue the middle platform (15, 16, 17, 19, 20) together and then on top ofthe fourth rail down from the top platform. Note: The railings go on the out-side edges of the platform base.
5. Glue the bottom platform (15, 16, 18, 19, 20) together and then on top ofthe fourth rail from the bottom. Note: The railings go on the outside edges ofthe platform base.
6. Glue the ladders (21) and cages (22) together. Note: The cage supports on#21 match the cage rings on #22. Then glue them in place along the side ofthe leg with the tops of the ladders protruding through the openings in theplatforms. Note: Start with the top ladder, angle it down through the openingof the middle platform then position it vertically up through the top platformand glue in place. Use the same procedure for the middle ladder.
7. Glue the grain head (23, 24) together and then in place. 3
TALL ELEVATORParts from on the following sprues:7002936/A; 7002936/B
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1 Assemble the basic ground conveyor by glu-ing the top (28) to the bottom (27) and gluingon the ends (29). To this you can add a motorassembly (35, 36, 37), a bottom/top connectingpipe (30 or 31, 32) and a side bin dischargepipe (43, 44). Add to pad #32 your choice ofbase pipe (33, 34). You can set these up to fityour Ethanol complex.
2. Glue the dry bin discharge pipe (38, 39, 40,41, 42) together and use this for connecting adry bin (not included) to your ground conveyor.
1. Glue the conveyor truss top (7) and truss bottom(6) to the inside of the conveyor truss side (8). Thenglue on the other truss side (8). Glue both sectionstogether lengthwise.
2. Glue the ground conveyor (27, 28, 29) togetherand then glue this to the conveyor truss top. Note:You may configure this differently by using theadditional conveyors supplied and depending onwhere further structures will be placed.
3. Glue the bases (10) to the bottoms of the supporttrusses (9). Then glue these under the truss bottom.
4. Glue a pad (32) to the top of #28.
5. Depending on where you place this in relation tothe Short Elevator, use either base pipe (33 or 34)with a connector (21). Place, do not glue, into thehole in the pad.
CONVEYOR TRUSS
GROUND CONVEYOR
Parts are found on the following sprues:7002936/A; 7002936/B; 7002975/B;7002975/C; 7003124/B
Parts are found on the following sprues:7002936/A; 7002936/B
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There are two options for applying signage to your structure. The first is by waterslide decals. Thisworks well on smooth surfaces. Follow the instructions for “Decals” below. For the second option,useful on corrugated surfaces, follow the instructions for “Signs”.
DECALS
1. After cutting out the decal, dip in water for 10 seconds, remove and let stand for 1 minute. Slidedecal onto surface, position and then blot off any excess water.
2. Lightly brush Micro Sol® on top. This will soften the decal, allowing it to conform to irregularsurfaces. DO NOT TOUCH DECAL while wet!
3. When decal is thoroughly dry, check for any trapped air bubbles. Prick them with the point of asmall pin or hobby knife blade and apply more Micro Sol®.
SIGNS
1. Carefully cut out sign, trimming as close as possible to the graphic. You will be using the paperbacking as a sign board.
2. Apply white glue on the back of the sign and place in position on the structure.
SHORT ELEVATOR
1. Glue the sides (2, 3) together and to the base (1).
2. Glue on the platform (4). Then glue the railings (12,13, 14) in place.
3. Glue the top (5, 6) together along with the motor (11).
4. Glue the distribution head (7, 8, 9, 10) together andthen in position on the top.
5. Glue the completed top onto the platform.
6. Glue the cage ladder (17, 18) together and then to theside of the elevator, under the hole in the platform.
Parts are found on the following sprues:7003124/A; 7003124/B
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1. Glue the Tall Elevator to the Silo base.
2. From the assorted straight pipes with an angled top, cut two lengths ofapproximately 3-5/16”. The angled top goes into the hole on the bottomof the elevator’s grain head. The other end of the pipe fits into the con-nector on top of the base pipe. Once all pipes line up, glue in place.
3. The Short Elevator and Conveyor Truss can be placed anywherearound the silos, usually on the opposite side of the Tall Elevator. Cut alength of pipe to span the area between the elevator and conveyor(dependant on where you place each piece) and place one end of the pipeinto the head and the other into the connector. When satisfied with thepositioning, glue in place.
FINAL ASSEMBLY
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