SHAFTLESS SCREW CONVEYOR (PALMEX 2011) - edited

SHAFTLESS SCREW CONVEYOR

P A L M E X 2 0 1 1

PRODUCT INTRODUCTION

*A typical Horizontal Type Shaftless Screw Conveyor

Introduction

The Shaftless Spiral is made from high tensile steel ST52.3 or equivalent

Design to be rigid under all load conditions

Specialized liner material provides optimum abrasion resistance

There are designs available specifically for vertical, inclined and horizontal installation

Design for vertical installation

Design for horizontal installation

Application

An efficient transportation system for :

Sterilized fruitlets,

Palm nuts, Palm kernel and shell,

Mesocarp fibre for boiler fuel,

Empty bunch fibre for composting plant

Sludge for composting plant (solid content ≥ 20%)

No fouling from hanger bearing

No chains/buckets to worry about

No clogging possible

Less chance of breaking down

In-line discharge possible

Longer service lifetime

Simple design

Higher filling capacity at lower rpm

Can handle large lumps & stringy material

Does not require frequent major maintenance

No carry-over at dischargepoint

Efficient operation

Options for installation orientation

Enclosed system means quieter operations & no leakage

Free up valuable space for future upgrades or for aesthetics purposes

Smaller footprint

DESIGN FEATURE

*A Blueprint of The Vertical Shaftless Screw Conveyor Drive System Assembly

SPIRALHelical coils, cold formed from special high tensile alloy steel or stainless steel bars.

SPIRAL INSERTSSmaller helical coils, butt or lap welded to the main spirals to increase axial strength and capacity. Reduce fall back during operation. Thickness & widths are selected to suit the application.

Spiral inserts

Spiral

TROUGHConveyor housing manufactured using SS 304 of 2.5 & 3.0 mm thick and if required SS 316 is available as an option.

UHMW POLYETHYLENE PLASTIC / HARDOX 400 LINERUltra High Molecular Weight (UHMW) polyethylene plastic liner is placed inside the trough along the spiral to absorb due to it’s low friction coefficient high resistance to abrasion. HARDOX 400 is utilized for high temperature operating conditions e.g. palm oil mills.

Semi-circularTrough

UHMW Liner

PolygonalTrough

HARDOX 400 Liner

Drive system assembly

Drive Shaft

Gland Packing

Electric Motor c/w Torque Limiter (optional)

Capacity ratings for available models

SMC Model Unit TPHSC315VSC315H 15

SC415VSC415H 30

SC480VSC480H 45

SC580VSC580H 60

Typical design 30% fill factor, but handle over 100% fill surges

Standard speed design is between 15 to 45 rpm

Standard design power ratingis using between 3 to 30kW motor

IMPLEMENTATION IN PALM OIL MILL

*Sepang Oil Mill Horizontal Fruit Conveyor

From Sterilizer

DoubleThresher

Bottom-thresher Conveyor

Integration with existing system Sample configuration for fruitlet transport

Fruitlet Feeder SSC

Frui

tlet S

SC

To Pressing Station

Integration with existing system Sample configuration for kernel transport

Kernel Feeder SSC

Kern

el S

SC

Kernel Silo

Wet Kernel Conveyor

Distributor conveyor

Hydrocyclone/Claybath

Implementation in Palm Oi l Mi l ls Existing installations

Project Name Mill Capacity Equipment Materia

lYear of

Installation

Sepang Oil Mill – Golden Hope

30 TPH 1 no. Horizontal Feeder and 1 no. Vertical Fruitlet Conveyor

MS 2004

MPOB – POMTEC 30 TPH 2 nos. Horizontal Feeder and 2 nos. Vertical Fruitlet Conveyor

MS 2005

Merotai Oil Mill – Golden Hope

90 TPH 14 nos. Vertical Conveyors

MS 2005

Hadapan Oil Mill – Consolidated Plantation Bhd

65 TPH 1 no. Vertical Fruitlet Conveyor

MS 2006

Existing installations


lYear of

Installation

Apas Balung Oil Mill – Borneo Samudera

60 TPH 2 no. Horizontal Feeder and 2 no. Vertical Fruitlet Conveyor

MS 2007

Tennamaram Oil Mil – Consolidated Plantation Bhd

65 TPH 1 nos. Vertical Fruitlet Conveyor

MS 2007

Seri Intan Oil Mill – Consolidated Plantation Bhd

65 TPH 1 nos. Vertical Fruitlet Conveyor

MS 2007

Gunung Mas Oil Mill – Consolidated Plantation Bhd

65 TPH 1 no. Vertical Fruitlet Conveyor

MS 2007

Implementation in Palm Oi l Mi l ls

Existing installations


lYear of

Installation

Elphil Oil Mill – Sime Darby Plantations

45 TPH 1 no. Horizontal Feeder and 1 no. Vertical Fruitlet Conveyor.1 no. Horizontal Feeder and 1 no. Vertical Press Cake Conveyor.

MS 2009

Kok Foh Oil Mil – Sime Darby Plantations

45 TPH 1 no. Horizontal Feeder and 1 no. Vertical Fruitlet Conveyor.1 no. Horizontal Feeder and 1 no. Vertical Press Cake Conveyor.

MS 2009

Implementation in Palm Oi l Mi l ls

Existing installationsImplementation in Palm Oi l Mi l ls

1 unit Wet Shell Vertical Shaftless Screw Conveyor

1 unit Wet Kernel Vertical Shaftless Screw Conveyor


1 unit Fruitlet Vertical Shaftless Screw Conveyor


1 unit Sterilized Fruit Vertical Shaftless Screw Conveyor 1 unit Sterilized Fruit Vertical Shaftless Screw Conveyor

INNOVATIONS

*An isometric projection of the vertical spiralc/w feeder conveyor.

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6-sided trough design (patent pending )

DESIGN DESCRIPTIONA trough design for housing the spiral conveyor (shafted / shaftless) consisting of two unequal sections joined by lateral longitudinal flanges, making up a hexagonal cross-section.

patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202

Cross-section

Side view

Top view

24

6-sided trough design (patent pending ) patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202

DESIGN FEATURESThe two halves can be separated as such that the upper part only consist of two plate sections out of the total six.

25

DESIGN FEATURESThe wear bars are placed off-centre on each inner side sections.

Wear plate


26

DESIGN ADVANTAGES

The four plate-sided trough section allow for perfect alignment of the spiral coil during a vertical installation involving multiple conveyor lengths, plus the remaining section provides better structural integrity for added safety during maintenance work.


8-sided design spiral coil fit 6-sided design spiral coil fit

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DESIGN ADVANTAGES

The unequal section separation means only 1/3 of the total trough mass is needed to be lifted to access the spiral during maintenance compared to 1/2 of the total trough mass for the 8-sided design, saving maintenance time while providing added safety.


8-sided designsection separation

6-sided designsection separation

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DESIGN ADVANTAGESThe off-centre installation of the wear bars makes it possible to install a second wear bar without removing the first one, saving resources and minimizing downtime. Second wear bar replacement will be done alongside the whole trough superstructure due to the fact that the wear bar lasts about half as long as the trough.

Wear platereplacement


Utilizing new, better material for spiral fabrication.

Other innovations

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Custom-made gasket for better leakage prevention.

Improvements on the inlet chute packing design.

SHAFTLESS SCREW CONVEYOR (PALMEX 2011) - edited

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