Grain Company Machines and Processes Report

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Updated: Jan 7th, 2024

Work Processes at the Company

The company receives large volumes of varieties of grains shipped from different countries, including Brazil, Argentina, India, and France. Some of the imported grains shipped for the company include corn; soybeans; soy husks; rice husks; palm kernel; sunflower seed husks; sugar cane molasses; husks of wheat; thin corn; and germinated wheat. It must handle these grains for subsequent transportation to other destinations.

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Given these assortments of grains, tasks at the port remain highly challenging. For instance, the company handles bulk grains for feed (WAFI) from foreign countries and stores them at the port. The subsequent process involved the exportation of the grains to various factories in Dammam, or the grains are hauled by transported to another factory situated in Al-Kharj.

The company has two warehouses with various capacities. The Old Flat warehouse has a storage capacity of 60,000 tons, while the New Flat warehouse capacity is 100,000 tons. The company operates two ship loaders at the port, which are used to drag the grain from the ship. The loaders can handle only 600 tons every hour.

Grains can be directly loaded into trucks or transmitted by Belt Conveyor to Transfer Tower. The Belt Conveyor can carry a maximum of 1000 tons. The next process involves the transfer of grain to the Transfer Tower using the Plastic Bucket Elevator located inside the Tower at the bottom. The elevator transports bulk grains to the upper part of the Transfer Tower. The Tower has a Slide Gate that puts the grain in the Belt Conveyor and identifies the path of the grain that goes to the Old Flat storage or the New Flat storage.

After the grain transfer at the Tower, the next process entails the conveyance of the grain to the Head house, which identifies the grain that goes to the silo or Flat storage.

Grains are also sent to the Old Flat storage. At this point, grains may be transported to industries by trucks and the trucks filling by Sheol or by truck loading.

The final process of handling grains at the company involves truck loading. From the Headhouse, the exact grain path is identified, and then Chain Conveyor transmits the grain to the roof of Flat storage. Many gates are available on the roof that can be managed through the Control Room in which the grain transmitted by the Chain Conveyor on the roof of Flat storage is deposited. Grains are conveyed above the gate of the control room for storage purposes.

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Belt Conveyor

The Belt Conveyor faces hazards from breaks when in operation. First, the support roller may be pulled and jam during when it breaks. The hazard may occur between the top and bottom of the belts. Consequently, the belt of the conveyor may tear. Second, the detector rollers at the bottom of the belt face risks of breaking. When these detector rollers break, the belt normally moves against the direction of the frame. This situation is most likely to cause high-rates of wear. Finally, failure to secure the suspension parts or the belt support properly is most likely to result in swinging and shaking of the conveyor.

Static charge is also identified in the Belt Conveyor, and the charge requires protection. It is necessary for engineers to earth the machine discharge such static charges.

In addition, it is imperative to observe the chain for breaks through the belt tear monitor installed at the tensioning station.

Safety Devices

The machine is installed with various safety devices to ensure the absolute protection of engineers. For instance, the emergency pull switch when operated causes emergency stop actuation using ripcord. The emergency pull switch may be installed on a single or both sides of the belt frame based on the manufacturer’s recommendations.

The emergency pull switch must be installed to respond at any moment. Thus, the tension spring must be avoided using a secure method, for instance, the use of a short loop.

The system initiators have a unique design to keep up with modern control systems. Changes in technology have necessitated new installations for older switchgear systems that could need assessment units for signal execution. Hence, engineers must check and ensure that the currently installed control system and initiators are compatible. An evaluation guide from the system manufacturer is the best for conducting the process.

The trough conveyor belt consists of several units, including the MFB, which has several other subcomponents.

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  • Drive station
  • Tensioning station
  • Reversing station
  • Adapter with the first trough
  • Feed hopper
  • Stretching element
  • Conveyor belt
  • Wiper
  • Safety equipment (speed, run-out monitor and emergency pull switch)

These parts are the entire elements that are bundled together to form the MFB. In addition, the MFB may also require fitted units.

The drive station of the MFB also consists of several other units. The reversing station of the unit has a frame with various components:

  • Braces, the housing with inspection openings
  • The drive unit
  • The drum wiper
  • The drive drum with drum bearing
  • Belt wiper with contact pressure weight

When the belt moves up, the reversing lock moves in to fit the drive station.

The drive unit also has the following components.

  • Three-phase AC motor
  • Slip-on gear unit
  • Elastic coupling
  • Coupling guard
  • Bracket with torque support

Chain Conveyor

Design and function

The drive station is extremely important for the chain conveyor. Its design includes the station, the conveyor trough, and the deflection end. These components are made of materials that are suitable for handling food. The measures for the components are mainly standard.

  • Bottom plates measure six mm, side plates measure five mm, and cover sheets measure three mm (400)
  • Bottom plates measure eight mm, side plates five mm and cover sheets measure three mm (600, 800, 1000)
  • An exact transition is noted between the troughs
  • It is entirely sealed and closed
  • All other movable parts are entire enclosed

Drive station

Engineers have options for installing the drive unit on the right or the left side of the station. The flange bearings offer support to the drive shaft while the gearbox with shrink disk and torque support is put straight on the drive shaft.

The conveyor chain is driven by the drive sprocket wheel. The chain control system is responsible for even a conveyor chain movement onto the return rail. The assessment window is for inspecting the product movement visually while the sensor identifies and signals any potential product left at the chamber.

Drive station outlet

The gravity spouts are installed at the outlets with a flange of Ø 400, 500, 600, 700, 800, 900 mm, square 350, 400, 500, 600, 700, and 800 mm. Either a middle flange, an outlet gate, a pneumatic cross slide gate, a closure cover, or the middle frame can be mounted at the drive station. In addition, the middle flange and the outlet gate may be joined with a 35° or 55° outlet.

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Deflection end

The deflection end ensures that the returning conveyor chain is rolled back to the direction of the movement using the deflection chain wheel. The flange bearings are responsible for providing support to the deflection shaft.

The system chain guide controls transfer processes smoothly when the chain wheel moves. Outside the system, the two tension plates offer support to the deflection roll. These plates may be controlled through spindles. In addition, the deflection roll is used to control the chain sag within the drive station when the system stops operating. The drive station also consists of the speed monitor to control the conveyor when the deflection shaft is not in motion, for instance, when the chain is broken.

Intermediate outlets on troughs

The system outlet is connected with specific measures to account for gravity spouts. These measures include Ø 400, 500, 600, 700 mm, square 350, 400, 500, 600, and 700 mm. In addition, the system outlets are located at 35° and 55°. They are also placed directly on the trough with an attached middle flange to control the chain. The troughs’ outlet gates may be expressly installed. Alternatively, outlets may also be directly installed on the outlet gate.

Upward and downward through bends

In some instances, straight conveyors are installed with a maximum slope of 15°. The direction of the conveyor may be altered downwards or upwards using 5°, 10° or 15° through bends.

Hopper-discharging trough

The middle hopper-discharging troughs with various lengths, including 3000/2400/1800/1200/600 mm, may be installed at placed at the end hopper-discharging trough or at the hopper discharging trough with the metering element. The engineers install the system to ensure that any deflection end is possible to be installed in direct sequences. The system has a completely enclosed return chain.

Hopper-discharging trough relies on the side through the bottom conveyor chain to pick materials for transportation.

Operates can accurately control the product flow and discharge from the hopper through the metering slide gate. They can also ensure that the metering slide gates are controlled in a balanced manner. Moreover, they must also observe almost 100 percent product depth of the feeder.

Conveyor chain

The conveyor chain has various components, including the drop forged chain and the hardened case chain, which are normally welded on the carriers. It is imperative to note that carriers have various shapes and capacities based on their respective usages. The chain link has chain pins, which are usually hardened, as well as a chain lock component known as the locking ring. The chain is made up of several pieces of chains, which are normally 1988 meters long (every chain unit consists of 14 links).

The conveyor chain consists of the following parts

  • Longitudinal chain link
  • Chain pins with preassembled chain lock element
  • Chain lock element (locking ring)
  • Longitudinal chain link with a carrier
  • Longitudinal chain link with a plastic scraper

Outlet gate

The recommended drive for the outlet gate is pneumatic. However, an electric drive is available as an alternative. The positioning switches are used to open and close all outlet gates. The floor of the trough becomes flat when the gates are closed while when the system is opened, all materials are discharged without any residues left.

Engineers have the option of installing the outlet gate any location they prefer on the conveyor trough floor or on the drive station. Moreover, operates may also include a deflection gate to ensure that all products that do not flow or move appropriately are removed properly. The deflection gate moves in the upper section when the outlet gate closes.

Cross slide gate

The cross slide gate is controlled through the pneumatic cylinder. The slide gate only has two positions, which are open and closed. This component does not have a position for intermediate parts. It has solenoid switches at the ends. These switches are responsible for providing feedback on the position and creating linkages with other components and equipment. The design of the cross slide gate ensures that no material can be trapped between the slide plate and conveyor chain in any case the cross slide gate is closed.

Metering hood with inlet

The metering hood discharges the conveyed product at approximately 60 percent to 100 percent based on the depth of the material. Generally, the materials have a natural slope of 300, while the position of the floor may be obtained by using a given dimension in addition to 200 mm. Engineers recommend that the metering plate should be closely installed to the inlet. In addition, they also recommend that the slot should be sealed using the sealing compound once it is properly adjusted.

Sight glasses

The sight glasses are installed for visual inspection of the trough chain conveyor. These glasses can be found on either side of the floor and the middle inlet floor. They also have various but optional designs for consideration. First, the sight glass may have a capacitive closeness switch for signaling. Second, the sight glass may also be installed on-site for assessing other outlets.

Drum Sieve

Safety is an important issue for the drum sieve. The intended use of the drum sieve is to separate coarse elements from other bulk materials. Specifically, the application areas include the following:

  • Cereal processing
  • Feed industry
  • Oilseed industry
  • Food industry

The manufacturers recommend that the machine should also be used as intended.

The drum sieve also has technical conditions to ensure safety, functionality, and availability. These aspects may be impaired if the machine is poorly operated.

First, it is recommended that the machine should only be operated when in perfect working status. Second, operators should adhere to all maintenance requirements and plans. Third, only original spare parts identified in the spare parts catalog should be used. Fourth, when any anomalies in operations of the machine are noted, it is recommended to assess the system for faults. Fifth, any identified machine faults should be fixed immediately. Finally, manufacturers strongly warn that no parts of the machine should be altered or converted, specifically without any authorization.

There are also clear designations, which indicate the conditions under which companies should operate their machine. These factors consider possible explosive areas and, therefore, operators should refer to the machine type plate.

Personnel qualification is also important for operating machine efficiently. Generally, any unqualified employees may not be able to identify risks posed by the machine. Thus, such employees are exposed to high operational risks. First, only qualified individuals should operate the machine as described in the manual. Second, the company should ensure that machine operators comply with local safety requirements. Finally, the company must define the responsibilities for employees and communicate them. In addition, only authorized persons should be given passwords and keys.

Drive

DescriptionValue Unit
Power of 50 Hz motor3 kW
Power of 60 Hz motor3.5 kW

Airborne sound emission

The airborne measured values are based on the ISO 9614-3 and ISO 11201.

DescriptionValue Unit
Equivalent sound pressure level around the machine Leq72… 75 dB (A)

Weights

Unpacked net weight

DescriptionValue Unit
Machine unpacked without options2692 kg
Geared motor (option)205 kg
The inlet pipe (option)83 kg
Mounting fixture (option)206 kg
Machine unpacked with all options3186 kg

The role of the drum sieve is to isolate course materials considered as impurities from oilseeds, cereals, and other bulk materials.

The sieve drum has a dustproof case, a gear motor, and a rotating screen. These parts operate in the following manner.

  • The product enters the screening drum through the feeding funnel and the baffle plate
  • The gear motor is responsible for driving the screening drum
  • The turning screening drum then lightly rearranges the bulk product
  • The fine bulk product is dropped via the screening into the product outlet
  • The movement at the helical coil drives the screen and projects it to the front section of the screening drum
  • The screen rejection then leaves the machine through the screen rejection outlet
  • The machine consists of a scraping brush, which cleans the screening drum
  • The system consists of inspection windows and Plexiglas cover for observation
  • Finally, the aspiration inhibits dust discharge and possible explosive condition

Electromagnetic Belt

Risk description

Equipment manufacturer warns that users should be aware of an extremely intense magnetic field created by the electromagnetic separator. Hence, equipment operators must observe safety instructions provided in the manual. Failure to comply with the provided instructions automatically, completely absolves the manufacturer from any potential liability.

General safety instructions for the electromagnetic separator are created to protect machine operators. For instance, the machine may cause severe heart and blood circulation challenges. Hence, users are advised not to spend much time directly in front of the electromagnetic separator. In addition, people who use pacemakers or other similar gadgets strongly warned not to approach the electromagnetic belt when it is in motion.

Based on the electromagnetic compatibility from the Directive 2004/108/CE, the following issues are important for consideration. First, operators must evaluate magnetizing susceptance. It is has been noted that the separator is not prone to external interference from electromagnetic. This situation normally takes place when electromagnetic is linked with the feeding source. Second, the emission factor is also considered for compatibility. The generated magnetic field can cover a small range of meters.

However, it has also been noted that the rectifier installed in the electrical feeding gadget may also produce some electromagnetic waves. Hence, manufacturers recommend that users should not install any electrical appliances or electronic equipment close to the electromagnetic separator.

Major components

The electromagnetic separator is required in all work processes that need the elimination of ferrous materials from other bulk materials or their components. The separator is normally constructed on the machine for handling bulk materials, including conveyor belts, vibrating feeders, and transports.

The electromagnet attracts all iron pieces in the material. The extractor belt then transports ferrous materials to the driven drum situated at the unloading end. This process ensures that all ferrous components are effectively removed from the bulk flow material, which proceeds onwards to the major conveyor belt. In most cases, one can locate the electromagnetic separator on the primary conveyor belt.

Alternatively, it may be found in a crosswise direction or in a longitudinal direction based on the position and the movement of the conveyor belt. Engineers prefer crosswise separator for an extremely large conveyor belt built with incredibly low sliding speeds. On the other hand, the longitudinal separator is preferred for normal situations with standard size conveyor belts. The separator is usually installed at the unloading end of the primary conveyor belt.

Through the same processes deployed in magnetic induction, the longitudinal separator can successfully acquire a high-level of separation because of its operators at the best conditions.

The type of preferred electromagnetic separator is influenced by the space required to install the machine and on certain kinds of separation cycle deployed.

Engineers warn that specific attention must be observed to eliminate or reduce to a minimum the number of ferrous materials or structures collected in the extraction area. If left, these materials are most likely to tamper with the effective running of the machine. Operators must ensure that the separator has at least one meter round it for safety purposes.

Description of the machine

Magnet structure

The electromagnet has a ferromagnetic core within, which also bears an electrical coil. The arrangement of the magnetic poles’ parts, distance, and the density of the coil have been optimized to ensure effective output during operations.

The welded steel plate is found within the magnet structure. It is designed with the correct required specifications to ensure that the magnetic structure can deliver the highest mechanical and magnetic outputs of the separator.

It is recommended that prior to the welding, the parts should be joined to ensure that perfect contact is attained between the crossing parts through magnetic force lines.

In the upper section, the electromagnetic separator is installed with four sturdy lugs, which are appropriate for either crosswise or longitudinal installation. The machine consists of safety gadgets and devices installed on both sides to minimize physical hand contacts or any potential objects that may come between the belt and the drum.

Electrical Winding

The electrical winding has one or several coils made of electrolytic aluminum wire. In most cases, the wire is insulated with heat-resistant covers, and then they are pre-treated with heat for nearly 48 hours in an industrial heating chamber to ensure that no inner moisture contents remain after the process. The special treatment is necessary to ensure that the insulating level attains optimal levels of coil protection of the electrical winding. It is recommended that the heating process should reach 220°C to ensure that the material becomes heat resistance. Thus, once installed, the insulating material will conserve electrical energy, reduce consumption, and provide longer life. All these processes lead to lower costs of maintenance.

Belt Mechanism

The belt system consists of several components.

  • One long multilayer rubber belt made of vulcanized transverse strips
  • One convex curve driven drum running on two sliding systems with roller bearings
  • One driving drum, which is similar to the idle drum, but it has a permanent pillow and rolling shaft
  • Two upper rollers to ensure deflection of the belt
  • One worm gear reducer consisting of hollow shaft joined with the driving shaft
  • One asynchronous three-phase motor installed with pressure die-cast cage rotor (the recommended protection class is IP 55)

Slide Gate

Description

The slide gate has well-defined roles. Its primary purpose is exclusively to shut off BKT conveyor discharge areas. The slide gate is appropriate for handling all types of common grains. Operators must note that any applications of the machine beyond the roles specified by the manufacturer are not allowed. In most cases, manufacturers do not bear responsibilities for the use of the machine beyond specifications.

In addition, operators are encouraged to observe operating conditions and instructions and conduct regular inspections and maintenance.

Nameplate

The machine normally has a nameplate. The nameplate bears important information for operators. It is strongly recommended that the nameplate should never be covered up or removed.

The slide gate diverter valve has a skirted casing unit with the following components.

  • Two slide gates
  • Two middle components
  • A welded casing and roller installed on the slide plate joined by the pneumatic cylinder
  • The slide gate diverter is preassembled at the factory – the cylinder
  • There is also the control valves, which are connected
  • The electrical cabling is installed at the end box
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IvyPanda. (2024, January 7). Grain Company Machines and Processes. https://ivypanda.com/essays/grain-company-machines-and-processes/

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IvyPanda. (2024) 'Grain Company Machines and Processes'. 7 January.

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IvyPanda. 2024. "Grain Company Machines and Processes." January 7, 2024. https://ivypanda.com/essays/grain-company-machines-and-processes/.

1. IvyPanda. "Grain Company Machines and Processes." January 7, 2024. https://ivypanda.com/essays/grain-company-machines-and-processes/.


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IvyPanda. "Grain Company Machines and Processes." January 7, 2024. https://ivypanda.com/essays/grain-company-machines-and-processes/.

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