Your efficient partner for modern and effective bulk material handling

PLANT DESIGN - ENGINEERING - EPC-CONTRACTING

� + 49 (0)40 36 13 090 info@ibauhamburg.dewww.ibauhamburg.de

I BAU HAMBURG

CEMENT - THERMAL POWER - MINERALS

Single silos. Ring silos.

Multicompart-ment silos. From 2 to

22 chambers,diameters:

14 to 27 m.

Advanced technology for

self-discharging Cement Carriers

including the Midship tunnel.

Marine Cement Terminals

Central Cone Silos EPC-Contracting

Silo Conversions

Components

Spare Parts

Cement Carriers

Ship Unloaders

Floating terminals.

Mini terminals.Silo systems.

Dome systems.Flat storage

terminals.

Stationary ormobile types:

From the5,000 class

up to the60,000 class.

Piling. Civil works. Steel structure, supply/erection. Electrical/mechanical supply and erection.

Economic modifications with advanced cutting-edge technology.

The key for a well functioning plant: Components, all made to measure.

High stock availability:Just-in-time supply of spare parts.After-sales Service.

I BAU HAMBURG

I BAU HAMBURGOriginal

Components

A HAVER & BOECKER CompanyZ/1

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The I BAU HAMBURG Original componentsCompetence and Innovation

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Information

This brochure shows a selection ofI BAU key components.

A trouble-free operationof silo plants andof either mechanical orpneumatic transportsystems depends signifi-cantly on the reliabilityof its single components.Components engineeredby I BAU HAMBURG inconnection with theI BAU plant engineeringare the key for a wellfunctioning plant.

Our scope of supplyincludes the planning ofcomplex plants up to thedevelopment andconstruction of singlecomponents such as the

I BAU Screw pump, I BAU Flow control gate,I BAU Loading devices

andI BAU Roller-type

dischargers.

REFERENCES MAKEDIFFERENCES

I BAU HAMBURG hasmore than 30 years ofexperience in storage andtransport of bulk materialand is one of the world’sleading companies.

These years of experi-ence help us to supportour customers in imple-menting their projectsby developing andapplying customisedsystems and concepts ofthe highest quality.

As an innovative com-pany, I BAU HAMBURGcontinually develops itsproducts and componentsand undergoes continuousquality improvements.

OriginalI BAUComponentsin the I BAUCentral cone silo

1 I BAU Pump

2 I BAULoading chute

3 I BAU Loaders

4 I BAU Mixer

5 I BAULump crusher

6 I BAUFlow control gate

7 I BAUTwo-way valve

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I BAU HAMBURG – The state of the art for modern bulk material handling

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The I BAU HAMBURG Original components Warehouse and assembly shop on more than 5.000 sqmin our giant store Allermöhe near Hamburg

Information

1 Pump 2 Mixer 3 Flow control gate 4 Cut-off gate 5 Simplex loader 6 Loading chute 7 Lump crusher 8 Roller-type discharger 9 Jet conveyor 10 Two-way valve 11 Airlift

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The I BAU HAMBURG PumpThe screw-type pump with decisive advantages

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Information

1 Pump screw2 Exchangeable

wear bushes3 Flare-shaped

chamber forplug formation

4 Non-return valve

5 Lever withadjustablecounterweightfor non-returnvalve

6 Pump dischargebox

7 Oil-level gauge8 Air supply

connection9 Stuffing box with

purge air10 Pump feeding box11 Heavy shaft barrel12 Cylindrical roller

bearing13 Roller bearing14 Coupling15 Electric motor16 Gauge for

compressed air

17 Gauge with cockfor purge air

18 Gauge forconveying line

19 Conveying line20 Thermometer21 Compressed air

nozzles

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Pump feeding is stopped. The material plug remains unchanged while the screw is rotating.

Pump feeding is 50% of the pump capacity.The material plug remains unchanged.

Pump feeding is 100% of the pump capacity.The material plug remains unchanged and the screwdoes not rotate in the heavily compressed material.

Pump feeding is 25% of the pump capacity.The material plug still remains unchanged.

The I BAUScrew pump

Two decisive featuresdistinguish the I BAUPump from conventionalpumps, as follows:

Operation

With I BAU Pumps thereis a short cylindricalspace between the end ofthe screw and the non-return flap which is filledwith pulverized materialduring conveying. Evenwhen the feeding is total-ly shut down and at pres-sures above 1 bar there isno blowback of air.

This means:

- Material feedingvariable 0 – 100%.

- Pulsation-free chargingof material intoconveying line due tosealing plug.

- Low wear.

- No penetration of thescrew shaft into thepressurized dischargebox.

Design

The screw is secured in asturdy barrel with a cone-shaped inlet connection.

This means:

- Incomparably quieterrunning, even underno-load conditions.

- Easy removal and refit-ting of the screw with-out disturbing the bear-ing seats.

The I BAU Pump

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The I BAU HAMBURG MixerContinuous or discontinuous mixing plants for the cement industry

Information

The I BAU Mixer

Continuousmixing systemwith I BAUFlow-through mixers

For the mass cementproduction with 2-3 maincomponents and withdifferent degrees ofgrindability it isadvisable to performa separate grinding ofthe components with thesubsequent mixing inflow-through mixers.

So that the grain sizedistribution of the indi-vidual components canbe influenced separately.

Often the basic materialssuch as fly ash arealready available in therequired fineness, andjoint grinding withclinker only consumesunnecessary energy.

Accordingly, the use offlow-through mixers pro-vides for a swift amorti-sation, additionallyallowing an increase ofthe grinding output of thecement mills.

Discontinuousmixing systemwith I BAUBatch-type mixers

Discontinuous mixingsystems are used for theproduction of specialcements with a largenumber of main andsecondary componentsand/or frequent productchanges.

Discontinuous mixingsystems provide for theproduction of specificrecipes "just-in-time".

Functional test of an I BAU Flow-through mixer type IB-DMSingle-shaft flow-through mixer type IB-DM

The I BAUSingle-shaft batch-type mixertype IB-M

1 Mixing housing with inlet socket

2 Mixer shaft3 Agitator4 Rotors5 Drop bottom

doors6 Control flaps7 Drive unit

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The I BAU Batch-type mixer type IB-M

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The I BAU HAMBURG Flow control gateStandard type and variations for all applications

Information

The I BAUFlow control gate

The I BAU Flow controlgate type IBNshows all advantagesand features of theworldwide acceptedI BAU Flow control gate.

The variations of thebasic type with differentactuators have incommon the extremelyhigh accuracy of acontrolled flowof pulverised bulk goodswith reproducible results.

They require practicallyno maintenance.

However, even goodthings are subject to wearafter many yearsof good service undersevere conditions.

Different designs of otherflow control gates maymake it necessary todisassemble the completeunit. However, thanksto the design of theI BAU Flow control gate,a complete disassemblybecomes unnecessary.

Maintenance can becarried out while theelement remains built-in.

After having taken offone of the side plates theroller can be taken out.

The gasket is thenaccessible and can bereplaced if required.

Reassembley is done inreverse order.

Silo discharge with motor-actuated I BAU Flow control gate

The I BAU Flow control gate in open positionGasket exchange

Silo discharge with the I BAU Flow control gate

1 Roller2 Felt gasket3 Deflector4 Limit

switch box5 Gear motor6 Side plate

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The I BAU HAMBURG LoaderThe simple way to quick and dustfree loading

The I BAU Loader

For fine granular bulk-goods like cement andlime as well as fly ashand alumina the I BAULoader is a proven andwell accepted aggregatefor quick and dust-freeloading of road and railtankers.

Fluidslides are used toconvey the bulkgoodswhich are to be loaded.

Using the advantages ofthe fluidslides for thispurpose means: highthroughput, low energyconsumption andpractically no noise.

As is suggested by thename they are of asimple design and easyto handle. They do notrequire much mainte-nance.

One of the specialfeatures is the smallspace requirement.

This is very advanta-geous, when usingmodern drive throughdispatch silos.

Long travelling waysare possiblewithout touching orpenetrating the silo wall.

Bulk loading with I BAU Simplex loader

Information

This picture demonstrates the principle of the I BAU Simplex loader

I BAU Mobile loader Loader with cross travel device

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1 Fluidslide; 2 Dedusting; 3 Slewing fluidslide;4 Sealed cover plate; 5 Rail track;

6 Simplex hopper; 7 Loading chute

The I BAU Simplex loader

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The I BAU HAMBURG Loading chuteThe element for trouble-free loading of powdered bulk materials

Information

Truck loading with I BAU Loading chute

The I BAU Loading chute

The I BAULoading chute

On all continents and formany decades the I BAULoading chutes are inoperation for the loadingof powdered bulkmaterial such as cement,lime, gypsum, fly ash,alumina, etc.

The chute is beinglowered onto the openedloading spout.

As soon as the cone of theloading chute is setdown on the loading spoutof the vessel, the sealingcone of the loading chutelowers itself and opens thematerial feeding line aswell as the annular ventingarea between the conesand the outer bellow.

At the silo outlet theI BAU Flow control gateis being opened and theloading process starts, atfirst with a small flow,then with the max. flow.

An adjustable sensor givesthe signal for the end ofthe loading process whenthe vessel is full.

When lifting the loadingchute, first the materialfeeding line and thenthe annular venting areaare being closed.

During the loading processa slack rope switch servesfor the automatic loweringof the loading chute.

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The I BAU Loading chute during positioning and feeding

1 Tapered weight2 Sensor tube3 External cone4 External hose5 Bowl6 Vacuum breaker7 Terminal box

with stroke limitation8 Slack rope switch9 Wire rope pulley

10 Dedusting socket11 Sensor blower

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The I BAU HAMBURG Lump crusherA silo discharge aid for unhindered material flow

Information

Lump crusher type H for horizontal flow-through The lumps shown on the silo wall can cause problems at the silo discharge

The I BAULump crusher

Cement which is stored insilos sometimes tends toconglobate especially insilos which have only onecentral or lateral dischargespout or in silos which arelocated in humid climates.

Occasionally parts of theagglomerated cementmove with fresh cement –which flows easily –towards the dischargespout.

At this bottle neck theselumps plug up thedischarge aperture causingdischarge trouble.

The cement flow isreduced or comes to a fullstop.

The lump crusher placedat the silo dischargedesintegrates the lumps toa size that the cementpasses the aperture of theflow control gate trouble-free. The lump crusher hasproved his ability sincemany years of service.

The combination of lumpcrusher and I BAU Flowcontrol gate has shown nowear when inspected afterone year of operation.It is advantageous that thecracked lumps can flowfreely and unhinderedthrough the I BAU Flowcontrol gate as the gasketis not an obstacle in theconveying stream.

There are no sediments orturbulances in the streamof conveying goodswhich may affect the flowof cement and whichconsequently wear downthe gasket.

The installation of lump crushers ensures a troublefree dischargeView from inside the silo to the lump crusher

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The I BAU HAMBURG Two-way valveThe proven diverter valve for pneumatic conveying

Information

The I BAU Two-way valve

The I BAUTwo-way valve

Pneumatic conveyingsystems for pulverulentbulk goods such ascement, raw meal, lime,fly ash etc. often haveto charge several silosone after the other.

For many year I BAUTwo-way valves arebeing used worldwidefor changing the directionof flow in pneumaticconveying lines.

The principle of thesevalves is simple andwell-known.

A cast iron housinghas one inlet socket andtwo discharge spouts.

One of the dischargespouts is always closedby a spring-loaded discand can be switchedeither manually orby a pneumatic pistonactuator.

A torque motor with gearand brake forms theelectric motor actuator.

This is to make surethat the final position iscorrect.

Of course all remotecontrolled valvesare equipped with limitswitches.

Two-way valves withoutactuator can have limitswitches as an option.

Limit switches can beof the conventional typeas well as of theproximity switch type.

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Two-way valve in a pneumatic conveying line for cement

Material distribution via two-way valves into different silos

1 Inspection cover; 2 Wear ring; 3 Movable disc; 4 Plate spring;5 Gear motor; 6 Limit switch

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InformationThe I BAU HAMBURG Roller-type dischargerEfficient tight-dosing diverter units for fluidslide conveying systems

1 Gear motor; 2 Roller; 3 Aeration pad; 4 Aeration air

The I BAURoller-type discharger

This unit for fluidslideconveying systems iswell-accepted byengineers and operatorsworldwide.

The sectional drawingshows the principle con-vincing by its ingenuity.

Dischargers and branch-ing chutes are equipmentindispensable in fluid-slide conveying systems.

Even the best flap-typedischargers availableup to now are oftenonly at the beginning ofoperation tight.

Incrustations and foreignbodies can cause troubleby causing leaks.

The I BAU Roller-typedischarger is different,being as tight as anI BAU Flow control gate.

Many parts are thesame as those used inflow control gates.

The bottom is perma-nently aerated.Maintenance is reducedto the very minimum.

Roller-type discharger in „straight“. . . . . . and „discharge“ positionThe I BAU Bottom discharger

Bottom discharger for feeding different silos in a cement terminal

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InformationThe I BAU HAMBURG Jet conveyorA straightforward, sturdy conveying element; dependable and free of maintenance

The I BAU Jet conveyor for spillage return

The I BAUJet conveyor

They are in operation onall continents in power-stations, aluminiumworks, cement factoriesand other works, wheresmall quantities ofabrasive, powdery goodshave to be conveyedin a straightforward anddependable way overshort distances.

The I BAU Jet conveyordoes not contain anymoving parts, which aresubject to wear and thusis free of maintenance.

The possible wear isreduced to the diffusor,which is made of wearresistant casted basalt.

No metered feeding tothe jet conveyor isrequired and pluggingof the conveyingline due to overfeedingis not possible.

The necessary conveyingair generally iscompressed by a rotarypiston blower.

Possible conveyingcapacities are shown onthe diagram on theright page(metric dimensions).

Capacity diagram for I BAU Jet conveyor

The I BAU Jet conveyor

Distance in m

Cap

acity

in t/

h

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5 Gauge for air box6 Gauge for air pressure7 Compressed air inlet8 Adjustable nozzle9 Diffusor with

basalt lining10 Gauge for conveying

line pressure11 Compressed air12 Material feeding

1 Housing withintake flange

2 Aeration plate3 Air box4 Control cock

for air box

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InformationThe I BAU HAMBURG AirliftThe continuously working vertical conveyor for minor and major capacities

The I BAU Airliftfor silo charging

The I BAU Airliftsfacilitates a dust-freevertical transport.

It does not require muchmaintenance as thereare no mechanical partsin the conveyingstream which have to bemaintained.

A rotary piston blowersupplying the conveyingair does not require muchmaintenance either.

Parts of an airlift systemare: The cylindricalair-lift body withfluidizing bottom, thevertical nozzle andconveying pipe, aseparator (when notcharging directly a heatexchanger or a smallsilo).

As with all other typesof pneumatic transport a dedusting at theend of the conveyingline is necessary.

A rotary piston bloweror a group of blowerssupply the necessaryoilfree conveying air.

A head of conveyingmaterial forms the airlock against atmosphericpressure; in other wordsthe higher to convey thehigher the airlift body.

I BAU Airlift in a cement plant

I BAU Airlift station

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1 Airlift body2 Fluidizing

bottom3 Vertical

nozzle4 Conveying

pipe

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1 Airlift2 Airlift feeding3 Conveying

pipe4 Raw

meal silo5 Filter unit6 Under / over

pressure flap

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Information

I BAU – Warehouse and assembly shop on more than 5.000 sqm pre-assembled components for fast delivery – the real just-in-time solution

The I BAU HAMBURG Original componentsin our giant store Allermöhe near Hamburg