Greenbank’s unrivalled expertise in 3D laser scanning, Computational Fluid Dynamics (CFD) analysis and the manufacture of wear-resistant pipework is set to drive down costs and improve operational efficiency at a UK cement plant.
Unplanned downtime due to failures in a pneumatic conveying line handling waste-derived fuel had become a significant burden on the facility’s maintenance resources. During these breakdowns, a more expensive, less environmentally friendly fuel also had to be used, resulting in increased production costs and reduced plant efficiency.
Over many years, the line had seen numerous repairs, but a full pipework replacement was required to resolve the ongoing issues, and Greenbank was tasked with delivering the most appropriate solution.
The extreme environment found within the plant presented numerous challenges, including the glass, grit, and non-ferrous contaminants found in the waste-derived fuel. These are the most abrasive elements of the fuel, but are not held in the pneumatic conveying air-stream, resulting in uneven wear within the pipework.
The simple solution would be to install pipework fully lined with alumina ceramic, but thanks to Greenbank’s in-house capabilities, a more cost-effective solution was found.
Using 3D laser scanning, combined with expert CFD modelling - based on the fuel properties and operating parameters of the plant - Greenbank was able to precisely identify sections of pipework most exposed to excessive wear.
This enabled Greenbank engineers to determine the optimum lining specification for the replacement pipework and to reduce manufacturing and supply costs with no detrimental effects to the performance of the line.
Now, Greenbank’s Basalux lining system (pictured here at our Derbyshire manufacturing facility) is set to be installed on a large proportion of the long straight pipework runs. This innovative product comprises alumina ceramic in the high-wear areas of the pipework and basalt in the less arduous areas.
Fully alumina-lined pipework was specified in all the high-wear areas of the line, and a suitable warranty period was also given to the client based on the CFD study results used to establish pipework lifespan calculations.
