Project Information
Project:
Resolving Screw Conveyor Center Pipe Failures Due to High-Wear Material
Client:
Norzagaray Cement Plant
Project Location:
Philippines
Background of the Challenge
At a cement production facility in Norzagaray, Philippines, the client was facing issues with the mill feed screw conveyors used to transport raw mill separator reject material. They were experiencing frequent center pipe failures, resulting in unplanned downtime and high maintenance costs. This equipment was critical to the operation, as its continuous availability was essential for the smooth running of the system.
The abrasive nature of the reject material was causing excessive wear on the center pipe, particularly in the inclined section of the conveyor. Standard design specifications were proving insufficient for this high-wear application.
Our Approach
Turbovent conducted a detailed engineering review of the existing conveyor’s design, layout, and material flow. Rather than overhauling the entire system, we focused on targeted modifications to enhance performance and reliability.
Implemented Solutions:
1. Optimized Screw Pitch at Inlet
Adjusted to handle the initial influx of material more effectively, reducing stress on the system.
2. Modified Screw Outer Diameter (OD)
Increased to prevent material rollback and reduce the chance of clogging or jamming between screw flights and the trough.
3. End Disk Added at Non-Drive End
Installed to prevent material buildup in the inclined section, which was overstressing the center pipe.
The Results
1. Uninterrupted Operations
The plant experienced smoother system performance without disturbances or unscheduled interruptions.
2. Reduced Downtime
Breakdown incidents significantly decreased, improving overall equipment reliability.
3. Lower Maintenance Costs
With fewer repairs required, the client achieved notable savings on service and spare parts.
Key Takeaway
Standard screw conveyor designs can prove inefficient in high-wear applications such as cement raw mill rejects. Customizing conveyor geometry—including pitch and outer diameter—based on the material’s characteristics is essential to prevent localized wear, premature component failure, and to extend equipment life.