Work performed
- Modification of the existing discharge duct section
- Installation of a new discharge duct
- Unblocking and discharging the overfill silo
Scope
A cement plant with an older silo system needed to empty an overfill silo — formed by the connection of four primary silos as a safety feature — that had not been used for several years. The cement had caked and blocked the discharge system. The client needed the silo emptied to restore its function and to pack the cement for sale.
Access
The silos stand on piles, raised from the ground to form a bunker housing the screw discharge system that feeds the packing plant. TALOS technicians reached the discharge area through the access doors underneath the silo.
Solution
TALOS first checked the level of cement inside the silo and estimated the tonnage that could be extracted, then reviewed the discharge system. The method statement concluded that the safest solution was to modify the discharge system to unblock the base port without spillage.
Ball valves were installed on the discharge duct as access points for hammer drills of various lengths to break up the solidified material. In case of an overflow of soft material the valves could be closed immediately to avoid spillage and engulfment; valve diameters matched the drill bits to keep openings minimal.
Because the client wanted to pack the fine cement, the discharge duct was also fitted with a sieve and hatch to remove large lumps of solidified material.
Results
The overfill silo was discharged safely and successfully. Regular checks of silo levels and timely emptying are crucial to prevent caking and overfilling, so that the silo keeps its intended safety function.