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Efficiency Improvement
at
Low Investment
by
Upgrade and Improvement
Of Existing Machines
Presented by Gisbert Gröble
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Table of Contents

• Main Reasons for Upgrades and Improvements

• Advantages of Upgrades and Improvements
• Executed Upgrades and Improvements
• Presuppositions for Offering
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Based on our 130 Years of Experience in Solely

Dealing with Stackers and Scraper Reclaimers
one of SCHADE‘s Main Focuses is:

Upgrade and Improvement

of
Existing Machines
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Reasons for Retrofits & Improvements

u Upgrading of Stacking and Reclaiming Capacity

- Process modification, requiring higher material flow
- Shorter reclaiming time required with same capacity in total
- Change in supply logistics (e.g. trains instead of trucks)

u Upgrading of Storage Capacity

- More space required due to more material at the same time
- More Independence from the Raw Material Market
- Additional Material required (new additive, e.g. gypsum)

u Lifetime / Availibility Extension

- Exchange of Existing Chain to well proven SCHADE Design
- Installing of High Quality Components
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Reasons for Retrofits & Improvements

u New Technology – Change of Operation Mode

- Frequency Converter instead of fixed speed, Change to Automatic
- New PLC generation or Integration into Central Control Room
- Automation, Optimizing of Existing Control Software

u Change of Bulk Material

- Changing of the Production Process
- Cheaper Purchase of bad flowing Material

u Enviromental Requirements
- No Reclaiming during the Night – Upgrading required
- Noise reduction, Dust suppression
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Advantages of Retrofits & Improvements

u Efficiency Improvement at Low Investment Cost

- Exchanging of only necessary Components
- Increase of Availability

u Short Realisation Time

- Well Prepared and Scheduled Desmantling and Assembly
- Shorter Assemling Time compared to New Machine
- Less Loss of Production due to a.m.

u Reduction of Maintenance Downtimes

- Installation of Well Proven Components
- Re-Engineering of “Problem Areas” of the Machines
(if necessary)
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Advantages of Retrofit & Modernization

u Avoidance of Permit Procedure

- For Retrofits no Permit is Necessary

u Guarantee Extension
- Guarantee on Every Component which has been Exchanged
- Performance Guarantee

u Tailor-made Solutions for Every Respective Machine

- Engineering of Tailor-made SCHADE Components to
Reach the Latest State of the Art
- Latest Safety Standards
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Retrofits & Modernizations

Selection of
References for Conversions of
SCHADE machines
and
Other manufacturers
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Fujairah Cement - U A E - Bridge Reclaimer Upgrade

Original Reclaimer by MVT:

Reclaiming capacity: 280 t/h
Belt conveyor capacity: 280 t/h
Storing Capacity: 36 000 t
Upgraded by Schade:
Reclaiming capacity: 400 t/h
- new chain with new scrapers
Material: Lime Stone - enlarged harrow
- new chain drives
Belt conveyor capacity: 400 t/h
- new belt conveyor
Storing Capacity: 43 000 t
- new rails for stacker/ reclaimer
- belt conveyor extension
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W.D.T. German Creek - Australia - Bridge Reclaimer Upgrade

Original Reclaimer by SCHADE

Reclaiming capacity: 1,200 t/h

Material: Coal Upgraded by Schade:

Reclaiming capacity: 1,800 t/h
- new chain with new scrapers
- new chain sprockets
- new wear stripes
- new chain drives
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Parcan Industria - Acominas - Brazil - Stacker Upgrade

Original Stacker by MITSUI

Stacking capacity: 690 t/h

Material: Iron Ore

Upgraded by Schade: -
Stacking capacity: 1,400 t/h
- new drive unit with higher speed
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Holcim - Cementos Boyaca - Columbia - Bridge Reclaimer

Original Reclaimer by MVT

High wear and tear at chain and scraper

Material: Lime Stone

Modification by Schade:
- new chain with new scrapers
- new chain sprockets
- new wear stripes
- new drive unit
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Formosa Heavy Industries – Taiwan Long Te – Circular Storage

Original Machine by SCHADE

Reclaiming capacity: 200 t/h

Material: Coal
Upgraded by Schade:
Reclaiming capacity: 400 t/h
- new chain with new scrapers
- new chain sprockets
- new slewing drive
- new chain drives
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Formosa Heavy Industries - Taiwan Mai Liao - Circular Storage

Original Machine by NOELL

Reclaiming capacity: 180 t/h

Upgraded by Schade:
Reclaiming capacity: 240 t/h
- new chain drive
Material: Salt - new chain and scrapers
- new tensioning station
- new slewing drive
- new lubrication system
- new bogie boxes
- new slewing bearins
- complete new electrical system
- etc.
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E.On Power Plant Scholven – Germany - Cantilever Reclaimer

Original Machine by SCHADE

Spring loaded tensioning station

Material: Coal

Upgraded by Schade:
Hydraulic tensioning station
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E.On (VKR) – Germany - Portal Reclaimer and Stacker

Original Machines by SCHADE

Relocation of Stockyard Equipment

Material: Coal
Modification by Schade:
- relocation from Rauxel power
station to Datteln power station
(20 km distance),
- modernization of control system,
- new scraper chain
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Loma Negra - Argentinia – Bridge Type Scraper Reclaimer

Original Machine by KRUPP POLYSIUS

Reclaiming capacity: 450 t/h
Increase of Availibility & Upgrading of Capacity

Material: Limestone Modification by SCHADE:

Reclaiming capacity: >700 t/h
- new chain drive
- new drive shaft and sprockets
- new chain and scrapers
- new chain guiding
- new tensioning idlers
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Sangwon Cement – DPR Korea – Stacker and Bridge Type Scraper

Reclaimer
Original Machines by KHD
Stacking capacity: 1.600 t/h
Reclaiming capacity: 800 t/h
Increase of Availibility & Upgrading of Capacity

Material: Limestone Modification by SCHADE:

Stacking capacity: 1.800 t/h
Reclaiming capacity: 900 t/h
- new drive shaft and sprockets
- new chain and scrapers
- new chain guiding
- new tensioning device
- new lubrication system
- new electrical system
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PT Semen Gresik – Indonesia – Bridge Type Scraper Reclaimer

Original Machine by FLS

Reclaiming capacity: 670 t/h
Increase of Availibility & Upgrading of Capacity

Material: Limestone Modification by SCHADE:

Reclaiming capacity: 1020 t/h
- new drive shaft and sprockets
- new chain and scrapers
- new chain guiding
- new tensioning device
- enlargement of harrow
- new lubrication system
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Loma Negra Catamarca – Argentina – Bridge Type Scraper Reclaimer Circular

Original Machine by PHB

Reclaiming capacity: 370 t/h
Increase of Availability & Upgrading of Capacity

Modification by SCHADE:
Reclaiming capacity: 600 t/h
Material: Limestone - new drive shaft and sprockets
- new chain and scrapers
- new chain guiding
- new tensioning device
- new lubrication system
- new drives
- new harrow system
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Cementos Yura – Peru – Bridge Type Scraper Reclaimer Circular

Original Machine by PHB

Stacking capacity: 400 t/h
Reclaiming capacity: 400 t/h
Stacking Method: Chevron
Increase of Availability & Upgrading of Capacity

Modification by SCHADE:
Stacking capacity: 800 t/h
Reclaiming capacity: 800 t/h
Stacking Method: Chevcon
Material: Limestone - new drive shaft and sprockets
- new chain and scrapers
- new chain guiding
- new tensioning device
- new lubrication system
- new drives
- new harrow system
- complete new electrical system
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Cemento Itambé - Brazil - Bridge Reclaimer

Original Reclaimer by Villares

Modernization of harrow system

Modification by Schade:
Material: Lime Stone
- 2 new enlarged harrows instead of 1
- Application of SCHADE standards
- Hydraulic harrow drive
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Warta Cement - Poland - Bridge Reclaimer

Original Reclaimer by SCHADE

Installation of new Active Harrow System due
to not free flowing material

Modification by Schade:
- Customized Active Harrow System
- Application of SCHADE standards
Material: Lime Stone
- Hydraulic harrow drive
- Integration of new electrical parts
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Cementos Lima – Peru – Bridge Type Scraper Reclaimer Circular

Original Machine by PWH

Stacking capacity: 1200 t/h
Reclaiming capacity: 1000 t/h
Stacking Method: Chevron
Increase of Availability & Upgrading of Capacity
Modification by SCHADE:
Reclaiming capacity: 1200 t/h
Stacking Method: Chevcon
- new drive shaft and sprockets
Material: Limestone - new chain and scrapers
- new chain guiding
- new tensioning device
- new lubrication system
- new drives
- new harrow system
- complete new electrical system
- new hydraulic system for stacker
- all steelwork supplied by SCHADE
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Upgrading & Retrofits of SLT worldwide

E.ON, VKR (E.ON), STEAG, RWE, Power Sangwon Cement Formosa Heavy Industries, Long Te
BP, Chemical North Corea Formosa Heavy Industries, Mai Liao
Warta Cement, Poland
Germany Taiwan
PT Semen Gresik
Tuban, Indonesia
Potash Corp., Canada,
Chemical

Holcim, Cementos Boyaca,

Colombia
Cemento Itambé
Brasil

Cementos Lima, Fujairah Cement

Peru Parcan Industria Dubai
Metallurgy, Brasil UAE

Loma Negra, Catamarca

Argentina

Cementos Yura,
Peru
Loma Negra, L‘Amali
W.D.T. German Creek, Mining, Australia
Argentina Sichuan Ya Dong Cement
W.D.T. Curragh, Mining, Australia
Peng Zhou, China
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Conversions & Retrofits

u As per our best knowledge so far a SCHADE machine has

never been converted or upgraded by a competitor

u SCHADE on the other hand is able to produce a

considerable reference list of converted machines from
other manufacturers
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And what now ????

Ask us and we will help you

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PROCEDURES FOR OFFERING

Requirements to start technical work:

u Detailed drawings and design data

u Static and Power calculation
u Knowledge of general operation situation
u Status/Condition of all main parts of the machine

No sufficient Data and Drawings available

u Research at site by SCHADE inspector

u Inspection costs will be free of charge if modification will be
ordered
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PROCEDURES FOR OFFERING (Budget

Offer)
For generating
a 1st budget
offer

Just fill out

the
questionnaire
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Thank you for your kind attention