Bulk Storage Solution for Coal, Limestone, Clinker, Additive, Lignite, Iron ore & Gypsum

Coal sheds are large in size and stores tons of coals. As for any thermal power plant, steel plant, cement plant etc where the boilers require the continuous supply of coal, the coal handling plants are a necessity and play a critical role. For continuous supply the conveyors and stackers reclaimers are installed for effective feeding. To protect equipments from extreme weather conditions and also to protect the coal exposed to these weather conditions, the need to construct the coal shed is important.

Moreover, the dusty conditions created by the coal, it is very important to have the covered coal shed. Due to the fugitive dust emission, the dust particles are carried by the wind and causes pollution. This would pollute the plant area and could damage other utilities of the plant. The loss of coal is also due to spontaneous combustion. Large quantity of water is consumed daily for dousing the fire due to spontaneous combustion. This should be avoided, as excessive moisture in the coal would aid heating of the coal. The erosion due to wind and rain is reduced with the covered storage. By providing the covered storage, the operating expenses of the plant are also lowered.

The covered storage can be longitudinal covered shed or Dome type covered shed.

Longitudinal Covered Shed

In this case, coal storage will be formed by the conventional rail mounted stacker cum reclaimer. The entire coal and the Stacker cum reclaimer machines will be covered within the shed. The length and span of the shed could be adopted depending on the quantity of storage required. In case of future expansion the length of the shed can be increased and same stacker reclaimer can be used for higher volumes.

Dome type structural storage shed

In this type of structure, the shape of the shed will be in the semi hemispherical form. There will be a concrete wall up to a certain height from the ground level and the structure will be erected above this wall. The dome structure of various sizes could be adopted depending on the quantity of storage required. A circular stacker and scraper type reclaimer could be used for reclaiming the coal. With this type of shed, coal will protected from wind and rain and hence the problems associated with these will be avoided. This kind of storage shed can accommodate higher quantity of coal in a smaller area as the height of storage could be increased.

OTHER USE FULL APPLICATIONS OF OUR STRUCTURE

LIMESTONE STORAGE

The cement manufacturing process starts from the mining of raw materials that are used in cement manufacturing, mainly limestone and clay.
The limestone is excavated from open cast mines after drilling and blasting and then loaded onto dumpers, which transport the materials and unload it into hoppers of limestone crushers. The clays are excavated from open cast mines and loaded onto dumpers, which transport the materials and unload it into open yard storage.
As we know cement manufacturer or cement company operator have to ensure that their product maintain quality and consistent properties. But most of the limestone quarries produce material of varying chemical composition. To obtain consistent quality in final product, quarried raw material must be blended before it is fed into the kiln. With our structure, any amount of limestone can be stored
Although stockpiles are created by slewing stacker to minimize fugitive dust, most of the cement producers enclose their stockpile to protect the surrounding environment, and to prevent loss of material due to water runoff and wind.
Limestone storage sheds are the best choice to cover stockpile. It is a low cost solution because fabrication and erection of the structure takes less time. We provide solution for Bulk storage -

In-house design, fabrication and erection of Limestone shed.
Designing and pre-fabrication of component by using computers.
Packaged and shipped in small units that can be by hand unloaded in remote locations.
Assembled over a stock pile or stockyard while the stockyard remains in operation.

The construction systems uses mild steel in case of limestone shed, no welding is required because the connection of the member consists of a very efficient moment-resistant mechanical joint. Limestone shed may be built in single- or double-layer configurations, depending on the load and span for the application. Experience suggests that for the spans required in limestone covers, a-double-layer is the most cost-effective
Limestone storage shed are often built over operating stockpiles since construction can proceed without interrupting operations.

CLINKER STORAGE

Clinker consists of various calcium silicates including alite and belite. Tricalcium aluminate and calcium aluminoferrite are other common components. These components are often generated in situ by heating various clays and limestone.
Clinker consists essentially of four minerals:

Alite: approximately tricalcium silicate (typically about 65% of the total)
Belite: approximately dicalcium silicate (typically about 15% of the total)
Tricalcium Aluminate: Typically about 7% of the total
Tetracalcium Aluminoferrite: Typically about 8% of the total

Cement is caustic, so it can cause chemical burns. The powder can cause irritation or, with severe exposure, lung cancer and can contain some hazardous components such as crystalline silica and hexavalent chromium . Environmental concerns are the high energy consumption required to mine, manufacture, and transport the cement and the related air pollution, including the release of greenhouse gases (e.g., carbon dioxide), dioxin, NOx , SO2 , and particulates. Therefore, it is essential that clinker should be properly stored in covered sheds.
The construction systems uses mild steel in case of clinker storage, no welding is required because the connection of the member consists of a very efficient moment-resistant mechanical joint. Clinker storage shed may be built in single- or double-layer configurations, depending on the load and span. Experience suggests large spans are required in clinker storage , a-double-layer is the most cost-effective Clinker storage sheds are often built over operating stockpiles since construction can proceed without interrupting operations. Because our erection process does not require machines to be installed internal periphery of the span.

GYPSUM STORAGE

A soft white or gray mineral consisting of hydrated calcium sulfate. It occurs chiefly in sedimentary deposits and is used to make plaster of Paris and fertilizers, and in the building industry. Gypsum, a white mineral soft enough to be scratched with a fingernail, is hydrated calcium sulfate [Ca(SO4) 2H2O]. Gypsum often begins as calcium sulfate dissolved in an isolated body of salt water. As the water evaporates, the calcium sulfate becomes so concentrated that it can no longer remain in solution and crystallizes out (precipitates) as gypsum. Many large beds of gypsum have been formed in this way.
Gypsum occurs in a number of distinct forms, including a clear, parallelogram-shaped crystal (selenite); a white, amorphous form (alabaster, used for ornamental carving); and a fibrous, lustrous form (satin spar, used in jewelry). When ground up and heated to drive off its water, gypsum becomes a powder termed plaster of Paris. Plaster of Paris has the useful property of hardening in any desired shape when mixed with water, molded, and allowed to dry. Gypsum is one of the most widely used minerals in the world. Some 90 countries mine gypsum, producing more than 100 million tons (91 million metric tons) annually. The construction industry has long been particularly gypsum intensive. In the late nineteenth and early twentieth century’s gypsum was widely used in plastering, which since the 1950s has been displaced by gypsum drywall (sheetrock). Gypsum is also an ingredient in Portland cement, which used in the construction of bridges, buildings, highways and millions of tons of gypsum used annually as fertilizer. Small quantities of pure gypsum are essential in smelting, glassmaking, and other industries.
We want to make Gypsum storage easy for you; we proved long span steel structure for your gypsum pile
We would like to propose Large Span Steel Shed, which can be used to cover gypsum; it can built with a span of up to 150 m and height of up to 40 m.
Gypsum storage sheds are often built over operating stockpiles since construction can proceed without interrupting operations. Because our erection process does not require machines to be installed internal periphery of the span.

IRON ORE STORAGE

Iron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, deep purple, to rusty red. The iron itself is usually found in the form of hematite (Fe2O3), magnetite (Fe3O4) goethite (FeO(OH)), limonite (FeO(OH).n(H2O)) or siderite (FeCO3). Ores carrying very high quantities of hematite or magnetite (greater than ~60% iron) are known as "natural ore" or "direct shipping ore", meaning they can be fed directly into iron-making blast furnaces. Iron ore is the raw material used to make pig iron, which is one of the main raw materials to make steel.
Our Iron Ore Storage Structure is fully Complying with new environmental regulations for air quality, Prevention and control of fugitive emission. Instead of investing in temporary solution, it is recommended to adopt permanent solution. Our solutions presented here not only allow affordable compliance, but also enhance the reputation of your plant. In addition, one time investment is much more economical than the periodic investments

LIGNITE STORAGE

“Lignite-generated electricity is abundant, low-cost, reliable and environmentally compatible.”
Lignite is a dark brown to black combustible mineral formed over millions of years by the partial decomposition of plant material subject to increased pressure and temperature in an airless atmosphere. In simple terms, lignite, often referred to as brown coal, is a soft brown combustible sedimentary rock formed from naturally compressed peat. It is considered the lowest rank of coal due to its relatively low heat content. It has a carbon content around 25-35%.
Lignite is brownish-black in color and has a carbon content around 25-35%, a high inherent moisture content sometimes as high as 66%, and an ash content ranging from 6% to 19% compared with 6% to 12% for bituminous coal We would like to propose Large Span Steel Shed, which can be used to cover lignite; it can built with a span of up to 150 m and height of up to 40 m.The construction systems uses mild steel in case of lignite storage, no welding is required because the connection of the member consists of a very efficient moment-resistant mechanical joint. Lignite storage shed may be built in single- or double-layer configurations, depending on the load and span. Experience suggests large spans are required in lignite storage , a-double-layer is the most cost-effective. Lignite storage sheds are often built over operating stockpiles since construction can proceed without interrupting operations. Because our erection process does not require machines to be installed internal periphery of the span.

ADDITIVE STORAGE

Additives are chemicals and materials blended into base cement slurries to alter the performance of the cement. Due to the inherent nature of base cements (Neat, Portland and Pozzolanic) and because of the demands placed on the cement cover throughout the life of the structure, the performance properties of the cementing slurry are modified to address the specific and unique conditions of each structure.
Additives are used to enhance cement slurries in all wellbore conditions. Variations in additive concentration may cause significant changes in thickening time, compressive strength, and viscosity, so determining the optimum balance of additives to achieve a reliable annular seal, particularly in extreme or corrosive down hole conditions, can be complex. Thus, field-proven technical solutions, laboratory-driven empirical data from analytical tests, and finite element analysis models play an important role when engineering an optimized slurry blend Additive storage sheds are often built over operating stockpiles since construction can proceed without interrupting operations. Because our erection process does not require machines to be installed internal periphery of the span.

Our Projects

ALCOX PRODUCTS & SERVICES

Airports

Pre-Engineered Buildings

Space Frames

Multi-Storey Buildings

Solar Energy

Bulk storage

Membrane Structures

Self Supporting Roofs

Airports

The integrated terminal buildings are designed with number of structural innovations. The key feature of airport structure is their long span roof covering with massive column spacing. The mega columns and large cantilevers make the structure unique. By using modular space frame structure supported by cantilevered columns makes the roof aesthetically good with doubly curved.

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Pre-Engineered Buildings

It offers a futuristic solution for creating durable and efficient structures in cost effective manner. Apart from great flexibility of designing and minimal construction time offered by PEB’s, they are also preferred for their robustness and durability. Moreover, it is possible to add a wide range of structural and non structural components, which enhances their aesthetic appeal and also improve their usability.

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Space Frames

Space frame is a three dimensional structure. The 3D behavior ensures optimum utilization of material. The quality of roofing is exceptional good as the deflections are almost negligible. Despite their light weight, these structures are designed to carry much heavier load and have a huge spanning capacity. Erection time is minimal as the material is pre fabricated from the factory.

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Multi-Storey Buildings

Steel frames construction is a very popular structural form for multi storey buildings as it provides great flexibility. The structure has adequate strength and stiffness to resist the applied loads due to gravity and wind. The function of the structure in resisting vertical loads due to gravity and horizontal loads due to wind is generally considers separately.

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Solar Energy

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Bulk Storage Sheds

Bulk storage sheds are large span structure to accommodate tons of coals for continuous supply to the boilers.The structures are designed with modular space frame to make it cost effective compared to other conventional structures. Catwalks, ducts and other services can be accommodated within the top and bottom chord.

Limestone Gypsum Additive Iron Ore Coal

Membrane Structures

Textile supported by steel combines the high flexibility of use of this one, from reticular arches to infinite space geometries, with a singular covering applied only with optimum conditions in order to avoid abrasion and corrosion due to contact with main bearing structure. The all season use is guaranteed by a singular system of side opening in order to obtain maximum ventilation in hot season.

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Self Supporting Roofs

Self supporting roofing system makes it possible to erect a warehouse in one span without trusses, purlins and rafters. The systems are mechanically sealed which ensures better weather proofing and a hygienic and clean environment. The absence of holes, nuts, bolts, overlaps or sealants, these structures require minimal to zero maintenance making them highly cost efficient.

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