SHAFTLESS SCREW CONVEYOR
P A L M E X 2 0 1 1
PRODUCT INTRODUCTION
*A typical Horizontal Type Shaftless Screw Conveyor
Introduction
The Shaftless Spiral is made from high tensile steel ST52.3 or equivalent
Design to be rigid under all load conditions
Specialized liner material provides optimum abrasion resistance
There are designs available specifically for vertical, inclined and horizontal installation
Design for vertical installation
Design for horizontal installation
Application
An efficient transportation system for :
Sterilized fruitlets,
Palm nuts, Palm kernel and shell,
Mesocarp fibre for boiler fuel,
Empty bunch fibre for composting plant
Sludge for composting plant (solid content ≥ 20%)
No fouling from hanger bearing
No chains/buckets to worry about
No clogging possible
Less chance of breaking down
In-line discharge possible
Longer service lifetime
Simple design
Higher filling capacity at lower rpm
Can handle large lumps & stringy material
Does not require frequent major maintenance
No carry-over at dischargepoint
Efficient operation
Options for installation orientation
Enclosed system means quieter operations & no leakage
Free up valuable space for future upgrades or for aesthetics purposes
Smaller footprint
DESIGN FEATURE
*A Blueprint of The Vertical Shaftless Screw Conveyor Drive System Assembly
SPIRALHelical coils, cold formed from special high tensile alloy steel or stainless steel bars.
SPIRAL INSERTSSmaller helical coils, butt or lap welded to the main spirals to increase axial strength and capacity. Reduce fall back during operation. Thickness & widths are selected to suit the application.
Spiral inserts
Spiral
TROUGHConveyor housing manufactured using SS 304 of 2.5 & 3.0 mm thick and if required SS 316 is available as an option.
UHMW POLYETHYLENE PLASTIC / HARDOX 400 LINERUltra High Molecular Weight (UHMW) polyethylene plastic liner is placed inside the trough along the spiral to absorb due to it’s low friction coefficient high resistance to abrasion. HARDOX 400 is utilized for high temperature operating conditions e.g. palm oil mills.
Semi-circularTrough
UHMW Liner
PolygonalTrough
HARDOX 400 Liner
Drive system assembly
Drive Shaft
Gland Packing
Electric Motor c/w Torque Limiter (optional)
Capacity ratings for available models
SMC Model Unit TPHSC315VSC315H 15
SC415VSC415H 30
SC480VSC480H 45
SC580VSC580H 60
Typical design 30% fill factor, but handle over 100% fill surges
Standard speed design is between 15 to 45 rpm
Standard design power ratingis using between 3 to 30kW motor
IMPLEMENTATION IN PALM OIL MILL
*Sepang Oil Mill Horizontal Fruit Conveyor
From Sterilizer
DoubleThresher
Bottom-thresher Conveyor
Integration with existing system Sample configuration for fruitlet transport
Fruitlet Feeder SSC
Frui
tlet S
SC
To Pressing Station
Integration with existing system Sample configuration for kernel transport
Kernel Feeder SSC
Kern
el S
SC
Kernel Silo
Wet Kernel Conveyor
Distributor conveyor
Hydrocyclone/Claybath
Implementation in Palm Oi l Mi l ls Existing installations
Project Name Mill Capacity Equipment Materia
lYear of
Installation
Sepang Oil Mill – Golden Hope
30 TPH 1 no. Horizontal Feeder and 1 no. Vertical Fruitlet Conveyor
MS 2004
MPOB – POMTEC 30 TPH 2 nos. Horizontal Feeder and 2 nos. Vertical Fruitlet Conveyor
MS 2005
Merotai Oil Mill – Golden Hope
90 TPH 14 nos. Vertical Conveyors
MS 2005
Hadapan Oil Mill – Consolidated Plantation Bhd
65 TPH 1 no. Vertical Fruitlet Conveyor
MS 2006
Existing installations
Project Name Mill Capacity Equipment Materia
lYear of
Installation
Apas Balung Oil Mill – Borneo Samudera
60 TPH 2 no. Horizontal Feeder and 2 no. Vertical Fruitlet Conveyor
MS 2007
Tennamaram Oil Mil – Consolidated Plantation Bhd
65 TPH 1 nos. Vertical Fruitlet Conveyor
MS 2007
Seri Intan Oil Mill – Consolidated Plantation Bhd
65 TPH 1 nos. Vertical Fruitlet Conveyor
MS 2007
Gunung Mas Oil Mill – Consolidated Plantation Bhd
65 TPH 1 no. Vertical Fruitlet Conveyor
MS 2007
Implementation in Palm Oi l Mi l ls
Existing installations
Project Name Mill Capacity Equipment Materia
lYear of
Installation
Elphil Oil Mill – Sime Darby Plantations
45 TPH 1 no. Horizontal Feeder and 1 no. Vertical Fruitlet Conveyor.1 no. Horizontal Feeder and 1 no. Vertical Press Cake Conveyor.
MS 2009
Kok Foh Oil Mil – Sime Darby Plantations
45 TPH 1 no. Horizontal Feeder and 1 no. Vertical Fruitlet Conveyor.1 no. Horizontal Feeder and 1 no. Vertical Press Cake Conveyor.
MS 2009
Implementation in Palm Oi l Mi l ls
Existing installationsImplementation in Palm Oi l Mi l ls
1 unit Wet Shell Vertical Shaftless Screw Conveyor
1 unit Wet Kernel Vertical Shaftless Screw Conveyor
Existing installationsImplementation in Palm Oi l Mi l ls
1 unit Fruitlet Vertical Shaftless Screw Conveyor
Existing installationsImplementation in Palm Oi l Mi l ls
1 unit Sterilized Fruit Vertical Shaftless Screw Conveyor 1 unit Sterilized Fruit Vertical Shaftless Screw Conveyor
INNOVATIONS
*An isometric projection of the vertical spiralc/w feeder conveyor.
23
6-sided trough design (patent pending )
DESIGN DESCRIPTIONA trough design for housing the spiral conveyor (shafted / shaftless) consisting of two unequal sections joined by lateral longitudinal flanges, making up a hexagonal cross-section.
patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202
Cross-section
Side view
Top view
24
6-sided trough design (patent pending ) patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202
DESIGN FEATURESThe two halves can be separated as such that the upper part only consist of two plate sections out of the total six.
25
DESIGN FEATURESThe wear bars are placed off-centre on each inner side sections.
Wear plate
6-sided trough design (patent pending ) patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202
26
DESIGN ADVANTAGES
The four plate-sided trough section allow for perfect alignment of the spiral coil during a vertical installation involving multiple conveyor lengths, plus the remaining section provides better structural integrity for added safety during maintenance work.
6-sided trough design (patent pending ) patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202
8-sided design spiral coil fit 6-sided design spiral coil fit
27
DESIGN ADVANTAGES
The unequal section separation means only 1/3 of the total trough mass is needed to be lifted to access the spiral during maintenance compared to 1/2 of the total trough mass for the 8-sided design, saving maintenance time while providing added safety.
6-sided trough design (patent pending ) patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202
8-sided designsection separation
6-sided designsection separation
28
DESIGN ADVANTAGESThe off-centre installation of the wear bars makes it possible to install a second wear bar without removing the first one, saving resources and minimizing downtime. Second wear bar replacement will be done alongside the whole trough superstructure due to the fact that the wear bar lasts about half as long as the trough.
Wear platereplacement
6-sided trough design (patent pending ) patent pending : PI 2011001753Ind. design 1 :11-00374-0102Ind. design 2 :11-00375-0202
Utilizing new, better material for spiral fabrication.
Other innovations
29
Custom-made gasket for better leakage prevention.
Improvements on the inlet chute packing design.
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