BEUMER Maschinenfabrik GmbH & Co. KG, the German regional company of BEUMER Group in Beckum, has a new managing director since May: Jörn Fontius (Figure 1). He succeeds Norbert Stemich, who after eight years in this position is now focusing on the activities in the Product Business area.
In 2013, Jörn Fontius joined BEUMER and was in charge of the topics of Corporate Strategy. Afterwards, he was head of the global Supply Chain Management. At the end of 2019 he moved to BEUMER Corporation in Arlington, Texas, the North American group company of BEUMER Group, where he was President Airport Division for North America until April 2021.
Before joining the system provider in 2013, he was a member of the management board of the Bundesvereinigung Logistik (BVL). The non-profit association with approximately 11,300 members from the management levels of industry, trade, services and science sees itself as a competence network for logistics. (BEUMER/Si.)
For an economical and sustainable operation, the Austrian plant Retznei of Lafarge Zementwerke GmbH relies on alternative fuels and raw materials to ignite the new calciner (Figure 1). In order to transport, store and dose the kiln-ready material efficiently, the manufacturer awarded BEUMER Group, Beckum/Germany to develop an individual single-source solution. The core of this system solution is a U-shape conveyor: the conveying system ensures an environmentally safe, dust-free and low-energy transport of the pre-processed waste.
In Austrian Styria, the small village of Retznei lies directly on the Mur river. The most important employer originate from cement production: Lafarge Zementwerke GmbH, a company of LafargeHolcim headquartered in Rapperswil-Jona in Switzerland.
In order to reduce greenhouse gas emissions and lower production costs, the company focused more on the use of alternative fuels for firing the new calciner. Instead of coal and oil, only pre-processed and selected recyclable materials of the waste disposal are fed into the kiln. This is already a low calorie material with a calorific value of approximately 14,000 kJ/kg. The manufacturer awarded BEUMER to install a conveyor line, which feeds the material into the calciner at a capacity of 15 t/h.
In order to support producers of cement in the alternative fuels and raw materials field (AFR), BEUMER has set up its own business segment dedicated to AFR systems. So the system provider is able to supply and install the whole chain from the acceptance and unloading of the delivery vehicle, up to the storing, conveying and feeding process of the solid alternative fuels for the specific user. The customer receives everything from one source, thus having a unique contact.
The alternative fuels and raw materials have to fulfil specific quality requirements. Only pre-processed waste with a minimum calorific value of 22,000 kJ/kg and correspondingly low heavy-metal contents may, e. g., be used. The material is supplied by Geocycle. The waste disposal service provider is part of the LafargeHolcim Group and pre-processes construction and mineral production waste for the clinker production in the recycling centre of Retznei. The material we receive has a particle size of 120 x 120 x 20 mm and a density of 100 kg/m3,” says Jan Tuma, Chief Sales Officer at BEUMER in the Czech Republic. The moisture content amounts to 30 %”.
The kiln-ready material is supplied by Geocycle in moving-floor trailers. The hydraulically controlled moving floor moves the load outwards on the conveying system. “All conveying systems supplied and the accompanying equipment are intertwined to ensure steady fuel feeding,” explains Tuma. “At this regard, we have installed our unloading station BG OptiBulk”. A chain belt conveyor with a length of 15 m and a belt width of 2.8 m conveys the material to this unloading station on a height of 6.6 m. The BG OptiBulk is equipped with a special housing, which protects the environment from dust escape and the material from environmental stress. “This station enables to unload up to 150 m3/h of fuel,” says the BEUMER expert. The material, which is delivered by trucks, falls from the unloading station into the BG OptiFeed screw weigh feeder in a container of 20 m3. A conveying system transports further combustible material of the waste disposal service provider Geocycle to a second BG OptiFeed in a container of 50 m3.
“In order to enable a continuous controlled feeding of the material, we have installed one BG OptiFeed for each material flow,” explains Tuma. The screw conveyors with weighing cells are suitable for completely different materials – that means, ideal for the continuous feeding of alternative fuel or raw materials (Figure 2).
Fig. 2. The BG OptiFeed is a screw conveyor with load cells. This allows the material to be continuously metered. Photo: BEUMER
Since the screw conveyors are positioned on the weighing cells, it can always be seen how much material is extracted. The feeding speed to the following conveying elements amounts to up to 15 t/h. The system is dimensioned for bulk densities reaching between 0.08 and 0.15 t/-m3, the regulation ratio is 1:20 and the maximum feeding accuracy between 1 and 2 %. In addition, the completely closed screw weigh feeder is protected against dust. “Thus we can feed the downstream U-shaped conveyor with up to 15 t/h material,” says Tuma.
Fig. 3. U-shape conveyosr are easy to integrate and are also suitable for horizontal and vertical curves. Photo: BEUMER
The U-shape conveyor is the key component of the entire system (Figure 3). U-shape conveyors can be simply integrated and are also suitable for long distances and rough terrain as well as horizontal and vertical curves. The material conveyed is protected against external influences such as wind, rain or snow and the environment against possible material loss. This conveying solution is suitable for coarse but also for very fine material. The system in Retznei has a diameter of 250 mm, a conveying length of 253 m and navigates at a speed of 1 m/s a height of 32 m with a maximum inclination of more than 20°.
At the feeding point, the U-shape conveyor is open as a traditional belt conveyor. A special idler configuration brings the belt in a u-shape. This way the bulk material reaches the discharge station. An idler configuration similar to that for the shaping is used for opening the belt. Compared to the pipe conveyor, the U-shape conveyors have, among other things, considerably higher feeding rates because a smaller belt is used.
The U-shape conveyor transfers the material to a double discharge screw conveyor of the BG OptiLock constructions series. The airlock of this system solution protects the pyroprocess from the infiltrated air from outside, which can arise in the combustion process. The BG OptiLock is also equipped with weighing cells. Therefore, the owner always has an overview of the actual material load. The discharge screw conveyor transfers the bulk material continuously on a screw conveyor, which feeds the calciner. As the material can catch fire, the system provider has designed all supplied systems according to the ATEX directive for the zones 21 and 22.
Further information: BEUMER Group GmbH & Co. KG www.beumer.com
In production, Märker Zement GmbH relies on alternative fuels (AFR). The manufacturer has therefore commissioned BEUMER Group with the supply of a single-source solution that is able to convey and store different materials efficiently (Figure 1). For the system provider, this is the largest order in this business segment to date.
With years of experience and tailor-made systems, BEUMER Group is able to supply and install the whole chain for a specific customer. The process spans from the reception and unloading of the trucks, up to the storing, conveying and feeding process of solid alternative fuels. Märker Zement GmbH is now also relying on this at its headquarters in Harburg in the Bavarian district of Donau-Ries.
As part of the project, BEUMER Group will build an intermediate storage and install a Pipe Conveyor connecting it to the new warehouse built by the customer. Furthermore, there is a connection to the new preheater and to the existing warehouse for the main burner. A fully automatic overhead crane, the buffer bins and magnetic separators, the screen and the feeding station for the Pipe Conveyor are distributed in and around the warehouse. The key component of the whole system is a 700-metre-long Pipe Conveyor.
The intermediate storage is provided with silos, distribution equipment and a screen. In addition, there is a screw weigh feeder of the BG OptiFeed construction series, which feeds the bulk material in a controlled manner to the pneumatic transport system leading to the preheater. The mechanical transport system to the preheater is composed of a belt conveyor and a bucket elevator. An additional Pipe Conveyor connects the intermediate storage and the warehouse to the main burner. Moreover, the order comprises a supporting line next to the intermediate storage, which can be used to quickly unload trucks into silos if required. This line is composed of the unloading station BG OptiBulk, a screw conveyor and a further bucket elevator. BEUMER Group has provided every important transfer station with dedusting filters.
The line will handle two different qualities of residue-derived fuel (RDF), which differ in their material grain size and calorific value, as well as shredded tyres, so-called “tyre-derived fuel” (TDF). It will be operated at a maximum capacity of 40 tonnes per hour. BEUMER Group will be responsible for the complete mechanical and electrical installation as well as commissioning for this project. The whole system is scheduled to go into operation at the beginning of 2022.
Further informationn: BEUMER Group GmbH & Co. KG www.beumer.com
An economical solution was required for transporting large quantities of iron ore from the Chinese port of Langshan to the plant of steel manufacturer Shandong Steel Group & Rizhao Steel Group. The general contractor Shandong Harbour Engineering awarded BEUMER Group, Beckum/Germany, with the installation of additional efficient pipe conveyors.
Shandong is an eastern Chinese region on the Yellow Sea. Its name translates to “east of the mountains” and refers to the Taihang mountain range, east of which lies this coastal province, strategically located between the Chinese economic metropolises Beijing and Shanghai. Another advantage is its access to the Yellow River. The region has a dense network of waterways and several important trade and transhipment ports. The steel manufacturer Shandong Steel Group & Rizhao Steel Group is also headquartered here.
For its manufacturing, the company requires large quantities of iron ore which is delivered to the port of Langshan. In order to transport the material to the plant, the company previously relied on a closed pipe conveyor, but the capacity was gradually exhausted and was no longer able to handle the transport volume. The managers were looking for an economical solution and approached the Shandong Harbour Engineering Group. The engineering service provider was commissioned as general contractor to create the infrastructure. Now the question was: Should the plant use a well-developed expansive railway and road network or invest in a conveyor system solution?
Shandong Harbour Engineering Group turned to BEUMER. The system provider develops conveying solutions for a variety of bulk materials, e. g., open troughed belt conveyors or closed pipe conveyors. BEUMER engineers were also involved in the system, which is already in operation.
“Of course, we had to prove that this investment was worthwhile”, says Zhengwei Zhang, project manager at BEUMER Machinery (Shanghai) Co., Ltd. “In advance, we performed an economic evaluation.” This included a feasibility study, an investment calculation, the project schedule and a cost-benefit analysis. Different variables are required to compare the costs of pipe conveyors with those of trucks or trains, e. g., the transport costs per ton, the material volume that needs to be moved within a set period of time, and also the specific investment costs and the tax depreciation plan. “More costs are added for the construction and the supply of the conveyor as well as for the mechanical and electrical installation”, explains Zhang. Complex construction work is also often necessary. The initial investment in a conveying system is usually very high, but the operational costs of a pipe conveyor can be considerably lower depending on the application. Important factors include the estimated cost of a ton of material to be moved or, in the case of vehicles, the number of round trips per hour. A significant advantage of BEUMER technology is that it enables horizontal and vertical curves.
Depending on the characteristics of the conveyed material as well as of the system’s geometry, it is possible to implement vertical curves with angles of inclination up to 30° and horizontal curves with a deflection angle of up to 90°. This ability to navigate curves reduces the number of supports and replaces the transfer towers, which results in substantial cost savings for the customer. The system transports the iron ore safely enclosed across various terrains such as roads, residential areas or rivers. During the projection phase of the system, BEUMER technicians use proprietary calculation software to determine the static and dynamic loads – loads, which do not only affect the belt but the steel structure frame as a whole. This is a prerequisite for safe and correct dimensioning of the structures.
Fig. 2. The total conveying length of the pipe conveyors is approxi-mately 6.6 km, the conveying capacity 5,500 t/h. Photo: BEUMER
BEUMER provides their belt conveyors with environmentally safe electric drives and low-energy belts. Therefore, especially in these times of climate change and increasing greenhouse gas emissions they are considered a more sustainable option. The motors used are usually adjustable, which permits the loads to be optimally distributed on the drive units under various operating conditions. The closed design of this conveying system also protects the environment from falling transported goods. Another advantage is the elimination of dust development on the running line. This is important because the section between the port and the plant leads through public roads and residential areas (Figure 1).
Together with the managers in Shandong, BEUMER engineers developed a solution that is optimally tailored to their requirements. The system supplier delivered a conveying system consisting of two pipe conveyors. The overall length is approximately 6.6 km, the diameter 500 mm. At a speed of 5.15 m/s, the systems operating together convey up to 5,500 t/h (Figure 2) considerably supporting the already existing conveying solution. In addition, a transfer tower is used.
BEUMER was responsible for the overall project, which included the design of the system and the entire steel structure. The completely enclosed conveying system ensures an environmentally safe, dust-free and low-energy transport of the iron ore. The system provider started the installation in September 2018 and commissioning took place only four months later. The complete project implementation took only eight months.
Further informationn: BEUMER Group GmbH & Co. KG www.beumer.com
Since the beginning of this year, Alexander Tigges has been head of sales at the Center of Competence (CoC) for Conveying & Loading Systems (CL Systems) at BEUMER Group, Beckum/Germany. The mechanical engineer can draw on many years of experience in international plant design. Before joining BEUMER, he was, among other things, product manager and sales manager for large-scale plants at an internationally active manufacturer of cement plants. (BEUMER/Si.)
BEUMER sales manager Kay Wieczorek is sure: In the coming years, there will be a lot of changes in the cement industry. Covid-19 makes personal interaction with customers nearly impossible during the current times and advises owners to be careful when making investments. Nevertheless, the crisis offers many opportunities for system providers: the digitalisation, the use of alternative fuels or the need for automation. The change from 50 kg to 25 kg bags in some countries world-wide will also be a big challenge for the market.
“Over the past months, Covid-19 has forced us to cope with some changes. This will probably bother us even more in the colder months,” Wieczorek is convinced. He is head of sales for the cement industry at BEUMER Group, Beckum/Germany, a company which since its foundation in 1935 develops future-oriented solutions for the construction and cement industry. .
Contacting with their customers world-wide is what Wieczorek and his colleagues in the sales department are missing the most over the past several months. This is very important in a sector where business deals are concluded not only with a signature, but mostly with a firm handshake. “The pandemic is massively changing our travel behaviour and the way we hold meetings and sign contracts,” he says. Communication is becoming more and more digital. Even if many cement plant owners are still reacting rather hesitantly to this development, they do see the advantages. “We may not be on site at the customers’ premises right now, but we can still support them, e. g., with our BEUMER Smart Glasses,” says Wieczorek (Figure 1). What happens if, e. g., a packaging system in Indonesia or Peru fails? BEUMER is globally well positioned with its numerous subsidiaries and representatives and can, if necessary, dispatch one of the world-wide stationed technicians where needed, but even this takes time – provided that the Corona measures allow it at all. Alternatively, the system provider is available around the clock via the hotline. But what about complex problems which cannot be clearly communicated over the phone? “Customers can work with a service technician while wearing our BEUMER Smart Glasses to have all important information displayed in the live image of the camera”, describes Wieczorek. “This enables the customer to repair the machine himself – just as if one of our technicians were at his side.” The data glasses serve also for remote commissioning and allow both parties to look over the whole system. Wearing the data glasses, BEUMER Customer Support can see the same images as the technician on site and can directly specify the correct actions to take. This way, the user is guided step by step through the commissioning process. Remote maintenance is also possible and enables BEUMER experts to connect to the system regardless of time or day. This increases the machine availability, as it is not necessary to travel long distances. However, personal contact is still imperative.
The increasing digitalisation implies the increasing use of sensors to collect and evaluate informations at critical points. This may concern the use of contactless proximity switches that reliably transmit signals without mechanical contacts. The use of high-quality photocells ensures signal transmission even under difficult environmental conditions and the sensors used increase the machine capacity. Thus, the user can both considerably reduce the maintenance costs and make the spare parts handling more transparent.
“Alternative fuels are another great trend in the cement industry,” recognises Wieczorek. “World-wide, this is also promoted by politicians in various countries in order to get air pollution under control”. When producing cement, large quantities of CO2 is emitted. Depending on the processes used, the emissions from producing cement are at 0.6 to 0.99 t of CO2 per ton of cement. The CO2 emissions from this sector are estimated to account for 7 to 8 % of the overall global CO2 emissions. An approach to sustainably reduce greenhouse gas emissions and production costs is to increase the use of alternative fuels. Fluid materials like waste oil or solvents, e. g., are used instead of coal and gas. The majority of the solid alternative fuels are composed of municipal and industrial waste, such as plastic, paper, composite material or textile mixes. “However, we cannot throw the complete household waste into the kiln,” Wieczorek says. “Because different materials also have different calorific values.” Especially in countries where waste separation is not developed like in Europe, the challenge is huge. On the contrary, the use of shredded waste tyres is welcome. The calorific value of the rubber from waste tyres is comparable to that from hard coal, and the iron from the reinforcement can be incorporated mineralogically into the cement. This minimises the addition of ferrous corrective substances.
As a system provider, BEUMER develops tailor-made solutions for the entire material flow chain from unloading the delivery vehicle to storing, weighing, conveying and control feeding of solid alternative fuels. BEUMER also provides fully automated systems that can control feed, singulate and convey large and heavy tyres to the inlet of the rotary kiln.
However, CO2 can be further reduced – and not only by energy-efficient systems and the use of alternative fuels and raw materials (AFR). An important aspect is the transport of raw materials from the quarry to the plant or the port. The routes often lead through rough terrain or even populated areas. This is a task companies often handle by trucks, which emit large quantities of CO2. “At this regard we offer troughed belt conveyors and closed pipe conveyors. The conveyors are more environmentally friendly and can be considerably more economical – they can. Deciding if the investment is worthwhile depends on several factors,” Wieczorek explains. The BEUMER specialists help with feasibility studies and cost comparison to take the right decision.
“What has been partly implemented in Europe since decades, will also be implemented in some other countries around the world in the coming years – the change from 50 kg bags to 25 kg bags,” says Wieczorek (Figure 2).
Fig. 2. The change from 50 kg to 25 kg bags will reach several countries. Palletisers such as the BEUMER paletpac have to be accordingly adapted at the customer’s. Photo: BEUMER
This was triggered by new legal requirements for the health protection of workers, who have to lift and tow these bags. “For us, this means that we have to gradually retrofit the systems in the packaging lines at our customers’ site,” the BEUMER expert describes. “This will be an enormous challenge, because the packaging lines in the plants must of course fill and pack the same amount of cement as before – and thus handle twice the number of bags in the same time”.
But even if the weight of the bags has been reduced to half of it – the manual loading on the truck bed is still hard work. “And fewer and fewer people in India, China and Africa are willing to do so,” says Wieczorek. Also in the emerging countries, it is becoming more and more difficult to find appropriate personnel for this kind of work. In addition, labour costs are climbing in these countries. Manual truck loading is exhausting and usually requires two people who alternate with their colleagues for each loading process due to the heavy physical work involved. Furthermore, there is the high level of dust formation, which affects the employees’ health. During the manual loading process, the loading performance as well as the quality of the bag stacks often fluctuates. “These problems are omitted if the BEUMER autopac is used”, says the BEUMER expert. “One employee is able to operate more than one machine.” This enables owners to optimise processes, achieve high loading capacities and work very efficiently from bagging up to loading. Thus, automation is a world-wide trend.
“We have further developed this machine,” says Wieczorek. “We offer a version, which can be adapted to very different truck bed widths”. The BEUMER autopac offers a further advantage – no pallets are required. In many countries there is simply a lack of wood, and the logistics to store the empty pallets. This exceeds the possibilities and capacities of many companies. “Imagine a plant which stacks 5,000 to 6,000 bags per hour on pallets. The storage of these pallets may require a surface of several hundred square metres,” says Wieczorek.
“In 2020, the pandemic caused a huge slump in the market,” reports Wieczorek. “The owners are unsettled because they cannot estimate how the coming years will develop. However, the reason is not only Covid-19”, he says. “The number of new built cement lines is considerably fewer than years ago. In 2010 approximately 200 cement lines were set up in China, in 2019 exactly 18. Of course, this is partly due to the enormous overcapacity, especially in China. For a long time, the Chinese government has pushed forward large building projects and as a consequence the production of huge quantities of cement – which were partly exported en masse. These times are over now. In the cement plants, the owners are e. g. having three lines retrofitted to a large one,” noticed Wieczorek. But this requires know-how and technique too. World-wide “Made in Europe” is still considered a quality seal, especially with regard to process-critical equipment, Wieczorek knows the market. The need for cement is still high, even if this is not reflected in the sale of new systems. Many owners wait before making major investments and consider whether the investment is really worthwhile. “But even if the industry is currently reserved, the number of concrete projects and inquiries is raising again,” Wieczorek says satisfied. “This movement gives us hope. I am sure that the willingness to invest will raise again in the near future”.
Further information: BEUMER Group GmbH & Co. KG www.beumer.com
Thanks to digitalisation, it is no longer unusual to parametise and commission single components remotely. BEUMER Group, Beckum/Germany, thinks ahead and, for the first time, commissions a complete packaging line including palletiser – from a distance of over 4,000 km.
Helping customers in the event of faults or shutdowns of existing systems is no problem for BEUMER – even from a distance. The system provider was confronted with a completely new situation when a planned commissioning, which involves the dispatch of service personnel to the site, could not be carried out due to travel restrictions caused by the Covid-19 pandemic. BEUMER was flexible and set the course for “remote commissioning” – commissioning from a distance.
“The trigger was clearly the pandemic,” explains Peter Teichrib, a department manager in Engineering at BEUMER. However, this is not the only scenario that requires BEUMER’s new service remote commissioning. Everything that makes personal access to systems and users difficult or impossible requires new solutions.
Fig.1. On site: BEUMER Smart Glasses, smart-phone and laptop provide an audio-visual connection to the BEUMER Group. Photo: BEUMER
As a concrete example, Teichrib mentions the packaging line of the cement manufacturer Norm LLC in Azerbaijan, which was almost completely erected on site. This line consists of two bag transport systems, the layer palletiser BEUMER paletpac 5000 and the BEUMER stretch hood A packaging line. “All components were already completely installed. Only some electrical installations and commissioning still had to be carried out when our experts had to leave the country due to the worldwide travel warning”. A delicate situation for the customer who has already included the capacity of the new packaging line in his calculations. If the line does not start up, the customer faces the thread of delivery bottlenecks and loss of market share.
BEUMER decided to launch remote commissioning as a pilot project. “The conditions were exceptionally good, which certainly cannot be taken for granted,” emphasises Teichrib. In general, a number of conditions must be met before the “remote commissioning” project can even be considered. The system must be tested in-house in advance. “With this system, we had indeed carried out an extended in-house commissioning, as the BEUMER paletpac 5000 was running with the new PLC S7-1500 for the first time,” says the department manager. “We wanted to make sure that everything would work perfectly later. Finally, it was this circumstance that made remote commissioning possible in the first place.” BEUMER also recommends to supply the BEUMER stretch hood with the film tested in advance. This way, possible differences in film quality can be excluded as a source of problems during commissioning.
In general the customer needs qualified maintenance and operating personnel who is preferably familiar with BEUMER systems. This is another prerequisite for successful remote commissioning. On the hardware side, several IP cameras provide the necessary overview of the complete system, while BEUMER Smart Glasses, specially developed data glasses, connect the BEUMER experts audiovisually to the user on site (Figure 1). “A broadband Internet connection is, of course, required,” says Teichrib. The data glasses allow a detailed view: The BEUMER Customer Support sees the same thing as the wearer on site and can directly specify the correct actions to be taken. In this way, the user is guided step by step through the commissioning process (Figure 2).
Fig. 2. The user is guided through the commissioning process from the back office. Photo: BEUMER
The cameras and BEUMER Smart Glasses are part of the plug-and-play set for remote commissioning. This also includes a WLAN router for the BEUMER Smart Glasses and a VPN client installed on an mGuard router. The IP cameras must be connected via LAN cable to ensure sufficient image quality and stable transmission. “First, we installed the hardware and software components in our factory and tested the configuration. The complete package has been shipped to Norm LLC,” says Teichrib. This procedure has proven itself and is also planned for future remote commissioning projects.
BEUMER set up a separate back office for this project at short notice. Using four monitors and a laptop, the service staff always had an overview of the images from the IP cameras, the field of view of the BEUMER Smart Glasses and the data of the system sent via the VPN client.
“Within a very short time we were able to develop a concept that will guide us safely and reliably through future remote commissioning projects. Standardised processes enable us to eliminate sources of error and offer our customers a reliable service – quickly and flexibly,” explains the department manager.
Regardless of external circumstances: If BEUMER digitally takes the users by the hand via remote commissioning, the understanding and know-how of the systems grow. This motivates the customer’s personnel on site, a fact from which the user benefits as much as BEUMER – a better understanding of the system will significantly simplify future remote maintenance and services.
Further information: BEUMER Group GmbH & Co. KG www.beumer.com
BEUMER Group commissions system from 4,000 kilometres away
Thanks to digitalisation, it is no longer unusual to parametise and commission single components remotely. BEUMER Group thinks ahead and, for the first time, commissions a complete packaging line including palletiser – from a distance of over 4,000 kilometres.
Helping customers in the event of faults or shutdowns of existing systems is no problem for BEUMER Group – even from a distance. The system provider was confronted with a completely new situation when a planned commissioning, which involves the dispatch of service personnel to the site, could not be carried out due to travel restrictions caused by the COVID-19 pandemic. BEUMER Group was flexible and set the course for “remote commissioning” – commissioning from a distance.
“The trigger was clearly the pandemic,” explains Peter Teichrib, a department manager in Engineering at BEUMER Group. However, this is not the only scenario that requires BEUMER’s new service remote commissioning. Everything that makes personal access to systems and users difficult or impossible requires new solutions.
As a concrete example, Teichrib mentions the packaging line of the cement manufacturer Norm LLC in Azerbaijan, which was almost completely erected on site. This line consists of two bag transport systems, the layer palletiser BEUMER paletpac 5000 and the BEUMER stretch hood A packaging line (Figure 1). “All components were already completely installed. Only some electrical installations and commissioning still had to be carried out when our experts had to leave the country due to the worldwide travel warning”. A delicate situation for the customer who has already included the capacity of the new packaging line in his calculations. If the line does not start up, the customer faces the thread of delivery bottlenecks and loss of market share.
Test run required
Figure 2. Never change a running system: BEUMER Group recommends to supply the BEUMER stretch hood A with the previously tested film to ensure a smooth start of the remote commissioning. Photo: BEUMER
BEUMER Group decided to launch remote commissioning as a pilot project. “The conditions were exceptionally good, which certainly cannot be taken for granted,” emphasises Teichrib. In general, a number of conditions must be met before the “remote commissioning” project can even be considered. The system must be tested in-house in advance. “With this system, we had indeed carried out an extended in-house commissioning, as the BEUMER paletpac 5000 was running with the new PLC S7-1500 for the first time,” says the department manager. “We wanted to make sure that everything would work perfectly later. Finally, it was this circumstance that made remote commissioning possible in the first place.” BEUMER Group also recommends to supply the BEUMER stretch hood with the film tested in advance. This way, possible differences in film quality can be excluded as a source of problems during commissioning (Figure 2).
Know how meets technology
Figure 3. On site: BEUMER Smart Glasses, smartphone and laptop provide an audiovisual connection to BEUMER Group. Photo: BEUMER
In general the customer needs qualified maintenance and operating personnel who is preferably familiar with BEUMER systems. This is another prerequisite for successful remote commissioning. On the hardware side, several IP cameras provide the necessary overview of the complete system, while BEUMER Smart Glasses, specially developed data glasses, connect the BEUMER experts audiovisually to the user on site. “A broadband Internet connection is, of course, required,” says Teichrib. The data glasses allow a detailed view: The BEUMER Customer Support sees the same thing as the wearer on site and can directly specify the correct actions to be taken (Figure 3). In this way, the user is guided step by step through the commissioning process.
The cameras and BEUMER Smart Glasses are part of the plug-and-play set for remote commissioning. This also includes a WLAN router for the BEUMER Smart Glasses and a VPN client installed on an mGuard router. The IP cameras must be connected via LAN cable to ensure sufficient image quality and stable transmission. “First, we installed the hardware and software components in our factory and tested the configuration. The complete package has been shipped to Norm LLC,” says Teichrib. This procedure has proven itself and is also planned for future remote commissioning projects.
Keeping the overview
BEUMER Group set up a separate back office for this project at short notice: Using four monitors and a laptop, the service staff always had an overview of the images from the IP cameras, the field of view of the BEUMER Smart Glasses and the data of the system sent via the VPN client (Figure 4).
Figure 4. The user is guided through the commissioning process from the back office. Photo: BEUMER
“Broadband Internet access, technology and know-how – at Norm LLC we encountered ideal conditions, which we made the best possible use of,” explains the department manager. “Within a very short time we were able to develop a concept that will guide us safely and reliably through future remote commissioning projects. Standardised processes enable us to eliminate sources of error and offer our customers a reliable service – quickly and flexibly.”
Regardless of external circumstances: If BEUMER Group digitally takes the users by the hand via “remote commissioning”, the understanding and know-how of the systems grow. This motivates the customer’s personnel on site, a fact from which the user benefits as much as BEUMER Group – a better understanding of the system will significantly simplify future remote maintenance and services.
The remote commissioning of the packaging line at Norm LLC has shown that with adequate framework conditions, such as well-trained maintenance personnel and technically high-quality IT equipment, new ground can be broken. BEUMER Group’s technology and competence have impressively confirmed this.
Machine malfunctions and standstills that are not eliminated as fast as possible may become expensive for manufacturing companies. BEUMER Group, Beckum/Germany, developed the BEUMER Smart Glasses as a pioneering product that supports users quickly and easily. The BEUMER Customer Support technicians use them to take a virtual look over the shoulder of the customer’s service technician to solve the problem together. This digital solution reduces travel times and costs.
“With the BEUMER Smart Glasses, our customers can get in live contact with our service experts anywhere and at any time,” promises Christopher Kirsch, team leader of BG.evolution. With this spin-off at the university location of Dortmund, the company brings digital innovation from outside into the company. In other words: “We are working on a customer problem with the support of start-ups to develop “Minimum Viable Products”. These are minimally equipped prototypes whose market potential and customer acceptance we put to the acid test,” explains Kirsch. This makes it easier for BEUMER to decide quickly whether a new technology makes sense to develop into a finished product – such as the BEUMER Smart Glasses.
Together with their colleagues from BEUMER Customer Support and the Department for Research and Development in Beckum, the employees in Dortmund made this digital solution ready for the market. “From October 2018 to January 2019, long-term tests were carried out with various customers, including one with live testing with a long-term customer from the building materials industry. We were successful in concluding this phase,” reports Kirsch. The user has been using a high-capacity palletiser BEUMER paletpac and a high-capacity packaging system BEUMER stretch hood for years.
If there is a problem during operation, this may easily result in production bottle-necks. In the worst case, this results in delays of day-to-day operations. “If a machine suddenly breaks down, the problem must be solved as fast as possible,” says Kirsch. This is the only way for the users to save time and money. If the users are not in a position to handle this by themselves, BEUMER sends their globally located technicians to prevent longer downtimes. In addition to service technicians, Customer Support also provides qualified telephone support for trouble shooting, which is available 24/7. However, it can be challenging to successfully communicate complex problems quickly and clearly over the phone. Imagine if the customer had the opportunity to have a BEUMER technician take a quick and easy look at the problem at any time – on-site support, without actually being there. The BEUMER Smart Glasses make it possible.
The employee at the machine puts on the glasses and starts the BEUMER Support app via voice command. The employee transmits a service number and a pin code to the hotline, and the connection with image and sound is established. The BEUMER technician receives the same image as the customer (Figure 1). The technician can directly give instructions and display all relevant information in the field of vision. The employee has both hands free to follow the instructions of the expert and carry out the necessary actions. Faults can be solved quickly and precisely – at any time. The BEUMER experts are available around the clock, seven days a week.
As part of the comprehensive BEUMER Customer Support, users add the BEUMER Smart Glasses as an extension to their monthly or annual hotline service agreement. Together with BG.evolution, BEUMER is currently developing further digital products under the umbrella of “Smart Solutions”.
Further information: BEUMER Group GmbH & Co. KG www.beumer.com
Hard coal is temporarily stored in stockpiles and then continuously fed to be processed, as needed. The design of the depositories must ensure constant filling and reliable emptying. The required capacity is determined based on the incoming and outgoing conveying flow. Different stacking and reclaiming options as well as various layouts for the stockpiles are also needed. The BEUMER Group, Beckum/Germany, provides the engineering for handling stockpiles and offers the required components to coal mine operators, such as stackers and reclaimers.
This most certainly includes Prairie Eagle Mine in Illinois, the largest coal mine of Knight Hawk Coal (Figure 1). This is one of the most efficient underground mining plants in the USA. They produce approximately 5 M t/a of coal, of which more than 80 % is processed and delivered in Prairie Eagle. Since spring 2019, a nearly 6.5 km long troughed belt conveyor from BEUMER has been transporting the coal from a new entrance to the mine to the main processing plant. This enabled the company to close part of its mine building. In addition, the new plant extracts the coal in the vicinity of the current mining operations after the surface.
Fig. 2. BEUMER Group provide the suitable stacker for stacking the coal. Photo: BEUMER
For BEUMER this was another project with curved overland troughed belt conveyors in North America. These systems are used worldwide. The system provider not only supplies customers in this industry with conveyor technology. He also supports, e. g., operators of coal mines with the engineering of heaps on which the coal is temporarily stored. BEUMER also supplies stackers (Figure 2) and portal scrapers.
Further information: BEUMER Group GmbH & Co. KG www.beumer.com
