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Cemex
A revolutionary compressed air moisture removal unit eradicates equipment downtime and boosts productivity at a Cemex site.
“The air dryer was ineffective, and there would be moisture in the air lines after the dryer, causing lots of problems. Moisture was even more of an issue in winter.” –Alexandru Flocea, Operations Manager for Ready-Mix Concrete, Cemex
Ready to Stop Equipment Failure and Save Thousands?
Project Background:
Cemex’s ready-mix concrete plant in Fulham uses compressed air extensively for day-to-day operations. Protecting pneumatic equipment at the site is essential for the site to function. Issues with compressed air contaminants were often responsible for equipment damage and failure, production downtime, increased maintenance and unnecessary costs. At the Fulham site, there were three critical areas of concern:
- Silo Area: When moisture infiltrates the aeration system on silos, it causes several issues. Firstly, it damages aeration pads, leading to repair costs. Secondly, problems with silos ratholing, bridging and arching can occur. Not only does this lead to product wastage, but the silos will gradually cave in and collapse, resulting in significant repair costs. Further moisture issues include faulty operation of butterfly valves and reverse jet filters. These problems regularly led to production downtime, additional maintenance, and part replacement.
- Mixing Station: Valves located by the hoppers and bins were also not functioning correctly due to moisture in the compressed air. For example, the butterfly valve discharging the ready-mix concrete would fail to open or close on demand. Malfunctioning valves would cause product dispatch delays and incorrect product mix ratios. The maintenance teams would then have to rectify the problem.
- Aggregate Bins: Moisture and oil emulsion fluids frequently damaged the valves, controlling the volume of required materials carried to the mixing station. The valves would malfunction, directly impacting the material added to the concrete mixture. The broken valves then needed replacing, increasing maintenance and costs.
Despite installing a refrigerant dryer and several conventional compressed air filters to stop these issues, these techniques proved ineffective. Operations Manager Alexandru Flocea reported large amounts of moisture build-up after the refrigerant dryer. Cemex required a permanent solution to eradicate problems caused by compressed air contamination.
Summary:
Application
Aeration pads, pneumatic valves.
Cost Saving
Expel stopped silo collapse, product wastage and replacement valve costs.
Reduced Environmental Impact
By choosing Expel, Cemex has reduced the amount of pneumatic equipment going to landfill sites.
Why Did Cemex Choose Expel?
Expel has gained a reputation of excellence amongst the world’s leading aggregate companies. Innumerable sites from the aggregate and building material sectors have completely eradicated issues from compressed air lines by installing Expel. Expel’s hard-earned reputation derives from its revolutionary design. Unlike any other solution, Expel operates consistently at 99.999%. It guarantees that equipment no longer suffers damage from liquid water, oil emulsion fluids, or solid particulates. In contrast, the performance of all other solutions degrades without continual maintenance or part replacement. And, even with high maintenance and ongoing costs, they can never guarantee the protection of pneumatic equipment.
Expel has been so effective at ready-mix concrete sites that it has eliminated the need for a refrigerant dryer. Therefore, sites can reduce energy consumption, costs and maintenance.
For those seeking a permanent solution to liquid water, oil emulsion fluids, and solid particulates, Expel is the perfect tool. Its 10-year guarantee provides reassurance that Expel’s performance will not diminish. Cemex selected Expel as its compressed air moisture removal solution for these reasons.
Since installing 4 Expel units, the Fulham site has not had any issues with compressed air contamination.
The Results:
Reduced Energy Consumption: Expel is more energy efficient than conventional compressed air filters because it instantly discharges the compressed air contaminants rather than retaining them in the internal element. Removing unwanted impurities makes the pressure bar drop consistently low and uses compressed air more efficiently. Additionally, Expel has reduced the site’s energy consumption by eliminating the need for a refrigerant dryer.
Reduced Costs: Expel stopped the unnecessary replacement of pneumatic equipment, including solenoid valves, rams and silos. The site also reduced its energy bill by removing all other air preparation products.
Reduced Maintenance: The maintenance teams no longer spend time rectifying the damage caused by compressed air contaminants. Expel does not require replacement filter elements, so it’s maintenance-free and doesn’t get saturated or clogged, saving time and money.
Reduced Downtime: Effective compressed air moisture removal proved essential to ensure the smooth operation of pneumatic equipment. Expel stopped downtime produced by water and dirt in the compressed air lines. Therefore, pneumatic equipment like valves and silo aeration systems are no longer compromised.
Our team is ready to answer your questions.
David specialises in improving business efficiency. By building strong industry relationships, David ensures Expel’s revolutionary technology delivers real value to businesses.
With vast pneumatics knowledge, Johan specialises in on-site assessments to identify strategic installation points to maximise performance and eradicate contamination.
Lauren is a key point of contact for customers. She handles general inquiries and provides exceptional after-sales support, ensuring a smooth customer experience.