Grain storage in steel silos - Technology in Grain Storage Terminal

THE STATE OF THE ART
BULK GRAIN STORAGE
A Switchover from Bagged to Bulk Handling
Pk Bhardwaj - https://www.linkedin.com/in/pkbhardwaj

Bags Vs Bulk Storage
Bags Bulk
Flexibility of storage Inflexible storage
Partly mechanizable Fully Mechanizable
Slow handling Rapid handling
Considerable spillage Little spillage
Low capital costs High capital costs
High operating costs Low operating costs
Easy inspection Inspection more difficult
Condition Monitoring very difficult Condition Monitoring very Easy
Fumigation not Effective Fumigation very effective

Major Bulk Storage Advantages
 Mechanized High Speed Handling of Grain
 Lower Cost per MT
 Ease of Handling Large Quantity in Bulk
 Condition Monitoring of Grain easy in Silos
 Ease of Automation
 Rapid and Smooth Transfer of Grains
 Most International Trade is in Bulk
 In Store Drying is possible
 Reduced Wastage

Storage Technologies
Bag systems Standard warehouses ('house-type godowns');
Permanent plinths (outdoor storage with bags stacked on plinths
and covered by tarpaulins).
Bulk systems Concrete silos;
Steel silos;
Bulk warehouses;
Open bulkheads (grain held outdoors between pre-fabricated
steel walls and covered with PVC sheeting).
Bag-cum-bulk Using standard warehouses, with grain stored in bulk within bag
walls.

What is Silo?
 Long time back Farmers used to
store their grain in Bulk in a Big Pit
or Tower or a Big Tank on their
farms which was called Silo.
 In the modern definition Silo is a
Structure for Storage of Bulk
Materials
 Silos are more commonly used
for bulk storage of grains, coal,
cement, woodchips and
sawdust etc.
Bunker Silo Bag Silo
Modern Silo Storage Facilities

Types of Grain Storage Silos
 Concrete Silos
 Steel Silos
 Bag Silos

The Genesis
The first Indian Bulk Grain
Storage facility was inaugurated
in 21.02.1959 by Dr. VV Giri in
Hapur (UP) Thereafter lot many
were constructed.
All were constructed in
Concrete.

Modern Grain Storage Facilities
One of the Biggest Grain Storage Facility in India
Adani Agri
Logistics
Ltd during
year 2006 to
08 was able
to setup the
first modern
Grain
Storage
facilities in
India

Beauty of Silo Storage Facility

Component of Grain Storage Facility
 Grain Receiving System
 Pre-Storage
 Grain Cleaning
 Bulk Weighing
 Drying Wet Grain
 Long Term Storage
 Reclaiming and Blending
 Shipping Silos
 Grain Unloading
 Rail Siding
 Utilities and CCS

Technology in Grain Terminal
Grain Receipt
Traffic Management System
 RFID Interface
 Boom Barriers
 Traffic Signal Lights
 Status Display Lights
 CCTV and Speed Dome Cameras

Grain Receipt
Grain Tipping Area showing
RFID System, Boom Barriers,
Status Display Lights etc

Grain Receipt
RFID
Antenna
Lane No.
Status Display
Lights
Boom Barrier

Grain Receipt
Boom Barrier Signal Light
Speed Dome Camera and CCTV

Grain Receipt
Sampling Weighing and Dumping
 Automatic Sampling Probes
 World Class Laboratory
 Highly Accurate Automatic Weigh Bridges
 Hydraulic Truck Dumping Stations

Grain Receipt

Grain Receipt
Hydraulic Truck Un-loader

Grain Receipt
World Class Grain Laboratory
Lab Components
•Sampling Probe
•Sample Collector
•4-Way Divider
•Boerner Divider
•Moisture Meter
•Grading Mats
•Dockage Testers
•Precision Balance
•Berlese Apparatus

Grain Receipt
Four Way Divider & Moisture Meter
Boerner Divider
Microwave Oven

Grain Receipt
Dockage Tester
Dockage Tester

Grain Receipt
Dumping to Pre-storage
 High Capacity Chain Conveyors
 High Capacity Elevators
 Automatic Magnetic Separators
 Remote Operated Gates
 Flat Bottom GI Pre-Storage Silos
 High Capacity Sweep Augers

Grain Receipt
Magnetic Separator

Dryer
Vertical Continuous Flow Dryer
 Buffer Hopper with Level Probes
 Dryer Column
 Automatic Discharger
 Furnace with Weishaupt Burner
 Hot and Cool Air Chamber
 Centrifugal Fans

Dryer

Dryer
Hot Air and Dust Extraction

Grain Transfer
Cleaner – 250 TPH
 Grain Inlet
 Grain Distribution
 Pre-Aspiration
 Post Aspiration
 Scalping Screen
 Fine Screen

Grain Transfer
Cleaner
Distribution
Chambers
To Dust
Collector
Pre
Aspiration
Scalpings
Fines
Post
Aspiration
Clean Grain
Screw
Feeders

Grain Transfer
Bulk Weigher
 Online Weigher 250 TPH
 Accuracy 0.1% at 2 Sigma
 Auto-Compensation
 In Flight Material Compensation
 Self Calibration Type
 Remote Controlled
 Stops immediately when goes out of order

Grain Transfer
Feed Gate
Weigh Hopper hanging on
Load Cells
Discharge Gate
(Pneumatic)
BULK WEIGHER

Grain Transfer
Online Sampler

Long Term Storage Silos
GI Corrugated Steel Silos – 12500 MT
 Temperature Monitoring-249 Sensors
 Insect Monitoring - 25 Insectors
 Ventilation System - 4 Exhauters
 Aeration System - 4 Centrifugal Fans
 Fumigation System
 Sweep Auger
 Remote Controlled Feed and Discharge

Construction of GI Corrugated Steel Silo
Making of GI Corrugated Steel Silo
Foundation Reinforcement Foundation Footer

Foundation Sidewall and Tunnel Foundation Backfilling

Aeration Trench and Discharge Openings Completed Foundation Base

Foundation Tunnel View Side Wall with Roof

Roof and Sidewall Jacks Ready for Lifting

Almost Complete Complete

Temperature Monitoring
System

Aeration Floor Patterns
Aeration Floor

Convection Air
Currents and
Moisture
Migration
in Silos

Phosphine Generator
Features
1. Generation of Phosphine
gas from Aluminum
Phosphide formulation
2. Portable Generator
3. Placed outside the Silo
4. Negligible Residue
5. Uniform Gas Distribution
6. Recharging of Gas in Silo
Possible
7. Phosphine Generation
Complete in 2 Hours

Phosphine Generator

Reclaim
Reclaiming Grain for Shipping
 Big Terminals have approx. 300 Mtrs Long
Conveyors in Tunnels
 Flame Proof Electric Fittings
 Possibility of Blending with Different Silos
 Calibrated Discharge Gates
 Online Samplers

Technology in Grain Terminal Shipping
Shipping Silos to Rail Rake
 To fill rake in Railway Free time, 700 MTs per
Hour Capacity is required
 High Speed Online Sampling
 Batch Weighers of 700 TPH
 State of the Art Wagon Loading System
 Loading time 5.2 mins per Wagon

Shipping
Special Grain Wagons
 Introduced First Time in India by Adani
 Self Unloading Type
 Pneumatic Discharge Gates
 FRP Top Hatches
 Capacity 64 MTs of Wheat

Shipping
SPECIAL FOODGRAIN CARRYING
WAGONS
2 Discharges at
Bottom
Top Hatch for Grain
Feeding

Shipping – Wagon Loading
Wagon Loading System
1400 TPH Capacity
Loads up to the Brim of Wagon

Shipping – Wagon Loading
Wagon
Loading
In
Progress

By-Products : Tailings and Dust
Tailings
 By Product generated by Cleaner
 Collected in Silo, and Weighed
Dust
 Generated by Cleaner and other Plant Equipment
 Collected in Silo, and Weighed
 Product Stored = Receipt – Tailings - Dust

Weighing and Bagging
Components:
1. Feed Gate
2. Weigh Hopper
3. Gravity Discharge Gate
4. Load Cells
5. Controller
6. Pneumatic Bag Holder
Features
1. Type : Electro-Mechanical
2. Capacity : 10 Bags per Min
3. TPH : 30 TPH
4. Accuracy : +/- 0.1% at Sigma 2
5. Coarse and Fine Feed

Bag Closing Machine
Components:
1. Slat Conveyor – 4 Mtrs
2. Sewing Head (Four Thread)
3. Controller
Features:
1. Capacity : 10 Bags / min
2. Adjustable Slat Conveyor
3. Foot Switch Control
4. Telescopic Column Mount
5. Ease of Maintenance

Electronic Net Weigher and
Sewing head Assembly
Components:
1. Feed Gate
2. Weigh Hopper
3. Gravity Discharge Gate
4. Load Cells
5. Controller
6. Pneumatic Bag Holder
7. Slat Conveyor
8. Sewing Head
9. Platform for Net Weigher

Static Rail Bridge
Features:
 Better Accuracy than In Motion Weigh Bridge
 Accuracy is +/- 0.25%
 PC Connectivity

Static Rail Bridge
LOADCELL
4 WHEELER
WAGON
Hopper

TOMS - Heart of the System
Terminal Operation and Management System
 Fully automatic facility
 Remotely Controlled from CCS
 Single Operator
 Beautiful interlock of Plant Operation and Management Systems

Thank You
P.K.Bhardwaj
https://www.linkedin.com/in/pkbhardwaj

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