GENERAL PRODUCTS

Being aware that high-quality production is only possible by specialized personnel, modern production techniques and full-automated production, OBIAL zinc-plated steel silos and conveyance equipment are designed by the product development/design department to address all grain storage requirements and produced accordingly. High-quality zinc-plated metal sheets used in silo production resist 450 MPA and are corrosion-resistant. The custom produced metal sheets used in the production of our silos have a zinc plating standard of 450 gr/m2 and 350 gr/ m². The zinc plating ratio changes according to customer demands. OBIAL offers difference silo options, including flat and conical-bottom silos, starting from a diameter of 4.51 m diameter to 31.60 m. To be able to carry the vertical loads on the silo, vertical suspension supports mounted on the silo surface are used to yield maximum strength. OBIAL vertical suspension supports perfectly distributes the pressure put by the grain in the silo on the side walls of the silo over the bottom of the silo. To ensure maximum strength at all joints in OBIAL steel silos, Dacromate 500Acoated bolts, grade 8,8, are used. To make the silos airtight and waterproof, special sealing elements are used on metal sheets on the silo frame and on the joints of upper roof. There are safe access doors that can be easily opened and closed on the second floors, and observation lids on the roofs of all OBIAL silos. The silo access door has two layers; the outer layer is made up of single piece of zinc-plated sheet, and the inner layer is made up of two doors placed one on top of the other. If the grain fill-level of the silo has gone up the access door on the silo side wall, the observation lid on the roof allows access into the silo. In all OBIAL silos, there are inner stairways to enter the silo, a safety cage external stairway to access silo observation lid on the outer surface of the silo, and a platform to rest. And there are double-railing and safety roof stairways on the roofs to be able to reach the top point of the silos starting from the eaves. OBIAL silo roofs are among the strongest silo roofs worldwide. OBIAL silo roofs are designed to resist the loads from upper roof conveyance equipment, snow loads, wind loads and the weight of temperature cables. The slope of the 30-degree silo roofs ensures an optimum fill level forth silos. To reinforce the strength and endurance of the upper roofs of wide grain silos, they are designed as cages using special cross-section profiles. The strength of the silo roof is maximized thanks to this architecture. The temperature command system used in OBIAL silos allows us to identify hot spots and insect activities, freeing our customers from reinstalling the grain conditions on the screen. The OBIAL temperature command system consists of temperature cables, temperature sensors installed inside the cables to measure the grain temperature, and portable or stationary temperature screens. There are special steel ropes inside the temperature cables, protecting the cables against elongation. The temperature command system is aligned with the PLC to allow for controlling the grain temperature inside the silos via the PLC screen.

OBIAL conical bottom grain storage steel silos can be used for multiple purposes. Conical bottom steel silos’ conical bottom angles are produced at 45-65 degrees according to the type and flow characteristics of grain to be stored. Conical bottom steel silos can especially be used in animal farms handling storage operations of various types of grains, and in facilities including feed and flour mills. They are also optimum for short-term and temporary grain storage. Side wall sheets, suspension supports and access doors of all OBIAL conical bottom silos are made up of zinc-plated steel sheet. Steel, due to its structural characteristics, is very resistant in conical bottoms. OBIAL offers you conical bottom steel silo options in various sizes and capacities from 2,11 m to 10,83 m.

OBIAL bucket elevators economically carry the grains vertically. The elevator system is designed for grains and is designed for the heaviest working conditions.

All OBIAL elevator systems consist of a column, drive unit cap, a tension unit, and zinc-plated sheet. Buckets used for vertical conveyance of grains are standard plastic, metal or zinc-plated metal buckets specifically produced by OBIAL.

Due to the water tight properties of the motor group (IP 55) located at the cap of the elevator system, it needs no cover. Drive from the motor to the reducer is through a V-belt pulley. The reducer is directly connected to the drive shaft. There are 2 observation lids at the cap of the drive unit, allowing easy Access and maintenance. The inner part of the cap is coated with rubber to make sure the grains are conveyed to the distributor with no damage. And the cylinder over the cap is rubber coated to prevent slipping of the belt and skidding.

There are 2 observation lids again for ease of access at the footing of the elevator system and 2 portable lids to make cleaning easier. The tensioning unit made up of zinc-coated sheet tensions the belt, which becomes loose during summer due to weather conditions and extended use, preventing it to perform less effectively. The lower cylinder consists of a steel cage to prevent the grains from being conveyed through the grain intake lid and the belt from being released.

OBIAL chain conveyors are available with capacity ranging from 45 up to 500 t/h.

OBIAL chain conveyors transport the grain horizontally or angularly, free of damage and in an economical way.

All OBIAL conveyor chains are extra hardened to operate under hard working conditions. Grain carrying scraper flights efficiently reduce the friction between the chain rails and the surface of conveyor box, they are made of plastic delrin material, connected by bolted system and assembled on the conveyor chain rails. Chains move easily inside the conveyor box on special delrin plastic bobbins which are located inside the conveyor and closely spaced. The chain conveyor sprockets are made of steel and extra-hardened by cementation. In comparison with welded conveyors which consist of one complete part, the repair, maintenance and assembly of the OBIAL conveyors are much easier because of the complete bolted system used.

Specially designed for intake pits, OBIAL chain conveyors handle the grain free of damage and with high performance.

 Belt Conveyor

Produced from Magnelis sheets, OBIAL multipath distributors are used in distributing the grains and are located under the upper cap of the elevator. Thanks to its insulated structure, it doesn’t permit release of dust. Screw assembly system is used on all joints of the distributor. The flow path of grains may be set as desired using a switch. OBIAL distributors are being produced with a capacity and strength to ensure problem-free operating in high-tonnage filling and discharge systems. The motors and sensors used on the distributor can easily be disassembled and replaced in case of any failure. The distributor frame also houses an observation lid to monitor the flow and to detect and remedy any failure and clogging in the distributor piping.

The lower discharge conveyor helps the grains in the silo Tobe conveyed out of the silo. Thanks to the lids over the conveyor system and the mechanism commanding these lids, the silo can be safely discharged. The command center first opens the central lid, not letting other lids to be opened. After the flow from the central lid ends, the other intermediate lids are opened. The conveying system is produced from zinc-plated sheets. The power is directly conveyed from the motor reducer to the drive shaft in the conveyor. This ensures a more efficient and safe operation of the conveyor.

And, OBIAL bottom cleaner conveyor discharges the grains remaining at the bottom of the silo by rotating 360 degrees around itself. The suspension bed system and the steel cage system are made by estimating the grain load falling on them. The drive and motion units are designed individually. This permits the maximum use of bottom cleaning conveyors.

Working Principle Fan aspirates air into combustion room through shutters and forms a controlled mixture with the gas coming from installation. This mixture is burned by the burner. The heat formed advances along combustion room with the help of burner fan and upper aspirating fan and passes through transition channel and is transmitted to air channels of product chamber. Thereby heat is transferred to product and some of heated air is extracted in a controlled manner and remaining heated air enters the system again and is mixed with the atmosphere air received from cooling shutters. Aires circulated along the system in order to reduce its humidity (saturation). Humidity of the product within this loop is reduced to desired humidity ratio and then product asses from unloading mechanism to hopper and exits the system. Grain which is equal to the amount of product leaving the system is added to system with the help of sensors. It is prevented that heat goes to flow pipe through transition connection by means of this adding process. 1.) It has galvanized and thoroughly fixed strong base structure.

General Specification

1.) It has galvanized and thoroughly fixed strong base structure.

2.) It allows to work easily under different products and product conditions thanks to grain intake system.

3.) Interior roof and supports ensure that humidified grain passes through chamber as granulated.

4.) Turbulent air circulation is avoided thanks to low static pressure and homogenous heat dissipation.

5.) In emergency situations, machine's burning system is closed thanks to heat sensors.

6.) Temperature values is increased to maximum value from nominal by means of air mixer.

7.) Burners keep temperatures needed fixed continuously.

8.) Burner system consists of Elster Krum Schröder or Dungs brand high-safe devices.

9.) Burner system is worked by using fuels like LPG, LNG (in gas phase) and NG

10.) Grain within chambers is kept under control with emergency unloading covers.

11.) Grain storing chamber is automatic controlled and it controls feeder elevator and provides electric saving.

12.) It keeps the product within chamber without loss thanks to unloading which is made invariable by pneumatic system and desired unloading time is adjusted by means of timing mechanism.

13.) It is ensured that fans are protected from external conditions with the fan shutters fixed by

pneumatic system.

14.) High capacity fans are covered by metal sheets, black sheets and coated with static paint and burners are covered with stainless and galvanized metal sheets. Doors and covers opened into these

sections allow easy intervention.

15.) Heat loss is reduced to minimum thanks to external heat-insulation.

16.) Whole heat flow, air flow and temperature values within the system are reached and adjusted

with the Siemens control panels (PLC).

World population has gradually increased and, as the result of this increase, cultivation areas of grain group which is one of the basic requirements of human have been expanded. As parallel with this expansion the grain group should be stored for short and long term. Since the grain group is not in pure situation within the place stored after harvesting, it should be cleaned from foreign matters i.e. from grass, stones and sands. While screening process made manually in sieves continued day after day in the past, the systems which sieve tons of grain per hour have been developed thanks to state-of- the-art technology nowadays. The name of this unit is pre-cleaning unit. Preclearing consists of 5 main components as of its general structure. Drum case, drum, upper chamber. It has high resistance against corrosion. 10,9quality class bolts have been used as fastening element. Bolts ant nuts are dacromate plated and have high yield strength. St 37 quality black sheet has been used for cyclone and its parts have been  joined by means of welding. In order to increase resistance against corrosion, 2 coats of primer have been applied and 1 coat of paint has been applied over primer.

 Product which enters hopper placed in upper chamber (aspirator) through the elevator which is the silo equipment is transported to rotary drum within the main case  While product is flowing into drum, dusts and substances lighter than air within product is drawn by radial fan mounted back of upper chamber and transmitted to cyclone mounted near the radial fan,   It is ensured that the product flows as horizontal by giving suitable inclination angle to rotary drum so that product sieving process will be carried out in rotary drum and the product is passed out in rotary drum and the product is passed through screens winded around rotary drum.  Intermediate chambers within main case avoid materials which are separated after being passed through screens from  mixing with the others and allow the materials to transfer into conveyor through bottom pouring compartments.

There are walkways and rest platforms on all OBIAL silos. The calculations of walkways are made in consideration of the clearance of support legs, load from the chain conveyors on them, wind load, snow load and other moving loads and produced accordingly. Assembled using screws, the modular system can easily be assembled, needing no maintenance since it is zincplated.

 All safety constructions can be custom produced as dyed orzinc-plated. All safety constructions are produced using angle iron and are fully joined using screw-type assembly, without any welding. The safety constructions also come with options including a service platform and stairs.

In order to safely command and control the machinery used in the system, OBIAL uses the MCC Boards and PLC-SCADA system produced by OBİ-Electrics. While MCC Boards are used in simple grain storage systems, OBIAL recommends PLC-SCADA systems in bigger and more complex systems.

While the MCC boards require the manual operation of the system, PLC-SCADA requires no expertise since it allows fully automated control. OBIAL prefers world-known and reliable high quality brands including Siemens,

Schneider Electrics (Telemecanique), and Phoenix Contact in switching materials for the command systems of both the PLC-SCADA and MCC boards. The PLC-SCADA command system supplied by OBIAL allows for controlling and managing the entire system from a single point. Thanks to the software custom-developed for grain storage systems, all potential errors of the operator are estimated in advance, making the system protected against human errors.

The operator is warned by the system to identify and remedy possible failures in running equipment and power boards with the exact position of the failure, allowing for immediate response.

The software shows the system’s actions so it becomes possible to respond to the system. The system is automatically interrupted and emergency stops are possible with Emergency buttons against potential dangers, which ensures maximized personnel safety. Since the system is operated in a certain order and by certain time intervals in conveying all types of grains, any potential failures otherwise (grain clogging the system and resulting physical breaks and failures in system elements caused by overload) are prevented at the onset. The ability to monitor and use the system, and detect failures over the internet saves time both on the customer and OBIAL side in solving the problem. The ability to control the command panel on 24V and the insulated structure of the command system and the power board prevents the system from damages in case of failure. With PLC-SCADA, only the motors needed for the intended work shall be operated, preventing unnecessary motor operation and saving energy. Since the switching materials used in the system are, as mentioned earlier, supplied by world brands allowing easy access to spares in any part of the world, potential failures in command systems can easily be remedied in a short time. The command system is designed with industrial and highly resistant products, which eliminate potential damages to the system caused by external factors including harsh operational conditions, humidity, high temperature etc.

Ventilation systems built according to the silo capacity and the characteristic of the grain to be stored are installed into the concrete during the laying of the foundation concrete. The secanals are coated using specially twisted and perforated Magnelis sheets specially designed for the product.

 OBIAL uses ALFAN branded radial and axial fans in varying capacities to ventilate the products stored in the silos of varying sizes and capacities.

 OBIAL ventilation chimneys allow for the easy discharge of dust formation and pesticides inside the silos. These chimneys are sloped, with wire curtains on their front surfaces. The securtains prevent birds and other foreign objects from penetrating into the silos. And thanks to its sloped structure, it prevents rain and snow to penetrate.

 Where more air outlet is needed, OBIAL produces ventilation fan with a wing diameter of 560 mm. This fan’s air suction direction contains a wire curtain, with the air outlet direction having a louvered structure. Louvers open during fan operation, and are designed so that they are shut when the fan stops.

 OBIAL also produces portable tunnel ventilation canals strengthened by corrugating and joining zinc-plated sheets to solve the ventilation problems in horizontal grain storages.