Cement Terminal Barge Unloader Crossover Valves
Industry: Cement Manufacturing / Bulk Material Handling
Application: Barge Unloader Crossover Valves Feeding Multiple Silos
The Challenge
Bulk cement terminals operate in one of the most abrasive and unforgiving material-handling environments. During continuous barge unloading, the customer relied on manual spectacle blind valves to isolate and route cement flow between silos.
This approach created multiple operational challenges:
- Long changeover times — over 20 minutes per valve operation
- Frequent cycling — approximately 3 cycles per day with abrasive cement powder
- Increased safety exposure — manual intervention during isolation
- High maintenance burden — cement packing, wear, and frequent adjustments
- Lost throughput — downtime directly impacting unloading efficiency
Manual blinds and conventional valves were no longer aligned with the terminal’s safety, reliability, and productivity goals.
The Everlasting Solution
Everlasting Valve replaced manual line blinds with automated Bulk Material Rotating Disc Valves (BMV Series), engineered specifically for abrasive powder service and continuous cycling applications.
Working closely with the customer, Everlasting application engineers designed a customized solution featuring:
- Pneumatic actuation for rapid, reliable switching
- Double-disc sealing design providing leak-free, bi-directional isolation
- Carbon steel valve body with 440 stainless steel discs and seats for superior abrasion resistance
- Self-lapping rotating disc technology that prevents material packing
- Fully automated operation, eliminating the need for on-site manual intervention
The result was a safer, faster, and far more reliable crossover valve solution during continuous barge unloading operations.
Value Delivered
By replacing manual blinds with Everlasting’s severe-service valve design, the cement terminal achieved measurable improvements:
- Eliminated manual line blinding and safety exposure
- Reduced unloading downtime and labor requirements
- Improved silo routing flexibility
- Lowered maintenance costs in abrasive cement service
- Increased terminal throughput and operational reliability
Total Cost of Ownership (TCO) Impact
Conventional Valves
- Long manual switching increases labor cost
- Accelerated wear from abrasive cement
- Frequent maintenance and adjustment
- Higher downtime and throughput loss over time
Everlasting Bulk Material Valves
- Rapid pneumatic switching minimizes delays
- Abrasion-resistant materials extend service life
- Minimal maintenance under daily cycling
- Lower lifetime cost despite higher initial investment
TCO Result:
Faster operations, fewer interventions, and extended service life resulted in a lower total cost of ownership over the life of the terminal
Application Specifications
| Specification | Description |
| Industry | Cement Manufacturing / Bulk Material Handling |
| Application | Barge Unloader Crossover Valves Feeding Multiple Silos |
| Process Media | Portland Cement Powder / Calcium Silicate (~200 mesh) |
| Valve Type | Everlasting Bulk Material Rotating Disc Valve (BMV Series) |
| Size | 10-inch |
| Pressure Rating | 100 PSIG |
| Actuation | Pneumatic |
| Cycle Rate | ~3 cycles/day |
The Everlasting Difference
Everlasting valves are engineered to wear in, not wear out®. In abrasive bulk material applications where conventional valves fail, Everlasting delivers safer operation, higher reliability, and unmatched lifecycle value.
If your bulk material handling process relies on manual blinds or valves that pack with powder, Everlasting provides a proven, severe-service solution – we are here to help.
Download Application Data Sheet