The Australian cement manufacturing industry relies heavily on efficient material handling for its complex processes, from raw material extraction to the final product. This article explores the crucial role of material conveying equipment in enhancing productivity, safety, and sustainability within Australian cement plants and highlights RUD Australia's tailored solutions.

Cement extraction is a complex process that requires efficient management of various raw materials. Given the logistics of manufacturing and the sheer volume and weight involved, material handling equipment is an essential component in any cement plant.

Since material handling equipment is used throughout the cement process, from extracting limestone to moving bulk clinker, proper use can enhance productivity and simplify operations.

As an innovative technological trendsetter, RUD provides a range of material handling solutions and equipment that can withstand the challenging conditions of the cement industry.

Significance of Material Handling Equipment in Cement Production:

Material conveying requires the safe and efficient transportation of raw materials (mainly limestone, gypsum, and fly ash) and bulk products (clinker). The right equipment can ensure safety, decrease downtime and ensure compliance with environmental and industrial standards.

Types of Material Handling Equipment for Cement Production

Bucket Elevators

Bucket Elevators transport bulk materials vertically, such as powdered lime scale or clinker. They also transfer, lift, convey, and store materials between different levels using less space and a large volume. Based on the application, a suitable (Chain or Belt) bucket elevator can be selected.

Benefits of Bucket Elevators:

• They can move bulk material vertically
• They keep the materials moving between the phases of production
• They are suitable for both powdery and fine granular material

Drag Chain Conveyors

Drag Chain Conveyors can transport a wide range of bulk materials. Their operation is based on the continuous movement of a chain placed in a rectangular section steel trough with a dust cover, coupled to a drive gear and sprockets/wheels. Although the material is usually dragged along the bottom of the trough by the lower section of the chain, it is also possible to convey material in the upper part. The drag chain conveyors from RUD are high quality, with sturdy construction, simple to set up for easy maintenance and reliable.

Benefits of Drag Chain Conveyors:

• Built to withstand heavy loads and rigorous operating conditions
• Can be tailored to specific application requirements, ensuring optimal performance
• Optimised power consumption to reduce operational costs
• Come with a closed dust dust-free operation which reduces pollution

Surface Feeders

Surface Feeders or Chain-Driven Belt Feeders are rubber belted pan feeders specially designed to convey materials discharged by trucks. These conveyors can receive a wide range of bulk materials, minimise spillage, and are suitable for quarries and terminals. They are available as a fixed or mobile option with dust covers.

Benefits of Surface Feeders:

• Can receive a rapid flow of material from tippers or trucks and convey them to a hauling and processing plant with a controlled and adjustable flow rate
• Since they only require a small ramp for the trucks, they are a lower investment compared to traditional feeders

Apron Feeders

Apron feeders consist of a chain equipped with interconnected pans moving at a controlled speed. They transport bulk materials like limestone, clay, and gypsum from storage bins or hoppers to crushers or other processes. Apron feeders are ideal for transporting large-sized, abrasive, and sticky materials, ensuring a steady and regulated flow of material throughout the production line.

Benefits of Apron Feeders:

• Apron feeders are built to withstand harsh conditions and heavy loads, ensuring long-lasting performance and minimal downtime
• They can handle a wide range of materials, including different particle sizes and moisture content
• Apron feeders provide precise control over the material flow rate, preventing bottlenecks and optimising production processes

Tips to Make Material Handling More Efficient in Cement Plants:

If your business involves large material handling equipment fitted with sensors, control systems, and automation technology, it may be possible to automate and operate the system ‘hands-off’, reducing labour costs while keeping production efficient. Modern bulk material handling equipment is designed to be energy-efficient, using electricity instead of fossil fuels.

Conclusion:

Effective material handling is crucial for the efficiency and success of cement manufacturing plants. RUD Australia can implement ideal bulk material handling solutions that facilitate production workflows, reduce operational costs, and improve safety levels.

As the cement manufacturing industry continues to grow and adapt in response to industry demands, there is a need to upgrade material handling equipment and improve the use of industrial material handling tools. Effective processing procedures are critical for efficient production which meets the standards required for safety and quality. From robust bucket elevators to reliable conveyor belt scrapers, RUD Australia offers innovative solutions that drive efficiency and sustainability.

Article copyright to RUD: This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.

Part 2 of the 2-part article. Click here to read Part 1.

Apron feeders are reliable and efficient solutions for material handling. Their robust construction, versatility, and ability to handle a wide range of materials make them indispensable for maximising productivity and minimising downtime.

Advantages of RUD Apron Conveyors:

RUD's apron feeders increase efficiency and effectiveness for bulk material handling in high-temperature and high-abrasive applications.

Flexibility:

• Low overall height of feeder for low clearance applications.
• The design allows horizontal conveying and bunker-loading functions with an inclined section in one process.
• Suitable for use as a feeder conveyor for a secondary crushing cycle or controlled product delivery.
• Unique plug-in apron design for easy installation
• Rollers can be located at the edge of the pans to reduce friction when required.

Durability:

• Robust, simple and wear-resistant.
• The absorption of higher bunker loads and impacts.
• Components are made from heat-treated, high-strength, wear-resistant components to extend service life.
• Highly wear-resistant chains and components.
• No lubrication of the chain is required.

Reliability:

• Overlapping apron plates even at deflection and inflection areas.
• Highly calibrated and matched drive components and apron plates with high tolerances ensure accurate alignment and efficient movement of components and materials.

Market Growth and Future Trends:

The global apron feeder market is expected to grow significantly in the coming years, fuelled by increasing demand in many industries.

The demand for efficient and reliable material handling solutions, particularly in industries like mining and construction, is driving this growth. As the need for sustainable and environmentally friendly material handling practices increases, apron feeders are well-positioned to meet these demands with their inherent efficiency and low spillage characteristics.

Conclusion:

Apron feeders are a testament to engineering ingenuity. They combine robust construction with precise control for efficient and reliable material handling. Their versatility, durability, and low-maintenance characteristics make them a crucial component in various industries worldwide. As demand for sustainable and efficient material handling solutions grows, apron feeders will continue to play an essential role in driving innovation and productivity in the future.

References:

• Market Research Future (MRFR): https://www.marketresearchfuture.com/reports/apron-feeder-market-4708
• **ASME: ** https://www.asme.org/
• Mining Technology: https://www.mining-technology.com/
• Powder & Bulk Solids: https://www.powderbulksolids.com/
• Conveyor & Bulk Handling: https://www.conveyorbulkhandling.com/

If you want more details of our conveyor and drive systems, email us or call us on 07 3809 1300.

Article copyright to RUD Australia. This information is sourced from several references and is accurate at the time of publication. RUD Australia takes no responsibility for any errors, inadvertent or otherwise. Some pictures may be shown for illustration only.

This is a 2 part article.

Apron feeders are crucial components of material handling in many industries. Their robust construction and precise control capabilities make them uniquely suited for transporting challenging materials, such as high-temperature materials, in demanding environments.

Understanding the Mechanics of Apron Feeders:

Apron feeders are conveyors in which material is carried on overlapping steel plates, known as "aprons," that travel over sprockets, rollers, and gears. These components are fabricated from high-strength steel and designed to withstand significant wear and tear. Motors and gearboxes power the feeder, enabling controlled movement of the aprons and the material they carry. RUD apron feeders are connected by conveyor chains driven by a calibrated toothed pocket wheel.

The overlapping design of the plates is critical because it ensures smooth and consistent material flow while eliminating spillage. This feature makes apron feeders ideal for handling materials that are difficult to transport, such as:

• Abrasive materials: Sand, gravel, crushed rock, and similar materials that can damage conventional conveyor systems.
• Sticky materials: Clay, cement, and other materials with high viscosity that tend to cling to surfaces.
• Hot materials: Molten metals, slag, and other materials requiring heat-resistant components.
• Lumpy materials: Coal, ore, and other materials with irregular shapes and sizes can clog conventional conveyors.

Advantages of Apron Feeders:

The unique design and construction of apron feeders offer several advantages, cementing their position as the preferred solution for material handling in various industries.

The benefits of apron feeders are:

• Precise Control: Apron feeders allow operators to precisely adjust material flow rate, ensuring efficient production and minimising waste.
• Minimal Spillage and Dust: The overlapping aprons effectively contain material, significantly reducing spillage and dust generation, improving worker safety and minimising environmental impact.
• Exceptional Durability and Low Maintenance: Apron feeders are built to last, with high-strength components capable of handling heavy loads and harsh conditions. This translates to minimal downtime and reduced maintenance costs.
• Adaptability: The design can be customised with different apron widths, lengths, and materials to cater to specific application requirements. This adaptability allows for effective handling of various material types and volumes.
• Preserving the Material: Apron feeders minimise material degradation when moving products.

Applications of Apron Feeders:

Apron feeders play an important role in many industries, such as:

• Mining: Transporting the ore, coal, and other minerals from the site to the processing plant.
• Cement and Aggregates: Handling raw materials like limestone, clay, and sand in cement plants.
• Power Plants: Transporting coal and other fuel sources to boilers.
• Metal and Steel: Moving raw materials and finished products in production.

Apron feeders are reliable and efficient solutions for material handling. Their robust construction, versatility, and ability to handle a wide range of materials make them indispensable for maximising productivity and minimising downtime.

To be continued ...

If you want more details of our conveyor and drive systems, email us or call us on 07 3809 1300.

Article copyright to RUD Australia. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise. Some pictures are for illustration only.

RUD’s apron conveyors are suitable for a wide range of applications, such as high-temperature materials, waste, aggregate, dry ash handling, mineral processing, and kiln applications.

RUD apron feeders increase the efficiency of bulk material handling in high-temperature and high-abrasive applications. They are extremely versatile and can convey bulk materials without causing spillage or degradation.

The advantages of a RUD Apron Feeder Conveyor are:

• Simple, robust construction with high strength, Quenched & Tempered plates.
• Permanently closed apron surface throughout the entire life cycle.
• Lower overall heights due to small chain Drive & Tail end wheel diameters.
• Highly efficient because all drive components are accurately calibrated.
• Sealed conveyor systems.

Project:

RUD Australia was tasked to design, build and install an apron feeder conveyor for an automotive recycling operation. The scope of the project was to offer a complete solution to solve issues around moving shredded auto parts.

Challenges:

The outdated handling process had individual aprons with rollers installed that required constant maintenance. The goal was to increase production and reliability while minimising maintenance and unplanned shutdowns.

Available data at the engagement stage:

• Collection of 24 cubic metres of recycled nonferrous material in a hopper.
• Providing a dump station for a WA500 wheel loader with a 3-bucket storage system.
• Transport the material over an inclined 70-degree slope as a tumble-back system.
• Provide a controlled feed rate into a post-process trommel and sorting equipment as the primary input conveyor system.

The RUD Solution:

RUD designed, manufactured and commissioned a workable solution as part of the improvement project. The RUD-engineered round steel chains proved to be a successful improvement over the plate and bushing pin-type chains.

The Result:

• 90 metres of 30 x 120 R100 Premium RUD Chain, PCD 614mm hubs and teeth on the drive and reversing tensioner wheel.
• 89 opposing type MEE-T attachments.
• RUD Australia designed and manufactured all rollers, frames and wear rails.
• RUD supplied a complete spare parts package with the commissioned system.

Comments:

• The fully commissioned technical and commercial reports were signed off as part of acceptance.
• This complete Apron Feeder system was manufactured in Brisbane.
• RUD Australia provided all Operating & Maintenance guidelines.

Technical Details:

If you want to know how the team at RUD can help you, please call us on 07 3809 1300 or fill out an enquiry form here.