Cement asphalt plants use bucket elevators to move the material to the plant mixing tower. Bucket elevators used in asphalt plants should withstand high material temperatures (frequently reaching 180-200°C) and operate at high capacity (e.g. up to 100-200 tonne/hour).
An asphalt plant in South Australia had operational capacity problems and frequent DIN bracket-type bucket elevator system breakage. The plant was only producing 85,000t annually, which was quite low compared to the standard 100t per hour over a 2,000-hour system life (200,000t per year). In addition, they experienced significant downtime due to replacing the chains and brackets every 8-12 months, negatively impacting their efficiency and throughput.
The Challenges with the Current System
The current system had a few shortcomings, such as:
In comparison to the short life of the DIN system, RUD endless chains only need to be replaced after producing approximately 200,000t. The bucket attachments, however, can be replaced after approximately 400,000t, which was a huge advantage to the plant. The RUD system is superior, with endless chains and bucket attachments, doubling the chain life and increasing component life by four times.
Description of the problem:
The chain contact with the DIN shackles was wearing out faster in the interlink area because it had lower hardness. The wheel diameter was also too small for optimal chain life. All the centrifugal load was applied on the bucket shackle as it moved around the wheel, resulting in higher interlink wear.
Some of the issues the plant was facing were:
Why did the client approach RUD?
Most bulk material handling sites in Australia using the DIN shackle system are gradually being replaced with the RUD 2WIN solution. The 2WIN system has a 3-link interlink contact, which makes conveyors more stable and provides longer component life.
The client was aware that RUD had successfully completed many upgrades of 2WIN conversions, so they invited RUD to propose a full conversion plan.
Some of the reasons for approaching RUD were:
The RUD Solution:
RUD implemented the 2WIN solution with a 3-link contact with the 19x75 chain, making the conveyor stable even on smaller-diameter wheels. This included replacing the treads with hardened wheels which fitted the existing casings. The treads were a bolt-on design for easy installation and replacement when required. The added benefit was that the capacity could be maintained or even increased with bucket spacing on a 19x75 chain.
RUD bucket elevator systems offer a range of proven, high capacity and flexible solutions for all vertical handling applications. The hardened steel chain systems support large capacity conveying, providing maximum throughput.
The Result:
Regular chain wear measurements will be monitored with a service and support plan to maximise chain life and performance. We use predictable life projections for scheduled maintenance to avoid unplanned downtime. Most of our component kits are planned and delivered well before a shutdown. Backup kits are supplied before planned outages to avoid unscheduled downtime.
A Win-Win Situation
The RUD 2WIN system ensures efficient operation in the demanding hot asphalt environment for many years. The 2WIN attachment, fixed on the bucket, distributes load, and extends the bucket lifespan. Additionally, these attachments are replaced only with every second chain change, maximising efficiency. Full tensioner wheel contact minimises tread wear and extends chain life. The hardened RUD components are superior to the previous wheel, and the treads only require changing every second chain set.
This upgrade with the 2WIN system is a WIN-WIN for both RUD and the client.
If you want more details of our conveyor and drive systems, email us or call us on 07 3809 1300.
Article copyright to RUD Ketten and 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.
A Tyre Protection Chain is ideal for creating a barrier between the tyres and the ground surface. TPCs provide maximum protection to sidewalls and tread areas, virtually eliminating tyre failures from rock cuts and staking. This guarantees maximum production from the loader and peace of mind with unplanned tyre maintenance expenses.
The Problem
Australian hard rock quarries have some of the most challenging environments in the world for rubber tyred machines. Boral Quarries' West Burleigh site has been providing road base and other quality aggregates into the Gold Coast and surrounding areas for many years. Maintaining uninterrupted supply is essential to the area’s economic growth and their rubber tyred CAT988G loader is a major asset in the quarrying process. Unplanned tyre failure can cause havoc to production schedules and require expensive and ‘hard to get’ replacement tyres.
The Solution
RUD Chains have been providing TPCs to West Burleigh for over a decade and have fitted a further four chains to their CAT988G wheel loader. The FELS Gigant Plus X19 close mesh ‘extra heavy duty’ Tyre Protection Chain has been proven in Australia and around the world as the best-performing chain for hard rock quarry applications.
More on the Gigant Plus X19
The Benefit
RUD’s Gigant Plus X19 provides maximum protection to sidewalls and tread areas, virtually eliminating tyre failures from rock cuts and staking. West Burleigh Quarry can now be confident that they will achieve maximum production from the loader and avoid unplanned tyre expenses.
West Burleigh quarry’s traction and fuel usage has improved, and tyre replacement has been reduced by up to 6 times.
What the customer says
“We see our long-term relationship with RUD Chains more as a partnership than supplier and customer. RUD’s product keeps our tyre costs down - a major expense for any quarry operation. With guaranteed production, our return on investment for the chains is exceptional.”
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. Some pictures are for illustration only. For more details on how RUD can help with your crane requirements, please call us on 07 3809 1300 or fill out an enquiry form here.
Sources:
