Efficient vertical transport systems are crucial for industries that manage bulk materials such as agriculture, mining, and cement production. RUD Bucket Elevators are ideal and reliable vertical conveying systems to move materials safely and effectively with a low maintenance cost.
This article explains the benefits and applications of bucket elevators and the manufacturers across various industries. We also discuss how RUD can help choose the most appropriate bucket elevator suited to your requirements.
Types of Bucket Elevators
Bucket elevators come in two types: Chain and Belt. They transport bulk materials such as raw meal, dry dust, cement, etc., at various temperatures. The buckets are fixed to a chain or belt, conveying materials from the loading point to the discharge point in a vertical configuration. The system is enclosed, minimising material spillage and dust generation. The bucket elevator casings are self-supporting but require horizontal guides at least every 15 meters and below the elevator head.
Benefits of Bucket Elevators
Vertical Conveyance: RUD bucket elevators move large volumes of bulk materials vertically. This is beneficial to grain storage companies because the grains can be moved into silos without compromising the speed or capacity. Similarly, in mining, RUD elevators ensure the smooth movement of crushed ore through processing equipment
Strength and Durability: RUD bucket elevators are manufactured from wear-resistant components. In chain bucket elevators, chains provide the required strength to handle heavy and abrasive materials at higher temperatures. Whether moving crushed stones, ores, or coal in mining, or transferring grains or raw materials in cement plants, chain bucket elevators are built to withstand extreme conditions with minimal downtime. Textile or steel reinforced belt bucket elevators are ideal to transport free-flowing bulk materials, dust-free, in a continuous vertical conveyance to significant heights
Reduced Maintenance and Operational Costs: RUD bucket elevators can operate at peak efficiency with minimal maintenance and downtime. Chain elevators are inherently hard-wearing and resistant to wear and mechanical damage. Their unique design requires minimal lubrication and virtually no maintenance, leading to lower operating costs, reduced downtime, and extended system life. This cost-effectiveness is critical in industries like gas and cement manufacturing, where continuous production is required
Versatile Applications: RUD Bucket elevators can be adapted across numerous industries, including:
- Chemical Industries: Safely convey fine powders and acidic substances without contamination or product damage
- Agriculture: Transport seeds, grains, and fertilisers to storage silos or processing units
- Mining: Convey heavy and coarse materials like rocks, coal, and ores
- Cement: Move raw materials like limestone and finished cement within the plant
This versatility makes RUD bucket elevators an essential equipment for which bulk material handling is a priority.
Improved Safety and Environmental Protection: Safety and environmental factors are critical in the cement and mining industries, where dust poses health or contamination risks. With their enclosed structure, RUD bucket elevators minimise material spillage and dust emissions. Additional safety features, such as speed governors, overload protection and emergency stop functions, further ensure employee safety
Selecting a Bucket Elevator Manufacturer
Choosing the proper manufacturer is crucial for ensuring the long-term reliability of your material handling system.
What should you consider when choosing a bucket elevator?
- Material Strength: RUD can select the best-suited bucket elevator system for your application, which withstands the challenges of vertical transport in extreme conditions
- Customisation: RUD bucket elevators can be customised to meet the specific needs of different industries
- After-sales Support: RUD offers technical support and spare parts across Australia, which are essential for minimising downtime and ensuring long-term system reliability
Conclusion
RUD bucket elevators are robust and efficient solutions for vertical conveying of bulk materials. By selecting RUD, you can ensure improved productivity, reduced downtime, and streamlined material handling processes.
Interested in our bulk-material conveying solutions? Call us on 07 3809 1300 or enquire here.
Copyright to RUD: This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.
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.
RUD Australia celebrated 40 years in November 2024. From humble beginnings in 1984 in a garage on the south side of Brisbane to a 6000m2 facility in Larapinta QLD, including an office and warehouse in Perth, we have come a long way as one of the most trusted companies in the lifting, lashing and material handling industry.
Our journey continues:
- 1984 - Jonathan Street - RUD Australia started in November 1984 in Peter Nuttall Senior’s garage in Macgregor, Brisbane.
- 1991 - Success Street - RUD Australia built a 1500m2 facility at Success Street in Acacia Ridge.
- 2005 - West Link Place - RUD Australia moved into a 3000m2 facility at West Link Place, Richlands.
- 2008 - Bassendean, Perth - We expanded into Bassendean, Perth, with an office and warehouse to service the growing WA market.
- 2013 - Commerce Place - In 2013, we invested significantly in our long-term future with a 6000m2 facility that currently includes our head office, engineering, warehouse, and fabrication divisions.
We celebrated our 40th anniversary with a gala dinner event in Brisbane. The evening was filled with fun, entertainment, camaraderie and speeches, going down memory lane of the 40-year journey.
With a 40-year history in Australia, RUD is committed to excellence in chain technology. We strive to be at the forefront of technology and innovation, such as our latest 9-axis robotic welder, which will drive our growth through continuous improvement for the future.
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:
- Low chain hardness: Forged chain links were wearing faster due to lower hardness.
- Small wheel diameter: The small wheels did not fit the chain size, accelerating wear in the interlink area.
- Single-link contact: Each wheel rotated and pivoted the bucket on a single link, concentrating the centrifugal load and causing high interlink wear.
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:
- High temperature - Resulting in the tempering of the forged shackles.
- Head wheels getting worn - Because they were non-hardened.
- High link wear due to the small diameter of the wheels and single link contact.
- Noisier operation due to chain and shackles not being matched. For example, an 18mm chain was used for a 20mm shackle.
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:
- Limited availability: The original 20mm shackles required frequent replacement and became difficult to source globally.
- Proven quality: RUD's German-made components ensured reliability.
- Enhanced chain performance: The 19x75 chain spacing offered improved pitch length and higher hardness (82hV, a 10% increase).
- Superior hardening: Continuous chain case hardening provided significant advantages over existing chain hardness.
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.
- Increased Efficiency - Ultra-hardened chain R100 chain systems handle larger capacities and process more material.
- Easy Adaptability - Perfect for a lump or granular material.
- Durability - German-engineered with long-lasting hardened steel chains and components ensure reliable operation.
- Simplified Maintenance - Easy access casings facilitate fast replacement of teeth, treads, and wheel segments.
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.
