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:
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.
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.
