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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.
Ensuring a safe and controlled operation is critical in the challenging conditions of marine projects. Marine environments are corrosive and heavily influenced by currents and tides. Hence, it is paramount that all factors are considered before installation to ensure long-term performance.
This article discusses the reasons why the RUD TECDOS drive solution was ideal for the Brisbane River Ferry Terminals.
The Challenge: Decoupling Walkway in a Marine Environment
International Consulting Engineering company Aurecon approached RUD seeking a drive solution to decouple the Brisbane River Ferry Terminal walkways. The biggest challenge was enabling controlled release and rotation of the walkway undercurrents and tides and preventing damage caused by the ebb and recess of the water flow.
Why TECDOS? Addressing Key Requirements
RUD invited Aurecon to a site visit to the Brisbane factory to demonstrate and showcase the capabilities of the RUD TECDOS system.
RUD TECDOS possessed several benefits that aligned with the project's specific requirements:
Click for more details of TECDOS Pi-Gamma Drive and Omega Drive technology and why RUD is the world leader in drive technology based on the RUD round steel chain mechanism for horizontal, vertical and rotational applications.
The RUD Solution: A Controlled and Safe Decoupling Mechanism
The implemented solution leverages the TECDOS chain drive system to achieve a controlled and safe decoupling process:
The Result: A Proven and Replicable Solution
The success of the RUD TECDOS implementation at the Brisbane River Ferry Terminal is evident by:
Watch the video of the engineering and design from Aurecon, which ensured an ideal option to ensure the critical ferry infrastructure is flood resilient, accessible and for travellers to enjoy and celebrate the river.
Conclusion: Addressing Marine Challenges with Innovative Solutions
The RUD TECDOS system on the Brisbane River Ferry Terminal demonstrates its versatility and effectiveness in addressing complex challenges in the marine sector. Its corrosion resistance, 3D flexibility, compact design, and precisely rated load capacity make it an ideal solution for applications requiring controlled movement and reliable operation in challenging environments.
In addition, the system's modular design and proven track record across multiple installations highlight its potential for wider implementation within the conveying and drive sectors, where accurate control, corrosion resistance, and space optimisation are critical considerations.
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
Welcome aboard Australia’s leading material lifting and handling technology company.
Click the button to read about us, our products, news, blog posts and everything happening at RUD in Australia and around the world.
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:
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:
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:
Comments:
Technical Details:
| Specifications | Dimensions |
| Horizontal Conveying Length | 8.2 Metres. |
| Hopper Capacity | 24 m3. |
| Inclined Conveying Length | 7 Metres. |
| Horizontal Conveying Length - Top | 0.65 Metres. |
| Linear Speed | 0.1 m/s typical speed 0.2 m/s maximum. |
| Conveyed Material | 50mm average height of material, 900Kg/m³ average density, process 50T p/hr. |
| Chain Capacity | 566kN (break load). |
| Apron Pans | 89 pieces at 480 centres, each weighing 120kg. Minimum 1550mm wide. |
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.
Welcome aboard Australia’s leading material lifting and handling technology company.
Click the button to read about us, our products, news, blog posts and everything happening at RUD in Australia and around the world.
Welcome aboard Australia’s leading material lifting and handling technology company.
Click the button to read about us, our products, news, blog posts and everything happening at RUD in Australia and around the world.
