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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:

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:

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 terminalsThey are available as a fixed or mobile option with dust covers.

Benefits of Surface 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:

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.

In the realm of industrial applications, the RUD Forked Link Chains stand out as a robust and versatile solution. Engineered with precision, this forged chain link system is designed to enhance operational efficiency, reduce maintenance costs, and ensure smooth operations across various industries.

Understanding the RUD Forky

The RUD Forky is crafted from drop-forged material, ensuring exceptional strength and durability. RUD's unique heat treatment process guarantees consistent material quality, making the Forky a reliable choice for demanding industrial environments. The chain's optimised grain structure further enhances its resilience and performance.

One of the standout features of the RUD Forky is its sophisticated wear indicator. This visible indicator allows easy monitoring of chain wear, enabling proactive maintenance and reducing the risk of unexpected breakdowns. This feature ensures operational continuity and significant cost savings.

Why does the RUD Forky stand out?

Why is it a Good Decision to choose the Forky?

Choosing the RUD Forky is a good decision for the following reasons:

Applications of the RUD Forky

Forked-link chains are suitable for transporting powdered, flaky, grainy, and fragmentary bulk materials but not sticky bulk materials. The RUD Forky is suitable for a variety of industries, including paper production, construction, woodworking, food and feed production, plastics, mills, chemical industries, agriculture, ports and cargo handling, and recycling.

The RUD Forky is a strategic decision for any business aiming to enhance efficiency, reduce costs, and ensure smooth operations. Its robust construction, intelligent design, and versatile applications make it an asset in modern industrial settings. By minimising downtime and maintenance costs, the RUD Forky offers a reliable and cost-effective solution for various industrial applications.

Forky comes in 2 strand variants:

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.

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

Western Australia's maritime industry faces unique challenges, particularly with vessel access due to the region’s extremely high tidal ranges, which can reach up to 11 meters. These high tides complicate the boarding process from jack-up barges or jetties, posing safety risks to personnel and impacting operational efficiency. Traditional methods of vessel access often prove inadequate and potentially unsafe in these demanding environments.

This is why the RUD TECDOS system is recommended as an ideal solution.

Exceptional durability:

The extreme conditions of Western Australia's coastal waters require equipment designed for exceptional durability and reliability. The RUD TECDOS system is ideal because it is resistant to corrosion and engineered for long exposure to seawater, contamination, and environmental wear and tear arising from the constant buffeting of waves. TECDOS systems ensure long-lasting performance even in the most challenging environments.

Compact and easy to install:

A key advantage of the RUD TECDOS system is its compact design and simple installation process. This minimises disruption to ongoing operations and reduces the time required to integrate the access system into existing infrastructure. Reduced installation time minimises operational downtime and maximises project efficiency. 

Tolerance to misalignment:

The TECDOS system is tolerant of misalignment. Currents, wave action, and the limitations of floating platforms can affect vessel positioning and alignment. The TECDOS system delivers reliable performance even when equipment is shifted or not perfectly aligned. 

The RUD TECDOS system offers a comprehensive approach to vessel access challenges in harsh marine environments. By combining exceptional durability, compact design, and adaptability to misalignment, the system empowers marine operators to navigate the complex tidal conditions of Western Australia.

By leveraging RUD TECDOS, marine operators can enhance safety, streamline operations, and ensure reliable vessel access, thereby mitigating risks and maximising efficiency.

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.

If you want to know how the team at RUD can help you, please call 07 3809 1300 or fill out a 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.

Click here to read

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.

Click here to read

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:

Durability:

Reliability:

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:

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:

Applications of Apron Feeders:

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

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.

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.

Click here to read

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.

Click here to read

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.

Click here to read

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.

Click here to read

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