bucket elevator belt installation

belt and bucket elevator rgel | grain conveyors | bhler group

This elevator features round bolts. These are intended to reduce residue between the buckets and the bottom of the elevator. The casing also has a rounded shape to prevent dust settling on the machine.

This elevator features round bolts. These are intended to reduce residue between the buckets and the bottom of the elevator. The casing also has a rounded shape to prevent dust settling on the machine.

The belt and bucket elevator RGEL has an integrated speed and belt skew monitor to track performance. It also comes with a temperature monitor for the bearings which will stop the conveyor if a bearing overheats.

The elevator is designed in modules. This allows you to choose between a wide range of options to perfectly match your terminal, silo, or processing plant. Special attention was paid to design a particularly compact housing to facilitate shipping.

Billions of people come into contact with Bhler technologies to cover their basic needs for food and mobility every day. Our motto is creating innovations for a better world. Find out more about our key topics.

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considerations in replacing a bucket elevator

When it comes to vertically conveying bulk solids, the bucket elevator is unmatched in its capabilities. This diverse, high-capacity machine has become an essential tool at plants handling everything from fertilizers and minerals, to specialty chemicals and aggregates.

The criticality of the bucket elevator is such that when it comes time to replace it, special considerations and precautions must be taken in order to minimize downtime and ensure the best elevating solution is reached.

A wide variety of issues may cause a bucket elevator to operate poorly or below its rated capacity. This might include such things as worn or deformed buckets, slippage of belt on pulleys, improper filing of buckets, and more.

Additionally, many bucket elevators perform inadequately because of their design. Not all elevators are created equal and some designs simply outperform others. Further, the diverse handling characteristics of different materials demand a customized handling solution in most cases. Elevators designed based on a one-size-fits-all approach are often riddled with problems and increased downtime because they were not designed to work with the specific requirements of the material being handled.

Similarly, problems can also result if a significant change in feedstock occurs. Well-designed elevators can quickly become problematic when feedstock parameters change. Some adjustments, like changing belt/chain speed, or switching bucket style or spacing, may be able to resolve the issues, but in some cases, replacement may be necessary, depending on the level of change encountered. In any case, when a change in feedstock occurs, bucket elevator design should be reassessed to ensure optimal performance.

Unless planned for at the time of construction, plants requiring additional capacity usually have to replace their bucket elevator to accommodate the added load. Bucket elevators are available in a wide range of capacities for use in nearly any setting, making the upgrading process fairly straightforward. Elevators may also be over-designed for anticipated operational growth in the future.

A worn or damaged bucket elevator is one of the most common reasons for replacement. Damage may be due to a corrosive material, inadequate or improper maintenance, old age, or a number of other factors.

If at any point a bucket elevator becomes a safety hazard or the structural integrity of the casing has been compromised, and the issue cannot be resolved through repairs, the elevator must be replaced.

As an arterial component of most operations, an out-of-commission bucket elevator can hold an entire operation hostage. To avoid a catastrophic failure during the production schedule, bucket elevators should be preemptively replaced before they have a chance to break down.

Since bucket elevators are a very custom component, replacement can take up to a few months. Preventative replacement will minimize the amount of downtime required for replacement and also avoid the problems associated with an unanticipated outage.

Choosing a new manufacturer for the unit may or may not be necessary. In the case that the original equipment manufacturer (OEM) is no longer in business, or when the OEM did not provide adequate quality or support, there may be a need to select a new OEM. There are many things to factor in to the selection of a bucket elevator manufacturer.

Keep in mind that most OEMs use the same vendors and offer similar casings and sizes, but every OEM has different fabrication designs, shop practices, and standards that can make the difference in the end product. This might include using different casing thicknesses, chain recommendations, take-up seal and design, instrumentation, sprocket vs. traction wheel in the boot, and so forth.

Facilities with the potential for operation growth should consider future capacity needs. As mentioned, elevators can accommodate a larger capacity in the future by designing for the greater needs and running at a reduced capacity in the interim to avoid having to replace the elevator more than once.

Every bucket elevator installation is unique. Because of this, the process of replacing a bucket elevator can vary significantly from one job to the next. To minimize downtime, replacement is best coordinated with a planned outage. Further planning varies widely across each application, with considerations such as foundation requirements, removal of structural steel, additional equipment replacements, and more coming into play.

The chosen manufacturer will require a broad range of data. If only a duplicate unit is desired (with little-to-no required change), and the original manufacturer will be used, this process is fairly simple. In this case, the process may only require reviewing the original drawings to confirm the specifications are still a fit.

In other cases, the bucket elevator manufacturer will require a variety of different data points in order to properly size and spec a replacement elevator. Some of the key data points required include:

The manufacturer will likely make a site visit to verify dimensions before the engineering begins, particularly when tight clearances are involved or the elevator will be passing through several floors of the building. Alternately, detailed drawings may suffice in some cases.

As a critical component in any production setting, replacing a worn out or inefficient bucket elevator requires careful attention to detail. While every installation is unique, considerations such as preventative replacement, improvement of the existing design, and manufacturer selection should all be taken into account.

FEECO is a leading provider of custom bucket elevators and complete bulk material handling systems. All FEECO handling equipment is engineered around the characteristics of the material to be handled and the unique process specifications to ensure an optimal handling solution. All equipment is manufactured to the highest quality standards for a long life of reliable performance. For more information on our bucket elevators, contact us today!

bukcet elevator conveyor belt monster belting

Bucket elevator conveyor belt is been used in sand, gravel, stone industry, cement, concrete plant, heating station, power station, waste incineration station, and asphalt mixing plant etc. We are high-temperature bucket elevator belt manufacturers, heat-resistant temperature can reach 300 degrees, this in the country has not been able to reach this temperature peer.

The core of the core is interwoven by a plurality of layers, and the skeleton cloth having the same cross-section as the multilayer structure of the rubber belt is stretched or compressed, the force is uniform, and no surface peeling and interlayer peeling are used. Ensure better tracking and not easy to get out of the barrel. The integral core is plasticized after dip-molding, and the whole core is compacted to ensure its excellent lifting capacity. At the same time, the tear-proof and anti-screw pull performance is better, and the bucket and the lifting belt can be connected more firmly.

For high performance elevators such as in the cement industry, steel cord conveyor belts are used in diverse designs. It is generally using heat and ageing resistant rubber compounds for their steel cord elevator belts. Special designs according to customers specifications may be realized at any time. The elevator belts can be delivered ready-to-install including mechanical fasteners, bucket protection sheets as well as punched holes for bucket installation.

Elevator belts optimize transportation in limited spaces. Our elevator belts with EP-layers are produced according to strict regulations of the DIN22102 and DIN22104 standards. Elevator belts are highly qualified for upright conveyance of bulk material. Special designs according to customers specifications may be realized at any time. The elevator belts can be delivered ready-to-install including mechanical fasteners, bucket protection sheets as well as punched holes for bucket installation.

The demand side should provide with hole diameter, spacingdetails and exact data when you need bore holes on the belt as the graph below.Of course the demand side also can provide with samples if it is convenient for you. And the samples should be some metal sheets or other materials that are not easily deformed and not influence the exact hole diameter. We need at least three sets and the hole spacing deviation at 1mm. At the same time the hold should be as smooth as possible.

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Monster Belting is the custom belt fabricator. Our belts are ideal for bulk handling a wide range of heavy and abrasive materials successfully catering to various industries, stone crushing & screening, sand washing, chemical fertilizer and many more. Welcome to Online communication.

bucket elevator belts | features & benefits

One common method of elevating elevator buckets is attaching them to a belt. Belt is available in a variety of materials, cover thicknesses and grades selected to meet the specification application. Belt-type bucket elevators can utilize a PVC belt, common in the feed and grain industries, or a rubber belt for the heavy-duty industrial applications.

KWS Manufacturings belt-type bucket elevators include a heavy-duty, abrasion resistant black Styrene Butadiene Rubber (SBR) belt with covers on both sides. The SBR compound is a synthetic rubber that offers superior abrasion and cracking resistance. The belt has a working temperature of -20F to 225F with heat resistant (HR) belt up to 400F also available. Other belts available include Moderate Oil Resistance (MOR), Mine Safety Health Act (MSHA) approved and Static Conductive (SC) for various applications.

There are various methods and fasteners used to splice or join the two ends of the belt. KWS standard method is the mechanical splice. This clamping style splice minimizes the stresses on the outer plies of the belt that occur as the belt passes around the head and tail pulleys. These splices install and can be removed easily for elevator maintenance.

KWS utilizes a minimum 2 ply 220 PIW with 3/16 thick top cover and a minimum 1/16 thick bottom cover to provide smooth contact surfaces resulting in a long wearing, mildew and rot resistant, low stretch belt.

tracking belts on bucket elevators and short belt conveyors

Tracking belts on bucket elevators and short belt conveyors. Flexible, flat belts are used on bucket elevators and belt conveyors to carry loose, bulk product. The belt is stretched tight from head drum to tail drum and the friction generated on the turning head drum is used to drive the belt and carry the product. The belt must run true on the end pulleys (drums) and stay within the sides of the equipment structure. If the belt runs off the drums, buckets will be destroyed and belt edges frayed. In the worst cases the belt runs off the pulleys resulting in a breakdown repair. Proper and long- lived tracking of belts is critical for trouble-free operation.

The head and tail drums on belt bucket elevators and short conveyors are usually steel cylinders. A shaft is mounted thorough them at the center and extending outward long enough to mount bearings on both sides. Often the shell is steel pressure pipe and the ends are cut from flat plate and welded in place. The shaft can be welded into the end plates, but for easy repair, it is best mounted in taper lock hubs that are welded to the end plates and the shaft clamped into them. The shell length is usually 25 40 mm (1 1-1/2) longer than the belt width

On belt bucket elevators carrying powdered or dusty product the shell on the bottom pulley can be replaced with round bars spaced around the end plates so that the gap between them and the edge of the belt allows the product to fall out and the pulley self-cleans.

To insure the belt runs centrally the two pulleys must be in- line center to center. This is done with a string line stretched from the mid-point on both drums. The distance from a straight edge datum on the support structure is measured and the position of the shaft on the bearings adjusted until the string lines up with the datum straight edge.

The head and tail pulley axes are also initially aligned parallel to each other and in the same plane. Once the drum centers are inline, the centerline distance shaft to shaft on both sides is measured from a datum line on the support structure. Bring the drums as close together as possible so that the belt can be later stretched. Once the drums are aligned both horizontally and axially the belt is fitted on the pulleys.

Belts for short conveyors are usually purchased with the ends joined and are slipped into place over the pulleys. A splice at 45o to the belt running direction and not square is preferred. This allows the edge to lead into the scrapper and lessens the chance of the join catching and ripped.

The belt for belt bucket elevators can be supplied either with buckets already mounted or without. Once the buckets are mounted it must be fed into the structure from the top and the ends of the belt joined later through a hatch in the wall of the structure. There are three common methods to join the ends of bucket belts overlap, butt and strap and turn-up clamp. Figure No. 1 shows the joining methods.

Belt tracking is greatly improved when one of the drums is crowned. The drive pulley is the one usually crowned though the bottom drum can also be used. Only one of the drums is crowned and not both. Crowning allows the natural elasticity of the belt to act like a spring and pull the belt back down the rise of the crown if it starts to wander to one side. The height of the crown is 1.5% to 2% of the pulley length.

Once the belt is installed and pulled tight, the distance between drum shafts is measured on both sides and positioned the same distance apart. The belt is run unloaded and if it wanders the tail pulley is adjusted and made tighter on the side the belt moves toward. The basic rule is that the belt moves toward the slack side and away from the tight side (this is also why crowning one pulley works). Another way to look at it is that the belt goes from the high-energy side (tight) to the low-energy side (loose).

Some times the belt can take on a banana shape or crescent camber along its length. Usually this is a sign of uneven internal fibre lengths. In this case the belt wanders from side to side during a rotation and little can be done to control it except to get it running as near to center as possible. Depending on the severity of the banana it may even require that one of the drums be offset from the center- to-center alignment so that the belt stays on the pulleys. If the camber exceeds 1% of the belt length replace it.

It can also be useful to install digging buckets every tenth bucket. These buckets are slightly oversize in length and depth to the rest of the buckets and act as a scrapper to clear away any product build-up on the sides of the structure. Make them of metal or a harder material than the regular buckets.