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Bucket elevators are a type of bulk material handling equipment which are important in processing feed for fertilizer plants and other emerging energy-related applications. However, continuous operation under extreme conditions leads to unavoidable wear. Nevertheless, the constant usage and the usage terms would be of extreme conditions and would reach a certain tighter wear that would not be avoidable. Wear and tears also result in expensive downtime and maintenance not to mention the decrease in the overall system performance and security.
Our experience in equipments design and supply (certified equipment ISO, CE, SGS) spans more than 30 years in more than 50 countries and therefore we have extensive experience in making sure that the equipment has long life at Shanghai Yuanyuda International Trade Co., Ltd. The steps to be calculated to save a lot in bucket elevator wear and an extension of useful life is a handy guide as given below.
Begin with the Right Design and Choice
Combat wear before installation through proper design.
Analyze material characteristics: The properties of your material， be it abrasive grains of fertilizer, dusty grains of feed or corrosive grains of new energy raw material are what determine how the elevator is constructed. Knows its corrosiveness, moisture, size, temperature and particle size.
Select based on duty conditions：In analysis, choose:
Bucket Material: Highly abrasive steel Bucket: Abrasion-resistant (AR) steel or polyethylene. Corrosive use may require stainless steel.
Chain/Belt and Sprockets/Pulleys: Use hardened chains, high-grade elevator belts with strong cleats, and properly profiled sprockets/pulleys are to be employed to ensure that there is no slippage or unequal wear.
Casing Liners: Fit wear liners on high impact sections such as boot section, so that the main casing is not damaged.
Check to be Precise with Installation and Alignment
The most quality materials will be torn within a limited time in case they are not attached appropriately.
Perfect alignment: The lack of centering between the feet shaft and the head shaft can be considered to be one of the main reasons of uneven wear of belts/chain, scraping and overloading of the bearing. Ensure the shafts are properly aligned.
Tension of Belt/Chain: This should be done according to the specification of the manufacturer. Strain on components and bearings are caused by over tension, slipping and whipping that cause impact damages.
Vibration-free Foundation: This is required to ensure that the whole structure is not at the pressure and strain.
Adopt the Optimal Operational Practice
How you operate the elevator daily makes a significant difference in the manner you ride on the elevator day in day out.
Control Feed Rate: Avoid overloading. A continuously choked elevator would add unwarranted strain on the drive, bearings as well as the belt/chain. The controlled inflow has to be controlled using regulated feeding devices (such as a vibratory feeder or screw conveyor).
Empty Starting: Start the elevator empty, especially centrifugal discharge models. the starting of the elevator with empty tubes, particularly centrifugal discharge models, is preferred. This decreases massive start-off load of the drive train.
Watch the Loading and discharging: When loading and discharging material into the boot, make sure to place material in the proper direction (centered and with the proper velocity) to ensure that the buckets are not hit directly. The discharge chute should also be clear to ensure that the material does not revert and recycle and spill over.
Devote to an Active Maintenance Program
The prevention cost is less than the treatment cost.
Create an inspection checklist:
Daily/Weekly: noises (scraping, banging). Investigate the spillage of materials, the wear or misfit.
Monthly: Make sure that check bucket bolts are tight. stretch / belt alignment and wear of the check chain. Look at bucket lips and backs, and determine whether they are thin or crooked.
Quarterly/Annually: It should be by a thorough inspection of all bearings, seal, sprockets and pulley lagging. Check casing of contacts wear.
Follow a strict lubrication schedule: At least in respect of chain driven elevators then tight lubrication schedule should be followed with the usage of recommended lubricant. On other occasions an excessive amount of lubrication may be drawn by dust and grit creating an abrasive paste.
Keep It Clean: In the casing, any material that spills is an abrasive. Wash the boot regularly to make sure that this material cannot be used again, to wear buckets and belts in less time.
Wear Monitoring and Smart Upgrades
Check Critical Predominant Parameters: Install ammeters on the drive motor. Amperage draw may gradually increase due to misalignment, binding, or overloading misalignment, binding, or overloading.
Fit Wear-Resistant Parts: As far as the parts wear out during the maintenance period, it is better to replace the material with a superior one. Some of them include utilization of ceramic lined or hardened buckets instead of the normal steel buckets in locations with a high level of abrasion.
Protective Equipment: Level sensors on the boot to prevent an overfill and impact beds on the loading point to cushion the impact of the falling material are bolted on.
Worked with Expertise in a Long-term
Wear reduction is not a project but a philosophy that involves right choice, proper usage in addition to good care plan. The foundation will be used to make the bucket elevators durable in Shanghai Yuanyuda International Trade Co., Ltd. Our turnkey business solutions would be used to suit your equipment and material process since it was being designed.
More than that, our global network of support and 30-year experience could help us to offer you the accurate spare parts, maintenance recommendations, and retrofit deals that will help your elevator to remain active and efficient even during decades and translate into an increased ROI.
Call us and see what we have to say in terms of our high performing and long life bucket elevator and what we can do to assist you in streamlining your material handling system to the least possible wear as well as the highest possible uptime. We should be able to put up a more efficient and sustainable functioning.
