how to optimize cement elevators using sj elevator buckets and steel w

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Elevator Buckets & Steel Web Belting for use in Cement Elevators PRESENTED BY 4B www.go4b.com

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4B Components has: Researched and tested products for over 15 years Produced an integrated system composed of 4B Steel Web Belting, Starco Jumbo (SJ) elevator buckets, and designs for compact industrial bucket elevators With demand for larger capacity, more efficient and cost effective elevators for handling industrial products such as cement;

What is the SJ System? : 

Replaces traditional chain bucket elevators Replaces large and heavy fabricated buckets in bucket elevators Replaces poor quality steel cord belts on the market with 4B Steel Web Belts What is the SJ System?

Restrictions of Traditional Systems : 

Use heavy chain and large fabricated buckets Limited number of buckets per meter Max speed of 1.3M/S restricts capacity Chain and sprockets wear quickly High maintenance and replacement costs High capacity requires very large fabricated elevator buckets, therefore larger construction Restrictions of Traditional Systems

Starco Jumbo Elevator Buckets : 

ILLUSTRATION OF STARCO JUMBO BUCKET & STEEL WEB BELT Uses 1 to 4 rows of closely spaced heavy-duty Starco Jumbo seamless steel buckets In conjunction with: - Purpose designed steel web high temperature elevator belt Capable of up to 2.3M/S belt speed Achieves far greater capacities per case size than any other system Starco Jumbo Elevator Buckets

4B Steel Web Belt : 

4B Steel Web Belt Saves over 40% of component costs Belt wears less than chain Reduces down time and maintenance costs Steel web does not stretch 0.35% permanent elongation at 10 s.f. 0.15% unique elastic elongation at 10 s.f. Allows low pulley crown, avoids drift High elongation at break 5% Guaranteed for 1 year - with lifetime in excess of 7 years Detailed View of Steel Cords

4B Steel Web Belt Types : 

4B Steel Web Belt Types 4B Steel Web Belts are manufactured in accordance with DIN 22102 and ISO norms and are available in four different types: Type T60 - highly abrasion resistant, maximum ambient temperature 140°F (60°C), cover hardness 60° A shore Type T100 - highly abrasion resistant, maximum ambient temperature up to 212°F (100°C), short peaks 230°F (110°C), cover hardness 64° A shore Type T130 - good abrasion resistance, maximum ambient temperature up to 266°F (130°C) continuous, short peaks 302°F (150°C), cover hardness 66° A shore Type CR - oil and fat resistant, anti-static ISO 284, flame retardant ISO 340, cover hardness 70° A shore

4B Steel Web Belting : 

Specially Constructed to suit the SJ Buckets and Fasteners, or standard existing steel cord belts Strengths of 800 up to 2500 Kn/m Negligible Belt Stretch - Ideal for Very Tall Elevators, With Very High Capacity Abrasion Resistant Good Bolt Holding Will Withstand Temperatures of up to 130°C 4B Steel Web Belting

System Benefits : 

Up to double the elevator capacity Throughputs up to 1300 TPH and over Much lower capital investment Longer trouble free life Reduced maintenance and spares cost; Opportunity to upgrade capacity of existing elevators Compared to traditional chain and bucket elevators, Steel web belt fitted with Starco Jumbo buckets offer you: System Benefits

Comparison : 

Chain and Bucket Sprocket 900 PCD Chain Speed 1.3M/S Bucket DIN 15234 1250 x 400 Case 1400 x 560 Steel web Belt and Jumbo Buckets Pulley 900 Dia Belt Speed 1.9M/S Buckets 2 x SJ370-250 Case 930 x 400 = reduced case and lower machine cost Traditional Chain Elevator Compared to Starco Jumbo & Steel Web Belt to Handle 300M³/Hour Comparison

Case Size : 

Case Size Bucket Elevator Capacities with SJ Buckets at 4.9/Metre (Material: Portland Cement at 1.12 Density and With 90% fill of Bucket Water Level)

4B Steel Web Belting : 

Tensile Strength : 1600 Kn/m Working Tension : 160 Kn/m Cord dia. Weft : 1.29 mm Binder Yarn : Nylon 940*2*3 RFL dipped 250 N/mm Top/Bottom Covers : 5mm Cord Diameter : 3.9mm Belt Weight : 22.5kg Belt thickness : 13mm Cable Brass Coated :67.5 CU 32.5 Zn Typical Belt Specification Example: 4B Steel Web Belting

Steel Web Belt Comparison : 

Steel Web Belt Comparison Steel Cable Belt DIN 22131 – Longitudinal Cables Only Cables of greater diameter 4.5 – 6.0 mm Cables at larger pitch More open construction Bolt holes in wide cable free zones, requires special bucket attachment Flexible in width, does not aid tracking Conventional steel cables require cylindrical pulleys Ends reinforced by vulcanizing textile ply into cover to provide holding for clamps 4B Steel Web Belt DIN 22102 – Longitudinal and Transversal Cables Cables of smaller diameter 2.85 – 3.9 mm Cables at smaller pitch More dense construction Bolt holes in full cable construction Allows fitting buckets with standard bolts Very cross rigid, excellent tracking aid Elastic cables allow running over crowned pulleys Clamps fitted in virgin material

Belt Manufacturing : 

Belt Manufacturing

Belt Manufacturing : 

Belt Manufacturing

Belt Quality Control : 

Belt Quality Control Abrasion Testing

Belt Quality Control : 

Belt Quality Control Rubber Strength Test E Cord Pull Test

Belt Quality Control : 

Belt Quality Control Shore Hardness Test Stretch Test

Poor Quality Steel Reinforced Belting : 

Poor Quality Steel Reinforced Belting

Poor Quality Steel Reinforced Belting : 

Poor Quality Steel Reinforced Belting

Poor Quality Steel Reinforced Belting : 

Poor Quality Steel Reinforced Belting

Special Allen Key Head Bolts : 

Special Allen Key Head Bolts

BC Series Belt Fastener : 

Specially Designed For Starco Jumbo Buckets and Steel Web Belt Combination Standard Clamp for Up to ST1200 Belt – Made in Aluminum Clamp for ST2000 Belt – Made in Steel and Aluminum BC Series Belt Fastener

BC Series Belt Fastener : 

BC Series Belt Fastener

BC Series Belt Fastener : 

BC Series Belt Fastener Construction of Belt Fastener and Bucket Position

BC Series Belt Fastener : 

BC Series Belt Fastener

SJ Bucket Handling Cement : 

SJ Bucket Handling Cement

Belt Installation : 

Belt Being Lifted into Place by Crane Belt Installation

Belt Installation : 

Belt Installation

Belt Installation : 

Belt Installation

Installation Examples : 

Installation Examples

Installation Examples : 

Bucket and Belt Inside the Leg Installation Examples

Installation Examples : 

Installation Examples

Installation Examples : 

Upgraded Cement Elevator to Belt and SJ Buckets from Chain Installation Examples

Starco Jumbo Bucket Sizes : 

Starco Jumbo Bucket Sizes

4B Steel Web Belting : 

Available 4B Steel Web Belt types: Type Strength Covers Warp Pitch Thickness Weight Min. Pulley N/mm mm Ø mm mm mm kg/m2 Ø mm SW800 800 3+3 2.85 6.67 12 17 500 SW1000 1000 3+3 2.85 5.38 12 18 500 SW1250 1250 4+4 3.90 7.04 15 22 630 SW1400 1400 4+4 3.90 6.25 15 23 630 SW1600 1600 4+4 3.90 5.50 15 24 630 SW1800 1800 4+4 3.90 5.00 15 25 630 SW2000 2000 4+4 3.90 4.65 15 26 630 Pull-out force of 1 warp cable approx. 85-110 kg/cm Cover adhesion value approx. 10 - 12 kg/cm Covers are recommended minimum thicknesses. Data are approximate 4B Steel Web Belting

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Basic Drawing for Cement Elevator

Basic Drawing for Cement Elevator : 

Basic Drawing for Cement Elevator

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Thank You! www.go4b.com