Describes how SJ elevator buckets and steel web belting can be used to improve the performance of heavy duty bucket elevators in the cement industry

1. Elevator Buckets & Steel Web Belting
for use in Cement Elevators
PRESENTED BY
4B
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2. With demand for larger capacity, more
efficient and cost effective elevators for
handling industrial products such as
cement;
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
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3. 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
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4. 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
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5. Starco Jumbo Elevator Buckets
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
ILLUSTRATION OF STARCO JUMBO
BUCKET & STEEL WEB BELT
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6. 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
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7. 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:
1. Type T60 - highly abrasion resistant, maximum ambient
temperature 140°F (60°C), cover hardness 60° A shore
2. 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
3. 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
4. Type CR - oil and fat resistant, anti-static ISO 284, flame
retardant ISO 340, cover hardness 70° A shore
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8. 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
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9. System Benefits
Compared to traditional chain and bucket
elevators, Steel web belt fitted with Starco Jumbo
buckets offer you:
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
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10. Comparison
Traditional Chain Elevator Compared to
Starco Jumbo & Steel Web Belt to Handle 300M³/Hour
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
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11. 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)
BKTS 250 MM PROJ SJ470 SJ470 SJ470 SJ370 SJ370 SJ340 SJ370
ROWS 1 2 3 1 2 3 4
BELT WIDTH MM 520 1040 1560 410 820 1230 1640
CASE WIDTH MM 650 1150 1520 540 930 1320 1710
CASE DEPTH MM 400 400 400 400 400 400 400
CAPACITIES
PULLEY DIA MM 900 900 900 900 900 900 900
BELT SPEED M/S 1.9 1.9 1.9 1.9 1.9 1.9 1.9
TPH 350 700 1050 280 560 840 1120
M³/HR 313 410 950 250 500 750 1000
PULLEY DIA MM 1000 1000 1000 1000 1000 1000 1000
BELT SPEED M/S 2.02 2.02 2.02 2.02 2.02 2.02 2.02
TPH 375 754 1130 298 595 890 1190
M³/HR 335 670 1010 260 530 800 1060
PULLEY DIA MM 1200 1200 1200 1200 1200 1200 1200
BELT SPEED M/S 2.25 2.25 2.25 2.25 2.25 2.25 2.25
TPH 420 840 1260 330 664 995 1325
M³/HR 375 750 1125 295 590 890 1185
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12. 4B Steel Web Belting
Typical Belt Specification Example:
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
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13. Steel Web Belt Comparison
Steel Cable Belt DIN 22131 – 4B Steel Web Belt DIN 22102 –
Longitudinal Cables Only Longitudinal and Transversal
– Cables of greater diameter Cables
4.5 – 6.0 mm – Cables of smaller diameter
– Cables at larger pitch 2.85 – 3.9 mm
– More open construction – Cables at smaller pitch
– Bolt holes in wide cable free – More dense construction
zones, requires special – Bolt holes in full cable
bucket attachment construction
– Flexible in width, does not aid – Allows fitting buckets with
tracking standard bolts
– Conventional steel cables – Very cross rigid, excellent
require cylindrical pulleys tracking aid
– Ends reinforced by – Elastic cables allow running
vulcanizing textile ply into over crowned pulleys
cover to provide holding for – Clamps fitted in virgin material
clamps
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14. Belt Manufacturing
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15. Belt Manufacturing
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16. Belt Quality Control
Abrasion Testing
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17. Belt Quality Control
Rubber Strength Test
E Cord Pull Test
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18. Belt Quality Control
Shore Hardness Test
Stretch Test
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19. Poor Quality Steel Reinforced Belting
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20. Poor Quality Steel Reinforced Belting
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21. Poor Quality Steel Reinforced Belting
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22. Special Allen Key Head Bolts
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23. 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
BC2 BC3 BC4
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24. BC Series Belt Fastener
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25. BC Series Belt Fastener
Construction of
Belt Fastener and
Bucket Position
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26. BC Series Belt Fastener
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27. SJ Bucket Handling Cement
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28. Belt Installation
Belt Being Lifted into
Place by Crane
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29. Belt Installation
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30. Belt Installation
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31. Installation Examples
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32. Installation Examples
Bucket and Belt Inside the Leg
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33. Installation Examples
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34. Installation Examples
Upgraded Cement Elevator to Belt and SJ Buckets from Chain
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35. Starco Jumbo Bucket Sizes
Dimensions (Inches) Bolt Holes Capacity (in3)
Back Front Hole
Length Projection Thickness Bolt Gross Water Min. Cup Weight
Part # Depth Depth Center
A B T Size Capacity Level Spacing (Lbs.)
C D F
SJ330-250/3 13-3/8 10-1/4 7-1/2 5-1/8 1/8 5/16 3-1/8 586 439 7-1/8 9.9
SJ370-250/3 15 10-1/4 7-1/2 5-1/8 1/8 9/16 3-1/8 659 507 7-1/8 11.3
SJ470-250/3 18-7/8 10-1/4 7-1/2 5-1/8 1/8 9/16 3-1/8 854 641 7-1/8 14.3
SJ330-250/4 13-3/8 10-1/4 7-1/2 5-1/8 5/32 9/16 3-1/8 586 439 7-1/8 13.3
SJ370-250/4 15 10-1/4 7-1/2 5-1/8 5/32 9/16 3-1/8 659 507 7-1/8 14.8
SJ470-250/4 18-7/8 10-1/4 7-1/2 5-1/8 5/32 9/16 3-1/8 854 641 7-1/8 19.0
SJ470-250/4.7 18-7/8 10-1/4 7-1/2 5-1/8 3/16 9/16 3-1/8 854 641 7-1/8 22.3
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36. 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
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37. Basic Drawing for Cement Elevator
ELEVATOR FOR 340 TPH OF Raw Meal DATE 9-Oct-00
ELEVATOR NO. 1 REF Robsons2-2
drive 75 kw
shafts 175 mm dia head
90 mm dia boot
belt 1000 mm x ep 1600 kg/cm
13
DIMENSIONS
NO 1 49.19 mts
11 14
NO 2 1000 mm
12
NO 3 1000 mm
31
NO 4 400 mm
NO 5 1150 mm
NO 6 900 2
NO 7 480 mm xrows 2
NO 8 260 mm
NO 9 1100 mm 10
NO 10 1000 mm 13 18
NO 11 1000 mm
NO 12 1000 mm
NO 13 150 mm 16 17
NO 14 1350 mm
NO 16 150 mm
NO 17 500 mm
NO 18 45 degs 4 6 4
NO 19 1700 mm 1
NO 20 820 mm
NO 21 35 mm
5 9 7
NO 22 450 mm
NO 23 50 mm
NO 24 870 mm
NO 25 55 degs 2 rows
NO 26 156 mm 2 SJ470-250
8
NO 27 714 mm 23 23
NO 28 920 mm 22
22
NO 29 0 mm
NO 30 0 mm
NO 31 117.5 mm 25 28
24 25 27
26 29
30
3
20
21 liner
19
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38. Basic Drawing for Cement Elevator
REFERENCE YOUR ENQUIRY FOR 340 TPH OF Raw Meal DENSITY
0.8 T/M3 IN AN ELEVATOR AT 49.19 MTS C/C HEIGHT @ 90 DEGS TO HORIZNTL
ELEVATOR NO 1
SPECIFICATIONS 1000 MM DIA HEAD PULLEY Lagged
1000 MM DIA BOOT PULLEY Wing
49.19 MTS C/C HEIGHT
INSTALL 2 ROW 0F SJ470- BUCKETS 3.8 PER MTR
250 at
AND A BELT SPEED OF 1.9 MTS/SEC 36.3 RPM
CAPACIT
Y
row lts fctr bkts/mtr mt/sec t/m3 s/fctr = TPH M3/HR
2 10.5 3.6 3.8 1.9 0.8 0.85 371.2 464
NOMINAL 340 TPH
DRIVE 75 kw 101 hp for 69.2 KW abs
BELT 1000 mm wide 1600 kg/cm SBR 896 PIW but calc kg/cm = 684.1
SHAFTS head 175 mm dia
boot 90 mm dia
INTAKES upside 450 mm deep 1150 mm wide 55 deg angle to case side
156 mm above the line of the boot shaft 2/3rds down its adjustment
dn side 450 mm deep 1150 mm wide 55 deg to case sd in line with btshft
OUTLET 500 mm deep 1150 mm wide 45 degs to head shaft
HEAD Gravity discharge type as sketch Lagged
BOOT Wing type as sketch boot plly rq wt/side= 0 kg=Nm Tq 0
TRUNKING 400 mm deep 1150 mm wide 900 mm between trunks
T1=KGS= 7977 T2=KGS= 3935
QUANTITIES
772 pcs SJ470-250 BUCKETS
3900 pcs 10 mm dia X 40 mm long bolts and nuts
3900 pcs 10 mm dia washers
105 mts of 1000 mm wide 1600 kgs/cm SBR belt = 896 PIW
3990 holes 10 mm dia punched in the belt
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39. Thank You!
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