sj elevator bucket and and steel web belt for cement elevators
DESCRIPTION
Describes how SJ elevator buckets and steel web belting can be used to improve the performance of heavy duty bucket elevators in the cement industryTRANSCRIPT
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Elevator Buckets & Steel Web Belting Elevator Buckets & Steel Web Belting for use in Cement Elevatorsfor use in Cement Elevators
PRESENTED BY PRESENTED BY 4B4B
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4B Components has: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;
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Replaces traditional chain bucket elevatorsReplaces large and heavy fabricated buckets in bucket elevatorsReplaces poor quality steel cord belts on the market with 4B Steel Web Belts
What is the SJ System?What is the SJ System?
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Use heavy chain and large fabricated bucketsLimited number of buckets per meterMax speed of 1.3M/S restricts capacityChain and sprockets wear quicklyHigh maintenance and replacement costsHigh capacity requires very large fabricated elevator buckets, therefore larger construction
Restrictions of Traditional SystemsRestrictions of Traditional Systems
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ILLUSTRATION OF STARCO JUMBO ILLUSTRATION OF STARCO JUMBO BUCKET & STEEL WEB BELTBUCKET & STEEL WEB BELT
Uses 1 to 4 rows of closely spaced heavy-duty Starco Jumbo seamless steel bucketsIn conjunction with: - Purpose designed steel web high temperature elevator beltCapable of up to 2.3M/S belt speed Achieves far greater capacities per case size than any other system
Starco Jumbo Elevator BucketsStarco Jumbo Elevator Buckets
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4B Steel Web Belt4B Steel Web Belt
Saves over 40% of component costsBelt wears less than chainReduces down time and maintenance costsSteel 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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4B Steel Web Belt Types4B 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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Specially Constructed to suit the SJ Buckets and Fasteners, or standard existing steel cord beltsStrengths of 800 up to 2500 Kn/mNegligible Belt Stretch - Ideal for Very Tall Elevators, With Very High CapacityAbrasion ResistantGood Bolt HoldingWill Withstand Temperatures of up to 130°C
4B Steel Web Belting4B Steel Web Belting
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Up to double the elevator capacityThroughputs up to 1300 TPH and overMuch lower capital investmentLonger trouble free lifeReduced 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 BenefitsSystem Benefits
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Chain and BucketSprocket 900 PCDChain Speed 1.3M/SBucket DIN 15234 1250 x 400Case 1400 x 560
Steel web Belt and Jumbo BucketsPulley 900 DiaBelt Speed 1.9M/SBuckets 2 x SJ370-250Case 930 x 400
= reduced case and lower machine cost
Traditional Chain Elevator Compared to Starco Jumbo & Steel Web Belt to Handle 300M³/Hour
ComparisonComparison
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Case SizeCase Size
BKTS 250 MM PROJ SJ470 SJ470 SJ470 SJ370 SJ370 SJ340 SJ370ROWS 1 2 3 1 2 3 4BELT WIDTH MM 520 1040 1560 410 820 1230 1640CASE WIDTH MM 650 1150 1520 540 930 1320 1710CASE DEPTH MM 400 400 400 400 400 400 400
CAPACITIESPULLEY DIA MM 900 900 900 900 900 900 900BELT SPEED M/S 1.9 1.9 1.9 1.9 1.9 1.9 1.9TPH 350 700 1050 280 560 840 1120M³/HR 313 410 950 250 500 750 1000
PULLEY DIA MM 1000 1000 1000 1000 1000 1000 1000BELT SPEED M/S 2.02 2.02 2.02 2.02 2.02 2.02 2.02TPH 375 754 1130 298 595 890 1190M³/HR 335 670 1010 260 530 800 1060
PULLEY DIA MM 1200 1200 1200 1200 1200 1200 1200BELT SPEED M/S 2.25 2.25 2.25 2.25 2.25 2.25 2.25TPH 420 840 1260 330 664 995 1325M³/HR 375 750 1125 295 590 890 1185
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)
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Tensile Strength : 1600 Kn/mWorking Tension : 160 Kn/mCord dia. Weft : 1.29 mmBinder Yarn : Nylon 940*2*3 RFL dipped 250 N/mmTop/Bottom Covers : 5mmCord Diameter : 3.9mmBelt Weight : 22.5kgBelt thickness : 13mmCable Brass Coated :67.5 CU 32.5 Zn
Typical Belt Specification Example:
4B Steel Web Belting4B Steel Web Belting
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Steel Web Belt ComparisonSteel 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
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Belt ManufacturingBelt Manufacturing
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Belt ManufacturingBelt Manufacturing
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Belt Quality ControlBelt Quality Control
Abrasion Testing
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Belt Quality ControlBelt Quality Control
Rubber Strength Test
E Cord Pull Test
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Belt Quality ControlBelt Quality Control
Shore Hardness Test
Stretch Test
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Poor Quality Steel Reinforced BeltingPoor Quality Steel Reinforced Belting
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Poor Quality Steel Reinforced BeltingPoor Quality Steel Reinforced Belting
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Poor Quality Steel Reinforced BeltingPoor Quality Steel Reinforced Belting
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Special Allen Key Head BoltsSpecial Allen Key Head Bolts
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Specially Designed For Starco Jumbo Buckets and Steel Web Belt CombinationStandard Clamp for Up to ST1200 Belt – Made in AluminumClamp for ST2000 Belt – Made in Steel and Aluminum
BC Series Belt FastenerBC Series Belt Fastener
BC2 BC3 BC4
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BC Series Belt FastenerBC Series Belt Fastener
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BC Series Belt FastenerBC Series Belt Fastener
Construction of Belt Fastener and Bucket Position
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BC Series Belt FastenerBC Series Belt Fastener
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SJ Bucket Handling CementSJ Bucket Handling Cement
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Belt Being Lifted into Place by Crane
Belt InstallationBelt Installation
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Belt InstallationBelt Installation
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Belt InstallationBelt Installation
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Installation ExamplesInstallation Examples
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Bucket and Belt Inside the Leg
Installation ExamplesInstallation Examples
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Installation ExamplesInstallation Examples
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Upgraded Cement Elevator to Belt and SJ Buckets from Chain
Installation ExamplesInstallation Examples
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Part # Length A
ProjectionB
Back Depth
C
Front Depth
D
ThicknessT
Bolt Size
Hole Center
F
GrossCapacity
Water Level
Min. CupSpacing
Weight (Lbs.)
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 9.9SJ370-250/3 15 10-1/4 7-1/2 5-1/8 1/8 9/16 3-1/8 659 507 7-1/8 11.3SJ470-250/3 18-7/8 10-1/4 7-1/2 5-1/8 1/8 9/16 3-1/8 854 641 7-1/8 14.3SJ330-250/4 13-3/8 10-1/4 7-1/2 5-1/8 5/32 9/16 3-1/8 586 439 7-1/8 13.3SJ370-250/4 15 10-1/4 7-1/2 5-1/8 5/32 9/16 3-1/8 659 507 7-1/8 14.8SJ470-250/4 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
Dimensions (Inches) Bolt Holes Capacity (in3)
Starco Jumbo Bucket SizesStarco Jumbo Bucket Sizes
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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 mmSW800 800 3+3 2.85 6.67 12 17 500SW1000 1000 3+3 2.85 5.38 12 18 500SW1250 1250 4+4 3.90 7.04 15 22 630SW1400 1400 4+4 3.90 6.25 15 23 630SW1600 1600 4+4 3.90 5.50 15 24 630SW1800 1800 4+4 3.90 5.00 15 25 630SW2000 2000 4+4 3.90 4.65 15 26 630Pull-out force of 1 warp cable approx. 85-110 kg/cmCover adhesion value approx. 10 - 12 kg/cmCovers are recommended minimum thicknesses.Data are approximate
4B Steel Web Belting4B Steel Web Belting
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ELEVATOR FOR 340 TPH OF Raw Meal DATE 9-Oct-00ELEVATOR NO. 1 REF Robsons2-2
drive 75 kwshafts 175 mm dia head
90 mm dia bootbelt 1000 mm x ep 1600 kg/cm
DIMENSIONS
NO 1 49.19 mtsNO 2 1000 mmNO 3 1000 mmNO 4 400 mmNO 5 1150 mmNO 6 900 NO 7 480 mm xrows 2NO 8 260 mmNO 9 1100 mmNO 10 1000 mmNO 11 1000 mmNO 12 1000 mmNO 13 150 mmNO 14 1350 mmNO 16 150 mmNO 17 500 mmNO 18 45 degsNO 19 1700 mmNO 20 820 mmNO 21 35 mmNO 22 450 mmNO 23 50 mmNO 24 870 mmNO 25 55 degs 2 rowsNO 26 156 mm SJ470-250NO 27 714 mmNO 28 920 mmNO 29 0 mmNO 30 0 mmNO 31 117.5 mm
liner
2
1214
13
11
10
16 17
9
4 6 4
75
28
2223 23 22
19
25 2728
20
26
2524
1
13
31
3 30
29
21
18
Basic Drawing for Cement ElevatorBasic Drawing for Cement Elevator
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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 SJ470-250
BUCKETS at
3.8 PER MTR
AND A BELT SPEED OF 1.9 MTS/SEC 36.3 RPM
CAPACITY
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
Basic Drawing for Cement ElevatorBasic Drawing for Cement Elevator
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