Bucket elevators: Is belt or chain best for your application?

By Claus Weyhofen

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Bucket elevators are essential for the vertical transport of a wide range of bulk materials, from powders like raw meal and cement to coarse materials like clinker. Using a belt or chain mechanism, these high capacity, heavy duty machines rely on a combination of centrifugal and gravimetric forces to eject the bulk material out of each bucket when it reaches the desired height.

Belt and chain bucket elevators use different transmission mechanisms. Each has its own advantages and disadvantages. In this article, we’ll dive a bit deeper into the differences between a belt bucket elevator and a chain bucket elevator so that you can better decide which one is the right choice for you.

Should I Choose a BELT Bucket elevator or a CHAIN BUCKET?

A belt bucket elevator uses an endless belt with a pulley, from which the buckets are suspended. The belt comprises a series of steel cords, which take the load, encased in rubber plates to protect the steel from environmental impacts. Centre distances of up to 250 m are possible, with conveying capacities in excess of m3/h to a height of 200 m. This technology typically exhibits low wear, and higher conveying capacities, making it a cost-effective choice in terms of both CAPEX and OPEX. Belt bucket elevators are also relatively smaller than a chain belt equivalent, which saves on steelwork and so reduces environmental impacts.

A chain bucket elevator uses an endless chain with a non-toothed sprocket and the buckets are attached by means of vibration-absorbing angular bucket holders to the chain. Centre distances of 70 m or more are achievable, with conveying capacities of up to m3/h to heights of around 70 m. Chain bucket elevators really come to the fore in transporting hot, abrasive, or granular bulk material, such as limestone, slag, and refuse derived fuel (RDF). However, chain bucket elevators are generally more expensive to purchase and to maintain and have a shorter lifespan under the same strain when compared to belt bucket elevators.

Ultimately, the selection of belt or chain bucket elevator comes down to three simple criteria: temperature, grain size, and material density.

Use chain bucket elevators in temperatures above 130°C

Temperature is the single most important factor in choosing between a belt or a chain bucket elevator. Belt elevators can operate happily for more than 10 years in lower temperature environments (<130°C). They can even cope with temporary exposure to higher temperature peaks. However, rubber deteriorates when subjected to high temperatures over long periods. If it gets too hot, the rubber on a belt bucket elevator will become hard, shiny and form cracks in its surface, an effect known as elephant skin. Ultimately, it will flake and crack, exposing the inner steel cords to moisture that leads to corrosion.

Chain bucket elevators, by contrast, will operate effectively without deterioration in 250°C heat and can withstand peaks of up to 350°C. So, for extreme temperatures – when the bulk materials reach temperatures above 130°C – you should always opt for a chain bucket elevator.

GRAIN SIZE CONSIDERATIONS

If conditions mean you opt for a belt bucket elevator, grain size is the second consideration when. This factor will determine whether you should opt for a standard or heavy-duty model. Typically, grains of up to 25 mm can be handled with a standard belt bucket elevator. Grain sizes between 80 mm-120 mm require a heavy-duty version.

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DENSITY DECIDES CAPACITY

One further operating parameter to consider in belt bucket elevator specification is the bulk density. For applications of less than 2,3 t/m3, standard belt elevators are perfectly adequate. Applications up to 1,2 t/m³ density are likely to require a high capacity belt bucket elevator.

Introduction

Welcome to BeaconEng! If you’re navigating the world of material handling systems, you’ve likely encountered both conveyors and elevators. While they might seem similar at first glance, they serve distinct purposes and are designed for different types of material transport. Let’s dive into the details to help you understand which solution might be right for your needs.

What is a Conveyor?

Conveyors are versatile systems used to transport materials from one point to another horizontally or at a slight incline. They are commonly used in various industries, including manufacturing, logistics, and food processing.

• Types of Conveyors: There are several types of conveyors, including belt conveyors, roller conveyors, and chain conveyors. Each type is tailored to specific materials and uses.
• Applications: Conveyors are ideal for transporting bulk materials, packages, or products along a production line. They are commonly used in assembly lines, sorting operations, and distribution centers.
• Advantages:
  • Efficiency: Continuous transport helps in maintaining a smooth workflow.
  • Flexibility: Various configurations can be used to fit different layouts.
  • Cost-Effective: Lower operational costs due to minimal manual handling.

What is an Elevator?

Elevators, in the context of material handling, are systems designed to move materials vertically. They are used when the transportation of materials needs to span multiple floors or levels within a facility.

• Types of Elevators: Common types include bucket elevators, pallet elevators, and screw elevators. Each type is suited to different materials and handling requirements.
• Applications: Elevators are often used in industries like agriculture (for grain), construction (for building materials), and manufacturing (for lifting bulk products between levels).
• Advantages:
  • Space-Saving: Ideal for facilities with limited floor space but multiple levels.
  • High Capacity: Can handle large volumes of materials efficiently.
  • Versatility: Suitable for transporting a wide range of materials, including bulk items and finished products.

Key Differences

1. Movement Orientation:
   • Conveyor: Typically moves materials horizontally or at a slight incline.
   • Elevator: Moves materials vertically, between different levels.
2. Design and Structure:
   • Conveyor: Generally consists of a belt, rollers, or chains that transport items across a flat or inclined surface.
   • Elevator: Features components like buckets, trays, or pallets to lift materials up or down.
3. Use Case:
   • Conveyor: Best suited for horizontal or inclined transport within a single level or between adjacent levels.
   • Elevator: Ideal for transporting materials vertically across multiple floors or levels.
4. Installation and Maintenance:
   • Conveyor: Easier to install in linear or slightly curved paths. Maintenance involves checking belts, rollers, or chains.
   • Elevator: Requires more complex installation to accommodate vertical movement and may involve more intricate maintenance routines.

Choosing Between Bucket Elevator and Chain Conveyor

When deciding between a bucket elevator and a chain conveyor, consider the following factors:

• Bucket Elevator: Ideal for vertical transport of bulk materials. It features buckets attached to a belt or chain that lift materials to higher elevations. This option is best for handling granular or powdery substances.
• Chain Conveyor: Suitable for horizontal or inclined transport of heavy or bulk items. It uses chains and slats to move materials, making it robust for handling heavy loads. Chain conveyors are often used in environments requiring durable equipment for tough conditions.

Bucket Elevators Vs. Belt Conveyors: What Is The Difference?

Bucket elevators and belt conveyors serve different purposes based on their design and functionality:

• Bucket Elevator: Moves materials vertically using buckets. It is efficient for transporting materials to elevated levels but is not suitable for horizontal transport.
• Belt Conveyor: Uses a continuous belt to move materials horizontally or on a slight incline. It is versatile and suitable for a variety of materials and distances.

Bucket Elevator vs Conveyor Belt

The choice between a bucket elevator and a conveyor belt depends on your specific material handling needs:

• Bucket Elevator: Best for vertical lifting of bulk materials. It is efficient for transporting granular, powdered, or small items to elevated locations.
• Conveyor Belt: Ideal for horizontal or inclined transport of materials over long distances. It is versatile and commonly used for moving products in manufacturing and distribution.

FAQs

• What is a conveyor and elevator?
  • Conveyors are systems used for horizontal or inclined material transport, while elevators are designed for vertical movement of materials between different levels.
• What are the three types of conveyor?
  • The three main types of conveyors are belt conveyors, roller conveyors, and chain conveyors. Each type is used for different types of materials and transport needs.
• What are the advantages of a bucket elevator over a belt conveyor?
  • Bucket elevators offer several advantages over belt conveyors, including:
    • Vertical Transport: Ideal for moving materials to higher elevations.
    • High Capacity: Can handle large volumes of bulk materials efficiently.
    • Space-Saving: Requires less floor space compared to belt conveyors.
• What is the difference between a vertical screw conveyor and a bucket elevator?
  • A vertical screw conveyor uses a rotating screw to move materials vertically, while a bucket elevator uses buckets attached to a belt or chain to lift materials. Vertical screw conveyors are generally used for smaller or powdered materials, while bucket elevators are preferred for bulkier items.

Why BeaconEng?

At BeaconEng, we offer expert guidance on selecting the right material handling solution for your needs. Whether you need a reliable conveyor system or a robust elevator, we have the experience and products to ensure smooth operations and efficiency in your facility.

The company is the world’s best Heat Resistant Conveyor Belt supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.