Digital Re-print January | February 2014

Keep running costs down operating en-masse chain conveyors

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28 | January - February 2014

GRAIN

&FEED MILLING TECHNOLOGY

Keep running costs down operating en-masse chain conveyors

by 4B Braime

hain conveyors are an essential part of many bulk handling systems, where they are used to convey bulk materials such as powders, grains, flakes, pellets, etc and include operations in the milling industries. Many of these conveyors use drop forged chains with flights as a means of conveying the material being handled. This en-masse conveying system is very popular as it is a simple but highly efficient system of moving material. When it comes to purchasing a chain conveyor, it is easy to look just focus on the one-time purchasing cost and the quality of the components. The problem with conveyors is that they are exposed to a lot of wear and tear, and even the best chains can fail after a certain period of time: although this can be many years depending on the conveyors use and its maintenance. If we look at the lifetime cost of an enmasse chain conveyor, wed find a big part is

and repair can cost a lot of money and time, usually requiring the services of a team of engineers and a considerable amount of resources. So how does the en-masse conveying system work, and where does the chain failure occur? In En-Masse conveying, the flight height can be as low as 12.5 percent of the material being transported in the chain conveyor. The material is fed into the conveyor from the top and falls through the moving chain to the bottom of the box. Because the particles interlock, the material moves as a single stream at the same speed as the chain. This highly efficient conveying process allows nearly the entire conveyor cross section to move as bulk.

Flights of steel and welded links

The links with flights are then assembled in many different arrangements using pins and circlips, headed pins and circlips or headed pins with collars and roll pins. The

to order new chain links with flights welded or grind the sides of the failing links and weld new flights onsite. In both cases, a lot of resources including time are needed to complete the maintenance procedure. Having new links with flights welded is only the first step of the maintenance process: the chain needs to be slackened, the circlips must be broken in order to take out the links where the flights have failed, new links with welded flights need to be put in, and finally the chain has to be re-tensioned before the conveyor is at last operational or the whole chain removed from the conveyor. One of the other major causes for concern with this traditional assembly is the fact that the circlips can sometimes come loose due to poor installation, not only causing the chain to collapse, therefore again stopping the conveyor, but also contaminating the product that was being conveyed and risking pollution and obstructions in the plant process.

Working to supress and minimise problems

Engineers have been working hard at suppressing and minimising the different problems encountered within a chain conveyor as much as possible with solutions such as more frequent maintenance checks, metal detectors, etc. Whilst this has helped to reduce the number of unexpected breakdowns, it hasnt removed the need for conveyor shut downs when the chains or flights need to be replaced. With 125 years experience providing solutions to customers within the bulk material handling industry, worldwide, engineers at 4B have come up with a revolutionary simple solution that minimises conveyor maintenance downtimes and overcomes a lot of the problems encountered when using drag chain conveyors.

maintenance: the cost of replacement chains and links, the cost of the labour and finally the cost of downtime. For each and every user of chain conveyors, it is of vital importance to have the conveyor running at full capacity for as long as the equipment can allow it. Maintenance

whole assembly is very robust and works well until general wear, operational errors, material build up and many other reasons that bring about maintenance shut down. In the case of a minor incident, such as the flights breaking, although the chain does not need to be changed, it is still necessary

New flight assembly

4Bs Bolt N Go system is a new flight assembly system that gets rid of the need for welded flights and pins and circlips assemblies which are quite costly and time consuming in terms of manufacturing. This new system includes:

15 | January - February 2014 29

GRAIN

&FEED MILLING TECHNOLOGY

A set of Nylon flights that can be cut to accurate lengths depending on the desired overall width. Nylon flights are very strong and wear resistant but remain light- weight, therefore reducing the amount of power required to drive the chain A hollow pin made of alloy steel (the same material as the link) and case hardened to C57-C62. This pin will take the load in the assembly. It is very strong and can be supplied in stainless byfor Richard Mills, FOSS, steel applications in a corrosive environment Denmark Bolts, nuts and washers are used to hold the flights onto the linkSenwes and outh African grain suppliers assemble together. Lock near nuts have tried the outlinks a new way of using are used (NIR) to secure the whole system infrared analysis to optimize At of noincreasingly point does the bolthigh-protein take the load the use scarce in contact pin. It merely wheator in is blends goingwith intothe milling. The new holds and the flights instrument will secures now become a permanent The system uses chain feature, helping to get 4B thedrop veryforged best out of links that special lugs on the sides both highand have low-protein material. onto which the flights are fastened, thetale assembly extra stability In giving the fairy Rumpelstiltskin, a miller The Bolt Go is can extremely boasts to a kingN that hissystem daughter spin easyinto to gold. install, yet very robust and has a straw long lifespan. has make many this advantages While nothingIt can enduring in comparison to modern the traditional and dream come true, process pins analytiassembly. calcirclips technology in the form of an in-line NIR This system will undoubtedly save a analysis system is making a real difference amount time money when toprecious what millers can of get out and of wheat grain conducting maintenance work. With the deliveries. It is not exactly turning straw into Bolt nis Go system, itnext is no longer required gold, but perhaps the best thing given toincreasing take the scarcity tension the chain and the ofout highof quality wheat. take the chain out of the conveyor before The new process analysis solution called Corporate Banner (190x132mm)(outlines)_Layout 1

How to get the mix right with in-line NIR

changing flights; the at old ProFoss hasthe been on trial a flights can be taken facility out and ones fitted while the Senwes in new South Africa. chain is stillconsists tensioned inside The solution of an NIR the conveyor. Since a shorter amount analyser, a sample interface and of time is required to assemble the nylon flights special software for graphical rather welding steel flights onto links, display ofthan the results. all can be It the has flights been used at delivered a group quickly, thus the need mill. to stock of eliminating silos next to a large The a lot of spare parts; or they can be different kept in stock on site different silos contain minimum at lowlevels: cost, since they are welded protein 9 percent, 10 not percent, 12to the chain. percent and so on. The sample interface is Theinsystem the full use installed a pipe also that enables delivers grain from ofdifferent the links since not necessary the silos ontoita is conveyor belt thatto change serves the the mill. links every time new flights are needed. Once again this represents The sample interface is installed by cutting a major forof facilities using system. a hole in saving the pipe about 10 cm this diameter. It has a sapphire window that sits flush with the sides of theheat pipe, allowing the NIR unit to Superior treatment take measurements grainlinks as it flows by. 4B's Bolt n on Gothe chain are made Measurements made every few secof special heatare treated alloy steel case onds and the areC57 displayed a a hardened to results Rockwell - C62 on with computer in thehardness control room, where they ductile core of Rockwell C40. can be viewed as heat a trend graph to technique make it 4Bs superior treatment easy tomaterial keep track of the protein content. If, and provides the optimum chain for example, percentresilient protein is the target link with 11 a more ductile core and the level starts to fall below that, then a for shock resistance and an extremely little higher protein wheat for can superior be added wear to hard exterior surface stabilize the overallresistance. protein content. and corrosion This results in reduced downtime and maintenance with an increase in the for the chain Lower grade to working higher life grade conveyor. Manager of special products Mariana The assembly system an excellent Purnell describes how the is ProFoss anaandwas robust solution will facility not only lyser installed at the that Senwes in improve the overall capacity of the conOctober 2012. veyor at its optimal ability When to theperform analyser was brought into use, for longer, but also helps to minimise the there were just over 5000 tonnes of grade 23/12/2013 08:54 Page 1

offline maintenance periods thus of improvB1, about 4000 tonnes B2 ing the yearly capacity and made and 4500 tons of B3profits grade, and using the lower chain conveyor. amounts of lower grades. The Bolt The n Go system has been used process analysis system successfully in many facilities, in a wide enables continuous monitoring of range of applications including agricultural, wheat protein levels, allowing inwood chips, animal etc. All line sugar, adjustment to feeds, regulate the these products used specific in conblendinghave and been maintaining veyors of various length, angles and high protein levels during outloading. As indicated applications. The system been bycapacity the B1B3 columns, this resulted inhas all the such a success that many suppliers of enlower grades being blended with higher protein masse chain B1 conveyors offer Bolt grades, yielding and B3 now grades thatthe were n Go chain and flight system as an option. considerably higher than the initial stock level. Bolt n Go ismanaged currently available for We successfully the optimiza4B102NA, 4B142NA and links tion of all protein levels and the4B142HA homogeneity flights to 750mm wide. of with quality in allup wheat batches, says Purnell. As far I am concerned the ProFoss works very well for managing your grain quality as it monitors 100 percent of the batch being loaded and reallyINFORMATION keeps protein FOR MORE : fluctuation within4B a narrow Braimeband. Elevator Components She also points Hunslet Road out that it is of course important to have the right quantities availLeeds LS10 1JZ able to maximize the usefulness of NIR United Kingdom analysis.Website: www.go4b.com The Email: trial completed, the plan is now to 4b-uk@go4b.com put the system into use on a permanent basis. Note: We can that the level 4Bssee drop forged chain of is control backed and management of the network protein level being by an international of compashipped far125 superior tobulk when it is niesout withis over years of handling controlled by a human being who infreexperience. 4B engineers are does specialised quentin sampling testing, says Purnell. the dropand forged chain industry and can By gathering more precise of proprovide engineering design data service and tein units leaving the drag silo, one can be assured advice for any or en-masse chain of a lower number of disputes related to conveyor application. protein levels and subsequent downgrading."

This digital Re-print is part of the January | February 2014 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.
January - February 2014

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