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SUBMITTED BY:Sandeep Kumar Mechanical,7th Semster Roll no. 2108424 Doon Valley Institute of Engg. & Tech.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
CONTENTS
Acknowledgement Profile of the company Introduction to Bucket Elevator Working of Bucket Elevator Parts of Bucket Elevator Accessories Types of Bucket Elevators Design of Bucket Elevator Maintenance of Bucket Elevator Preventive Measures Scope Conclusion References
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
COMPANY PROFILE
Infrastructure:
We have sufficient area available for our manufacturing activities. All machineries required for heavy fabrication and machining are present including Bending Machines, Hydraulic Press, Plasma Welding, Argon Arc Welding, Boring Machines, Milling Machines, etc. We have Handling facilities such as Overhead Cranes of 5 and 3 Tonne capacity, Chain Pulley Block etc.
Work Force:
We have experienced and skilled technicians for various activities like cutting, welding, gas cutting, fitting, machining, drawing, and designing. We nurture their skill and talent by exposing them to the latest technique.
Quality Assurance:
As internal inspection, the material is inspected for inputs and out puts physically, dimensionally and visually. The critical items are subject to laboratory testing for mechanical and chemical compositions before putting to process line. Further, stage wise inspection of sub assembly and assembly is carried out. Wherever possible, No Load running is carried out before dispatch for additional satisfaction of working.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
ELEVATORS
Vertical continuous bucket elevator: (1) belt, (2) bucket, (3) drive pulley, (4) backstop, (5) drive, (6) discharge spout, (7) takeup shaft, (8) loading spout
A bucket elevator consists of buckets attached to an endless chain or belt that revolves around a bottom pulley allowing buckets to fill with material and a top pulley where the bucket discharges their material. Bucket elevators are the most used systems for vertical transport of bulk, dry and liquid materials. Bucket elevator designed with various options of height, speed and constructive details depending on the type of material to be transported.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
A bucket elevator can elevate a variety of bulk materials from light to heavy and from fine to large lumps. A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend entirely on the action of centrifugal force to get the material into the discharge chute and must be run at speeds relatively high. Inclined elevators with buckets spaced apart or set close together may have the discharge chute set partly under the head pulley. Since they don't depend entirely on the centrifugal force to put the material into the chute, the speed may be relatively lower. Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They pick up their load from a boot, a pit, or a pile of material at the foot pulley. The buckets can be also triangular in cross section and set close to on the belt with little or no clearance between them. This is a continuous bucket elevator. Its main use is to carry difficult materials at slow speed. Early bucket elevators used a flat chain with small, steel buckets attached every few inches. Current construction uses a rubber belt with plastic buckets. Pulleys several feet in diameter are used at the top and bottom. The top pulley is driven by an electric motor. The bucket elevator is the enabling technology that permitted the construction of grain elevators. A diverter at the top of the elevator allows the grain to be sent to the chosen bin. A similar device with flat steps is occasionally used as an elevator for humans, e.g., for employees in parking garages. (This sort of elevator is generally considered too dangerous to allow use by the public.)
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
Front View
Boot Pulley
Grain entry may be on either side of the boot. However, when grain enter on the downleg, additional power is required for the "dredging effect" of pulling the bucket through the grain in the boot. Cleanout included on both sides of the boot to permit fast and easy cleaning. They are usually placed at an angle and should slide easily.
also providing a dust proof and waterproof enclosure for the elevator belt or chain and buckets. They are manufactured in standard lenght of 2.4 m, but could be manufactured in any lenght desired. Casing may be of single or dual design. The service door with removable panels is provided on upleg casing to allow access for servicing the belt or chains and bucket.
Bucket
Buckets are made of different materials such as steel, plastics and come in different shapes and sizes depending on requirements. The buckets are uniform, smooth and placed with a distance that allow for efficient filling of bucket and clean discharge. Normally a Norway bolt or ovalhead type of bolt is used to attach the buckets to the belts. Also spacers are provided in between bucket and belt to prevent accumulation of material.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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Plastics Bucket
Metal Bucket
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(Crosswise threads). Duck for belts is ordinarily graded as 28 oz, 32 oz, etc., according to the weight of a piece 91 cm long in the warp and 107 cm wide. Balata belts are made of waterproofed cotton duck belts held together by balata, a tree gum which is stronger than rubber at ordinary temperature but not so elastic. Stitched canvas belts are multi-ply duck belts whose plies have been stitched together and made waterproof. Solid woven belts are woven to thickness in looms and are not of multiple constructions. They are used primarily for power transmission.
Belt Splicing
Type of belt splice depends on the thickness of the belt and the severity of service. There are three types of splices normally used with elevator belts. Each is described below. 1) Lap Joint Splice This is the easiest splicing method. On a lap joint splice, the lap extends a distance of three to five buckets and is sucured by same bolts that hold the buckets.
This splice is not suitable for belts more than seven plies thick because it is too stiff to pass tightly over the pulleys.
2) Butt-strap Joint Splice The butt-strap joint splice may be used on belts of eight or more plies.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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3) Clamp Joint Splice/Mechanical Splice This is superior splice. For the clamp joint, belt ends must be bend outwards at right angles to form a ridge that is then bolted between a bar clamp.
Drive Unit
Drive Assembly
Sprocket
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Taper Bush
Accessories
Service Platform For Head and Ladder
Service platform provide work area for performing routine inspection and maintenance on the elevator head section, particularly the drive mechanism. Ladder provide access to the service platforms.
A transition is used to adapt a square outlet to round spouting or a distributor. Y section divide the flow of material from one way into two way and vice versa.
A. Centrifugal Discharge
B. Positive discharge
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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C. Continuous Discharge
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140*152
180*202
215*280
215*28 0 475*40 UCP 208 215*27 0 405*40 UCF 208 2 HP, 82 RPM 6 * 5
270*420
2 3
150*150
150*200
215*270
270*400
5 6
10
Bucket Size (Inch) Belt Size W(mm)*T(mm) Bucket Spacing (In mm) Belt Speed (In m/s) Casing Size (In mm)
4 * 3.5
130*10
178*10
195*10
195*10
230*10
11 12
180 0.79
125 0.97
210 1.20
160 1.20
180 1.27
13
180*180
210*180
260*210
260*21
315*225
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Where,
L= Width of Pulley(mm) D= Diameter of Pulley(mm) W=Width of Belt(mm) T=Thickness of Belt(mm) Component Material Used
Sr. No. 1
Bucket
HDPE (High density polyethylene) Polyester or Nylon or both MS Sheet of 3 mm MS Sheet of 3 mm MS Sheet of 1.6 mm MS Sheet of 4 mm MS Sheet of 4 mm MS Sheet of 3 mm MS Sheet of 5 mm MS Sheet of 3 mm
2 3 4 5 6 7 8 9 10
Belt Head Boot Casing Casing Angle Take up unit plate Take up unit angle Platform sheet Platform angle
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Inlet and outlet chute design. Considerations in choosing panel materials. Selecting belts and buckets. Methods to take-up belt tension. Protection against bogging the buckets. Clean-out considerations. Dust extraction requirements. Installing the bucket elevator in place. Correct operation of belt bucket elevators. Maintenance of belt bucket elevators.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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This will keep the buckets a constant distance off the elevator wall and product pick-up and simplify chute design and fabrication. Both head and tail pulleys need to be crowned to centralise the belt and permit the belt to be tracked if it wanders. The crowning should be 2 degrees both left and right from the center of the drum. The head pulley could be rubber lagged if desired to increase the coefficient of friction and lower the belt tension. This will allow use of a lighter duty belt. But there is always the possibility the lagging will be stripped off during operation. It is best to design for a metal drum and use lagged pulleys only when detection of bogged conditions is installed. Ribbing can also be mounted on the top pulley to increase friction and act by .digging. into the rubber belt and producing a grabbing effect. The ribs are placed across the full axial length of the drum and positioned so that at least two ribs are always in contact with the belt. The rigs should be 3 mm to 4 mm high and contoured into the drum so as not to rip the belt. The tail pulley should be a selfcleaning design. This can be achieved in two ways. Constructing the pulley drum of 20 mm or 25 mm round bars of length wider than the belt. The bars are spaced around the end plates with gaps for product to fall through. Size the spacing between ribs with sufficient clearance for small product to fall through. Larger product will not fit through the gaps. - provide a twin opposed-cone hub with the cone.s base starting at the center and tapering to the shaft at the ends of the pulley. 20 mm or 25 mm round bars are welded to the outer rim of the cones and gussetted back to the cone wall for stiffness.
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B. Periodically remove the drop-down clean out door from each end of the boot:Cleanse the boot of all accumulated dirt and material to prevent vermin infestation and corrosion. 1. If the boot has a screw takeup, clean the acme takeup screws and nuts. Apply a protective coating of rust-inhibiting lubricant. 2. If the boot has a Posi-Guide gravity takeup, cleanse the polyethylene guide sleeves and the stainless steel guide shafts of accumulated dirt to insure that the pulley and weight box assembly move up and down freely.
C. Examine the head lining:Extreme wear patterns can sometimes distort the discharge and if not corrected, wear completely through the head. Spouting may also wear through. D. Check to make sure the pressure relief vents, if installed, on the head and/or legging are unobstructed. In order to provide relief, they must be free to blow out. E. Inspect all ladders and platforms. Tighten any loose fasteners. Note any defective field welds and schedule immediate repair. Also schedule replacement for any damaged ladder sections, platform structural members, or floor grates. While inspecting platforms and ladders, be sure to examine guying cable brackets and /or bracing. Note any defects and schedule immediate repair. F. Examine guying. Tighten any clamp fasteners, which are loose. If a cable is excessively slack, adjust turnbuckles to restore tension.
DANGER
Excessive guy cable tension will twist,bend and/or collapse the Elevator structure,causing severe injury or death.Maintain proper gu cable tension at all times.
1) Dust Explosion(Deflagration)
Dust is generated at explosive concentrations during product feed and discharge due to the conveyance mechanics and material characteristics. As the buckets are loaded, move through the elevator, and unload, they disperse dust throughout the elevator. All that is needed for an explosion to occur is an ignition source. Ignition sources may include heat generated fire, welding, and sparks. Upon ignition, it can propagate throughout the elevator and to any areas connected to the elevator, causing secondary explosions. A dust explosion results when finely divided combustible matter is dispersed in an atmosphere containing sufficient oxygen to permit combustion and a source of
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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ignition of appropriate energy is present. Dust explosions have certain similarities to gas explosions, especially with regard to the chemical processes involved and in cases where the particle size of the dust is less than 5 pm. However, there are significant differences which make the study of dust explosions extremely difficult. For a dust explosion to occur there must be a degree of turbulence, if only to disperse the dust into a suspension. Gas explosions can occur when the gas is in a quiescent state, the mixture being homogeneous and consisting of molecular size particles.
The suspensions of dusts encountered in dust explosions are, however, unlikely to be homogeneous, and would normally contain a range of concentrations of particles which are many orders of magnitude larger and heavier than gas molecules and which settle out of suspension due to gravity. A dust explosion involves such a high rate of combustion that individual particles and agglomerates are either consumed or oxidized. The combustion of carbon in organic material produces gaseous products which in themselves take up more space than the solids of the parent material. An expanding flame front will also result from the ignition of flammable gases produced by the decomposition of the dust. A dust explosion therefore requires more space because of the expansion of the hot gaseous products. In industrial plant, the heat released during a dust explosion is likely to exceed the natural rate of cooling and consequently an explosion would be accompanied by significant, and, in some cases, uncontrolled expansion effects. In an unconfined situation, there would be mainly localized flames and pressure effects. However, in the confined situations commonly found in plant handling particulate matter, the expansion effects are likely to be sufficient to burst through the confines of the plant equipment and/or piping.
Explosive Limits:
Although a mixture of dust and air may burn with explosive violence, not all mixtures will do so. There is certain range of concentration of dust and air within which the mixture can explode, but mixture above and below this range cannot. The lowest concentration or lower explosive limit of grain and flour dusts may be assumed at (20 g/m3). Below this concentration dust do not explode because of the greater distance between the dust particles.
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Heat is consumed by the air before it reaches the next particles. Only if the particles are close enough to each other is the combustion released in a chain reaction resulting in a dust explosion. The upper explosive limits not well defined, but for flour dust 1000 g/m3 of air, and the other grain dusts 2000 g/m3 of air have been suggested. For still higher dust concentrations, the incomplete combustion of the dust particles retards the ignition and prevents the explosion. Particle size exerts a considerable influence on the explosiveness of the dust clouds. A reduction in size of particles means an increase in chance of ignition.
The moisture content of dust also influences the explosive limit. Dry dust tends to increase the flammability of dust particle and increase in chances of dust explosion.
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Preventive Measures
1) Use of elevators should also be avoided for dusts known to be readily ignited by friction, e.g., sulphur. 2) Where the use of bucket elevators is unavoidable, their positioning should be carefully considered and regular maintenance is essential. 3) The elevators should be mounted outside the building, e.g., supported by an outside wall, and the intake and delivery points should preferably be isolated from the rest of the dust handling plant by means of chokes. 4) The elevator casing should be a fire resistant construction, sufficient to retain a fire, dust-tight and of sufficient strength not to rupture in the event of an explosion. 5) To meet the strength requirements, the casing should be provided either with automatic suppression or with explosion relief at the head and the boot, with vent areas calculated per NFPA 68. Long elevators, say more than 6 m (20 ft), may require additional relief at intervals along the casing to ensure that no point is too remote from a vent. 6) Particular care should be taken to ensure that flame burning dust, etc., discharged from the vents during an explosion cannot injure operators or damage nearby plant. Provision of ducting or deflectors over the vents may be required. 7) Where it is unavoidable to site a bucket elevator inside a building it is desirable for the internal pressure to be slightly below atmospheric to minimize leakage of dust.
Steps should be taken during designing of bucket elevators to minimize Dust Explosion
1) The provision of strong fixing for the buckets and strong bearings for all shafts, external to the casing, provided with detectors for overheating. 2) The main drive to the elevator should be external to the casing. 3) Belt slip within the casing can be detected by belt speed meters, and anitrunback devices can also be installed. Development of friction within the casing can thereby be reduced. 4) Exhaust ventilation can be applied to the casing of bucket elevators which assists the removal of suspension of dust in air. These suspensions contain the dust fractions of smaller particle size, and ventilation would also give a slight negative pressure relative to atmosphere, within the casing. The ventilation system should be conducted to a dust collection unit in a safe area, and should be provided with explosion protection on a similar basis to that in the elevator casing itself. 5) Automatic explosion suppression can be used to protect bucket elevators when explosion relief is not practicable, often because of the situation of the elevator being located within a building.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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6) Preventative strategies such as bearing temperature and belt alignment monitoring, metal detectors, or spark extinguishing systems are often employed. However, these methods only reduce the frequency of explosion. 7) The correct explosion protection strategy for any application depends on the explosion protection objectives of the responsible engineer, as well as regulatory, system and economic considerations. For simplicity, the most commonly applied protection strategies in three levels, from minimum to maximum protection are 1) Explosion Venting 2) Isolation 3) Suppression
1) Explosion Venting
Explosion venting is the most widely accepted and utilized explosion protection strategy. The most comprehensive guidance for venting of bucket elevators is outlined in the 1999 edition of NFPA (National Fire Protection Association) 61, Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Products Facilities. This recently revised standard specifies vents to be located at intervals no greater than 20 ft. along the casing. Vents are to be installed on each side of the casing with a minimum area per vent equal to 2/3 the casing cross section. The head must also be vented with an area of 5 ft2 for every 100 ft3 of head volume.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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2) Explosion Suppression
Explosion suppression is most widely used for bucket elevators located indoors. It provides additional protection benefits when compared to venting, or venting with isolation.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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The optimum speed is shown in fig. B. At this speed the buckets fill and carry optimally and discharge the paddy directly into discharge chute. So there is no grain/seed spillage , no breakage. Theoretically, optimum speed of head pully is calculated by,
Where, RPM = Revolution per minute of head pulley R = Radius of the head pulley plus one-half the projection of the bucket(m). If the head pulley speed is too fast as shown in fig. C, grain/seed is damaged by rough and fast handling and the bucket will not fill properly. The bucket lose all their holding and discharge control. The result is inefficient operation as well as excessive breakage. Grain/seed damage depends not only on the design characteristics of the elevator unit and it's operating parameters, but also on properies of grain/seed. Moisture content and Temperature are two important grain/seed properties that mostly influenced on grain/seed damage. Previous reserch showed that moisture content and temperature of grain/seed significantly influenced the physical damages of grains/seeds. Physical damages increased with decreases in moisture content and temperature. The value of this basic information is important to engineers, food scientists and processors who may exploit these properties and find new uses. Public attention has been attracted to the grain damage problem because damaged grain/seed lead to a lower price in the export market and is vulnerable to attack by insects and mold. But the literature indicates, there is little published work on studying the grain/seed damage in vertical bucket elevator.
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If grain Industry is to reduce the amount of breakage caused by vertical bucket elevator, it needs reliable information on the causes and extent of grain breakage in vertical bucket elevator grain handling method now in use.
SCOPE
Bucket Elevators as name suggests lifts the material using bucket like containers. The Bucket Elevator is one more equipment that is most preferred when it comes to large capacity, more height and space restrictions. The Bucket Elevators can handle variety of materials from powders, granules and lumps very effectively with small handling cost. To suit various types of materials, various capacities and heights, there are different type of Bucket Elevators designed by engineers to increase ease, cost and effectiveness.
Belt Bucket Elevators using Belt as lifting element. Chain Bucket Elevators using Chain as lifting element.
Centrifugal Discharge or Spaced Bucket Elevators. Continuous Discharge or Closed Spaced Bucket Elevators. Chain Bucket Elevator may be Single Strand or Double Strands Chain Elevators.
SANDEEP KUMAR MECH.,ROLL NO -2108424 DOON VALLEY INSTITUTE OF ENGG. & TECH
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