BULK ELEVATOR

Working Principle
Material enters by flowing along the floor from which it is
the buckets scooped up by the digging action of
as they round the
foot wheel. The
proper speed, diameter of the head wheel
the (D), and
position of the head chute are important for the clean action.

H
h
B

a =
45-60 and B 300
= -

450
General Descriptions:
A bucket elevator consists of
() The endless pulling member. The elevating element may be a single strand of chain or twin
chains or belts
(11) Buckets (to contain the
material) rigidly secured fixed to the belts or chains at regular
interval
(iii)Top terminal pulley or sprocket
(iv)Motor with speed reducing unit and hold back brake
system, preventing reversal of the
moving part.
(v) Bottom terminal pulley or
sprocket with tightening arrangement.
(vi)A metal casing consisting of the
upper part (head), intermediate sections and the lower
part
(boot).
Manholes are
provided at the corresponding level of the casing permit to observe the moving
part during operation.

The pulling members with the buckets receives motion from drive unit and is initially stressed by
tightening gear. Bulk material is loaded into the feed
hopper (boot) at the lower conveyer end,
where it is dredged by the digging action of the buckets, lifted and discharged over the upper
pulley (sprocket) into the discharge spout.

Bucket elevators are

specified for the conveyance of various
powdered, granular and lumpy
materials (cement, sand, earth, peat, coal,
grain, flour, chemicals etc.). Elevators are extensively
employed building materials, chemical industry plants, foundry shops, food
in
industry, flour
mills, grain stores etc.

Advantage
(i) Transverse compactness
(ii) Ability to raise loads to a considerable height (up to 50 m)
ii)Capacities ranging from 5 160 m/hr
 Disadvantage:
) They are sensitive to overloads
(i) Must be loaded at a uniform load

Types of Bucket Elevators

) Centrifugal Discharge
ii) Perfect discharge
(ii)Continuous bucket (Single strand)
(iv)Continuous bucket (double strand)
(v) Gravity discharge

Centrifugal Discharge

Discharge
Spout

Feed:
Well fed by feeding hopper and bucket is filled by digging action.
Delivery:
By centrifugal action.
Bucket speed 1-2 m/sec
Suitability:
 KOugn handling of materials, since the material is thrown away during discharge. Slightly sticky
and wet materials can also be used. Brittle materials cannot be handled. Wear and tear of parts
cUSes much cost for
changing parts. Predominantly belt but rarely chains are used. High speed
O with spaced buckets is handling free flowing powdered granular and small humped

material. Bucket
spacing in high speed elevators should be such that the load particles ejected
from the bucket do not hit the
previous buckets.

Perfect Discharge:

Jockey Wheel
to deflect
Chain Inwards

Feed: As before construction.

In this case, the buckets
are tilted to some
greater degree.
Discharge: The material is discharged by gravity when the
buckets are inverted.
Speed: Slow.
Bucket speed: 0.6 -0.8 m/sec.
Suitability: used for slow-flowing powdered, moist flaky and wet materials (coal dust, chalk.
various chemicals, wet ashes, saw dust etc.)
In inclined elevators gravity discharge is ensured by the inclined position of the elevator.

Continuous Bucket (Single strand)

Discharge
Spout

Large lumped and abrasive materials (gravel, ore, large-lumped coal etc.) can not be scooped up
without high resistance which may tear away the bucket and even result in a broken belt (or
chain). For this reason large-lumped and abrasive materials are fed directly into the buckets. This
method of loading can be applied only in continuous bucket elevators where the material will not
fall through the spaces between the buckets and at low speeds (not above I m/sec) as lumps will
rebound higher speeds.
Feed:
When the bucket just starts to ascend vertically upwards the buckets are filled.

Discharge:
When the pulling member turns around the head puley (sprocket) each bucket discharges over
the front of the preceding bucket which forms a chute or guide for the material to the main
discharge of the spout.

Suitability:
Mainly used to handle heavyIrge lumped, abrasive and mildly abrasive material. gravel ore, slag
etc.) and also downgraded crushing materials like peat, charcoal, coak etc.
Gravity Discharge (V-bucket)
Construction:
This is a double strand elevator
conveyor with spaced V-section bucket. It may follow almost
any path in a vertical
plane.
Feed:

Buckets, while ascending scoop up the material.

Discharge
Material is unloaded into the
trough on the upper horizontal section. Material can be discharged
at any point on the upper horizontal run
through openings, closed by gates.
Speed:
It is slow
speed machine.
(Bucket speed: 0.1 to 0.5 m/sec)
Advantage:
(i) It convey loads horizontally and vertically without
can
rehandling.
(i) Permits discharge and distribution of the load at intermediate
points along the whole length
of the unloading area.

Disadvantage:
Crushing of the material conveyed.
Cii) Increased area of buckets and trough
ii) High power consumption
(iv) Need of a feeder for regular loading

Gravity Discharge (Pivoted bucket)

Construction:
As distinct from the latter, the buckets are pivoted to the bush roller chains so as to swing or tip
freely and move on both the horizontal and vertical strands parallel to each other.
Feed:
The material is fed into the buckets on the lower horizontal sections.
Discharge:
The buckets are
discharged at desired points on the upper conveyor section by trippers.
 Speed:
0.15 to 0.4 m/sec

Advantage:
(i) Take the material over subsequent horizontal and vertical section or inclines without
rehandling.
ii) Unload it at any desired point of the horizontal sections
ii)Do not crush or degrade the material.

Disadvantage:
(i) Complicated design and operations
(ii) Large weight of moving parts.
(ii)High cost
iv)Excessive swing of the buckets at high conveying speeds.

Continuous Bucket (Double Strand)

Construction is similar to that of the previous one, only difference is that it has got two strands of
the chain, thereby larger buckets can be accommodated. This is also called a Super-Capacity
bucket elevator.

Sliding
Gate Trough
Drive
Corner
Take p b e akecl)
Corner

Bucket Fixed
to two Strands
of Chain

b dbcdmte Feed
Hopper
Storage
3al CA Hopper

Tg

drve.shard elerntr Ca ver tpresel

V-2eeben utkel, n) irtl m chwe a Vts art
G i tip l
e lCminlu tmer c'n uwF W an.bdhav, 9 t)
reAnt fucke pee.d ftee) nid4 nd eel
 Selection of Bucket Elevators
i) Centrifugal discharge type is lowest in first or initial
cost.
(11) Continuous bucket
elevators operates at slower
speed and thus with less wear of buckets,
chains and sprocket
wheels; therefore the maintenance cost is
materials with less lower, Suitable for fragile
breakage than the centrifugal discharge type.
(1i)Perfect discharge elevators are used only for materials discharging
clay, silica sand, soda ash, rubber sluggishly e.g. Bentonite,
seat etc.
(iv)Continuous double strand elevators are used for
(v) Gravity discharge elevators larger capacity only.
are
nicely adopted to continuous where the lift is to be
by a short horizontal run or
followed
where changing over from elevator
damage to the material. to
conveyor may cause

Bucket Speed
Bucket speed
depends upon
) Nature of the material to be handled
(i) The inclination of the
buckets; (elevator)
(ii)The pitch of the buckets
(iv) Position of the delivery
sprout
Speed is high for light materials
(e.g. grains)
Speed is low for heavy materials
(e.g. minerals, sticky
Actual bucket speed: materials)
0.4 1.0 m/sec for
chain;
Upto 2 m/sec for belt
Also variable
speed drive is used to suit
varying conditions.
 Bucket Speed for Centrifugal Discharge Elevator
L
A

Before reaching the pulley, the bucket moves uniformly along a rectilinear path and only the

force of gravity, P=mg acts on the load; where the buckets begin to turn around the pulley (or
sprocket), the centrifugal force

F
is added to the gravity. In the above equation
m=mass of the load contained in the bucket
v= speed ofthe center of gravity of the load in the bucket.
r= radius of rotation, i.e. the distance from the center of gravity A of the load in the bucket to the
pulley center O,

g acceleration due to gravity, m/secs

The resultant of these two forces R changes its magnitude and direction as the bucket turns. If,
however, the resultant vector R is extended to cross the vertical line, raised in the pulley center,
the vector of force R will cross the said vertical at one and the same point B in any position of
the bucket. The point B is called the Pole.
From similar triangles A ABO and AAFR

mg

Hence, the polar distance l = g x = cOnst.

Substituting, v = Trn we obtain

30
3 0 9
nyn

where n is the shaft

speed, rpm
When Irh: Centrifugal force is of considerably greater value than the Hsavity force, The
discharge is centrifugal
P he lorce of
gravity in greater than
the centrifugal force. Bracket is discharged by gravity.
r the discharge is both by centrifugal and by gravity.
When r, mg mv

V=rg
And

30
vr

Position of delivery spout is represented by the specd of the bucket.

Problem.
A vertical elevator with
centrifugal gravity discharge is lifting grains to a height of 40m. The
speed of the bucket is 2m/sec. Caleulate the radius
of rotation of the buckets and also
design a
gear train for the speed reduction to be a
accommodation of space reducing units if the
the rotor is 1420 speed of
rpm

Answer
Given,
H 40m

v21m/sec

v= gr d 0408m
2x 60
uT2X x0.408 47rpm
47- x x
1420
 Parts of the Bucket Elevators

Buckets

The shape of buckets depends upon grain size, adhereness and various other factors.
Generally,
buckets are of three main types:
(1) Deep Buckets: They are used to convey very dry free-flowing bulk materials (earth, sand,
grain, fine coal, cereals)
B 135 to 450 mm
h
APecde
:101 to 240 mm
Capacity :0.75 to 14.5 litres

ii) Shallow Buckets: They are used for the conveyance of moist, clinging, slow flowing bulk

materials (flour, cement, etc.).

B :160 to 450 mm

h : 100 to 285 mm
Capacity :0.65 to 15 litre
Deep and shallow buckets have a cylindrical bottom facilitating discharge. They are used only in
spaced bucket elevators. Buckets spacing 'a' is 300, 400, 500, and 600 mm.

As
 i)V-type Buckets:
-buckets are used
only in continuous discharge elevators and
lumpy and abrasive materials. for the conveyance of hecavy,
B
:160 to 900 mm
:155 to 620 mm
Capacity 1.5 to
130 litres
Buckets are
designated by their type, main
Deep and shallow buckets are geometrical dimensions (B, A, and h) and
stamped or welded
capacity.
malleable iron. V-buckets are from 2 to 6 mm sheet steel or are cast of
welded or stamped. Buckets
strengthened lip protecting them against intended for abrasive materials have a
rapid wear.

Pulling Member
The pulling member is
usually a belt or chain, sometimes a steel rope.
Belts

Advantage i) Light weight

(i)Permit high conveying speed
(ii)Do not contain quick
wearing joints
Disadvantages: ) Pull is transmitted by friction and this calls for
makes high initial tension and
driving difficult when loads are
heavy.
(i)Limited service life under severe service
conditions
Chains
Advantages: i)Easily wrap around sprockets and
pulleys of small diameters.
(i)Provide for convenient and secure
attachment of the load
moving parts. carrying and
 (ii)Reliably transmit the pull by engaging with the
(iv) Stretch little under load. sprocket.
Disadvantages: G)Comparatively highown weight
(ii)High initial cost
ii)Many links calling for regular maintenance and lubrication and
clogging when operating in a medium containing abrasive dust.
(iv)Intensive wear of the chain at high speeds.

Type of Chain
(a) Detachable Chain
b) C-chain or Combination Chain
(c) Engineering Chain or Bush Roller link Plate Chain

Capacity of the Bucket Elevators

Weight of the load/metre of elevator length kg/m =
=
q =
kg/m
a

where, io =

Capacity of the bucket (litres)

i-fillingcapacity
-bucket loading efficiency
Ybulk density, tons/m
a bucket spacing in metres at interval of a
>(2.5 to 3) h for deep and
shallow buckets and a>h for continuous
V-buckets (where h is the bucket
heights)
Handling capacity: Q tons/hr
3600
1000
10004.= 3.6qvtons/hr
where, vbelt or chain speed, m/sec
Thus, Q =
3.6qv =oloYo
a

The dimension of the buckets

selected should be consistent with the
dimension of the largest
lump amax. The value of the bucket project 'A' should
satisfy the condition that
A>amaxTm
 Factor m2 to 2.5 when the material contains 10-25% by weight of lumps sized amax

M 4.25-4.75 when the material contains 50 to 100% by weight of lumps sized amax

Simplified empirical equations are generally used to approximate the elevator parameters. These

cquations give results close to actual values, since the principal resistance in an elevator is the

pOwer required to lift the load. For vertical elevators the maximum static tension of the driving
member Smax for steady motion can be approximated rom equation
Smax 1.15H(q + k1qo)
where. Hheight to which the load is elevated, m
9weight of the load/metre of elevator length, kg/m
9o weight/m of belt or chain with buckets, kg/m
k= factor allowing for the resistances to motion and
bending of the driving member and
bucket on the upper and the lower
pulleys (sprockets) including the resistance of the load
to scooping up.
The value of qo is obtained from manufacturer's specifications or design data and may be
approximated from the equation

9ok20
where, k2 is the co-efficient weight of belt/chain with buckets/m
(it is basically the frictional
resistance factor of moving parts)

Required motor power on the drive shaft of vertical conveyers (not including losses in the
driving gear) may be approximated from the following equation:
1.15QH
No 367 k34oHKw
367
QH
3671.15 +kzkgv)KW

Power consumed to lift the load

(including the safety factor equal to 1.15) is determined from the
first component- frictional resistance of the moving parts-from the second.

Problem:
 Calculate the
capacity, power required and the efficiency of a
elevator, carrying crushed stone verticalcentri fugal discharge type
when 80% full contains 1.6 weighing 1.25 tonns/m to a height
of 20m and each bucket
litres of material.
Given that

Bucket loading efficiency: 0.8

Radius of rotation of the buckets: 0.408m

Pitch of the buckets: 300mm

K:2.5
K2:0.45 to 0,54
K3: 1.6

Solution:

Belt speed, v = ygr = v9,81 x0.408 2m/sec

Capacity '0' = 2Y _ 3.6x1.6x1.25x21o tonnes

a 0.3 hr

Power required,

QH
No 3671.15 + k2k3V)

48X20
3671.15 + 0.45X1.6X2)

=6.77 KW

QH
Neff367
Thus, efficiency

Ne y100 34.8%
No
Elevators for Large Objects (unit loads): In this category, there are two types of elevators
namely,
) Rigid Arm Elevator (for large objects, viz. Bags, Barrels, Rolls of carpets, packing cases,
bales, sacks, blocks of ice etc.
 (ii) Swing Tray Elevator
Rigid Arm Elevator
These elevators are
various unit loads.
low-speed units moving at a rate of 0.2 to 0.3 m/sec. and are used to lift

Advantages:
(i) Initial cost is low
(i) Space occupied is small
(ii)Power consumption is moderate
(iv)Considerable labour saving
Disadvantages
(i) Can be used for two fixed
(ii) Both elevating and points at atime
lowering are not
(ii)Material suffer injury while thrown possible
upside down.
Note: can be avoided
by providing jockey wheels, unloading is on the
Swing Tray Elevatoors ascending strand.
To serve several
floors and where
grates, baskets, etc. or any
elevating and lowering are required for
other fragile materials. handling bottles,
Trays or carrying platforms are
suspended at intervals on the endless chains.
Trays instead of fixed to the chain are
point of suspension keeping the freely pivoted to the chain and C.G. is
trays stable at all kept well
below the
points manually loaded and
-

Advantages unloaded.
) Packages can be loaded in the
ii) ascending side
Unloading can be either from the
(ii)Carrying capacity can be increasedascending descending side.
or

quickness of the person to load and by pulling the trays closer. Limits being fixed the
(iv) This is more unload. by
balanced, hence power
consumption
is less.