Bucket elevator basics | Processing Magazine

Bucket elevators are often used to raise free-flowing bulk solid materials to a higher elevation in a range of industries, including chemicals, minerals, foods, wood products and wastewater treatment. As the name implies, bulk solid materials are conveyed via buckets, which are firmly attached to a belt or chain. As shown in Figure 1, each bucket gets filled as it pushes through a pile of material at the elevator’s bottom inlet (or boot) section. The buckets then travel upwards and empty at the elevator’s top (or head) section. Bucket elevators excel at conveying material upwards vertically, which most other mechanical conveyors struggle with, especially if the vertical distance exceeds 10 or 20 feet. Bucket elevators can be small or large and can convey over short or long vertical distances. One of the most common applications is filling silos — the material is moved to the top of the bucket elevator, where it falls out of the bucket into spouting, through which it flows by gravity into the silo.Continuous bucket elevators move at about half the speed of centrifugal bucket elevators, so their capacities are correspondingly lower. However, the lower speed makes them more suitable for abrasive or fragile materials. Instead of flinging material out of the bucket at the top, the slower speed allows material to fall out of the bucket by gravity right after the bucket turns over at the top. The loose material then flows past the back of the previous bucket and into the outlet chute. Most bucket elevators are unidirectional, moving material only in the vertical direction. However, a few designs use buckets that are not rigidly attached to the belt — they swivel to remain horizontal even if the belt changes direction. The buckets are then mechanically tipped at the discharge point to empty the buckets. These elevators typically form an S- or L-shaped layout in the plant.

Bucket elevator maintenance

Bucket elevators are not maintenance-free. Wear is a factor, especially since the buckets fill by pushing through a pile of material in the bottom boot. Regular maintenance and parts replacement are needed, so it is important to ensure that critical areas at the top and bottom are easily and safely accessible.Belts and chains stretch, so an adjustment or take-up is required to maintain the correct tension. Various take-up designs are available. Frequent checks of slack or proper tension are important for reliable operation. Moreover, economical instrumentation is available to monitor factors such as belt alignment, speed, bearing temperature, and material plugging. These can provide early warnings to greatly decrease downtime and increase safety.  

Bucket elevator sizing

The capacity of a bucket elevator is a function of the bucket volume and how many buckets go past in a given time. In other words, volumetric throughput equals the volume of each bucket times the linear speed of the belt divided by the bucket spacing. Gravimetric throughput equals the volumetric throughput times the bulk density of the material.Typical spacing between buckets is 2 times the bucket’s projection, which is a measurement of the distance from the bucket’s outer lip to the belt, as shown in Figure 3. 

Bucket elevator advantages

Bucket elevators are simple and reliable and are one of the most efficient methods for conveying materials vertically. They can handle a wide variety of free- to medium-flowing materials and are available in a wide range of standard sizes and capacities. While conveying rates can be small, high rates are more common, up to hundreds of tons per hour. The initial expense is reasonable since bucket elevators are built in modular designs and then assembled for the particular application. Furthermore, components are economical since designs are standardized and mass-produced. 

Bucket elevator disadvantages

Standard bucket elevators only convey in a straight direction, vertically upwards, and direction changes are not possible.

In the world of material handling and industrial processes, efficiency is paramount. Two key players in this domain areconveyor belts and bucket elevator belts. Both serve crucial roles in transporting materials within various industries. This blog aims to provide a comprehensive comparison between these two types of belts, shedding light on their applications, advantages, and maintenance tips.

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Comparison between bucket elevator belt and conveyor belt

Applications:

Conveyor Belts:

Conveying belts are versatile systems that find application in a wide range of industries. They are commonly used for horizontal transportation of bulk materials such as grains, coal, ores, and packaged goods. Conveyor belts are extensively employed in industries like manufacturing, mining, agriculture, and logistics. Their adaptability and capacity to handle various materials make them indispensable in modern material handling processes.

Bucket Elevator Belts:

Bucket elevators, on the other hand, are designed for vertical transport of materials. They are particularly suited for moving bulk materials vertically, such as grains, seeds, fertilizers, and various powders. Industries like agriculture, food processing, and mining often rely on bucket elevator belts to efficiently lift materials to different elevations. The distinctive buckets attached to the belt play a crucial role in this vertical conveying process.

Advantages:

Conveyor Belts:

Horizontal Transportation: These belts excel in horizontal material movement, making them ideal for industries that require continuous, level transport.

Cost-Effective: Conveyor systems are generally more cost-effective for horizontal transport compared to vertical lifting systems like bucket elevators.

Versatility: Conveyor belts can handle a variety of materials, from small components to bulk items, offering flexibility in different industrial applications.

Bucket Elevator Belts:

Vertical Transport: The primary advantage of bucket elevator belts is their ability to efficiently move materials vertically, saving valuable floor space.

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Gentle Handling: Bucket elevators are known for their gentle handling of materials, making them suitable for fragile or delicate products.

Customization: Bucket elevators can be customized for specific applications, allowing for variations in capacity, speed, and material handling requirements.

Maintenance Tips:

Conveyor Belts:

Regular Inspections: Conduct routine inspections to check for wear and tear, misalignment, and material spillage.

Proper Cleaning: Keep the belts clean to prevent material buildup, which can lead to increased friction and decreased efficiency.

Tension Adjustment: Regularly check and adjust belt tension to ensure optimal performance and prevent unnecessary wear.

Bucket Elevator Belts:

Bucket Inspection: Periodically inspect and replace buckets that show signs of wear or damage to maintain the system's efficiency.

Belt Alignment: Ensure proper belt alignment to prevent unnecessary strain on the system and reduce the risk of premature wear.

Lubrication: Lubricate moving parts, such as pulleys and bearings, to minimize friction and extend the lifespan of the bucket elevator.

Conclusion:

In the blog post above, we discussed the comparison between conveyor belts and bucket elevators, highlighting their applications, advantages, and maintenance requirements. But when it comes to choosing the best conveyor belt for your needs, one name rises above the rest: Continental Belting Pvt Ltd.

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