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Energy Savings
Belt Bucket Elevators
versus
Pneumatic Transport
Introduction Comparison Assessment Special Features
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Introduction
With their ability to handle large capacities and lifts of 130 m and more,
Belt Bucket Elevators offer significant advantages compared to airlifts :
only 2 ! 33 " of the energy #hich is re$uired for airlifts
reduced dedusting volume
reduced e%haust fan po#er #ith preheater feeding
reduced noise level as no air blo#ers are re$uired
Energy Savings - Belt Bucket Elevators vs. Airlifts
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Energy Savings - Comparison cart !ased onconveying capacity of "## t$
k% re&uired
Belt Bucket Elevator
Airlift
Introduction
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ROI assessment – theoretical comparative study
Energy Savings - Belt Bucket Elevators vs. Airlifts
Example 1 – kiln capacity nom. 2, ! max. 2,2 t!d clinkerExample 1 – kiln capacity nom. 2, ! max. 2,2 t!d clinker
Introduction
&oday, #e #ill focus on e%ample 2featuring a kiln capacity of nom' 3,000 t(d
Example 2 – kiln capacity nom. ", ! max. "," t!d clinkerExample 2 – kiln capacity nom. ", ! max. "," t!d clinker
&his study consists of:
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)eeding of preblending silo
** + 0 m ! 300 t(h ra# meal
)eeding of preheater to#er
** + 100 m ! 22 t(h ra# meal
E%ample 2 ! kiln capacity 3000 t(dE%ample 2 ! kiln capacity 3000 t(d
Comparison
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Comparison
B' Po(er savings on dedusting
20'000 m(h vs' 11'000 m(h '000 m(h saving
20 kW vs' 11 kW ( k) savin*
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Comparison
C' Po(er savings on E)aust fan
2$.
0
0
10'000
20'000
30'000
r e $ u i r e d a i r
m 1 ( h
-irlift Elevator
Example 2 ' kiln capacity " t!d
/reheater feeding
.aving on air volume 2,000 m(h %+ k) poer savin*
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Comparison
Summary of Po(er Savings
conveyin* "(1 k)
dedustin* ( k)
exhaust fan %+ k)
add. e-uipment '2# k)
otal #"2 k)
"(1
(%+
'2#
#"2
60
0
10
20
30
50
.otal savin*s Example 2 ' kiln
capacity " t!d
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Assessment
/ased on/ased on
&2 h ! per year of operation&2 h ! per year of operation
+early savings
and 0 .1 ! k) hand 0 .1 ! k) h
3dependin* on country of3dependin* on country of
installation4installation4
",11,# k)h
0 "11,#
Example 2Example 2
5iln 6apacity " t!d5iln 6apacity " t!d
otal 7oer avin* #"2 k)otal 7oer avin* #"2 k)
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Assessment
Investment Costs
E)ample " , kiln capacity ### t$d
ilo feedin*ilo feedin* 7reheater feedin*7reheater feedin*
)ei*ht 0 )ei*ht 0
-umund supplies and services 13 t 10,000 1 t 230,000
7ocal manufacturing part 35 t ,000 58 t 5,000
-dditional e$uipment 3,000 ,000
)ield assembly 58 t 0,000 2 t 0,000
*ivil #ork 13,000 1,000
Electrical installation 23,000 2,000
&otal "$2, %2,
&otal investment costs 0 $$#,0 $$#,
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Assessment
/I Assessment
E)ample " , kiln capacity ### t$d
otal investment costsotal investment costs
8early savin*s 8early savin*s
0 $$#,0 $$#,
0 "11,#0 "11,#
ROIROI " years
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Assessment
Increased kiln capacity
!y e)ploiting te po(er saving for e)aust fan
9ependin* on the kiln system, the fresh air can :e used to9ependin* on the kiln system, the fresh air can :e used to
increase the kiln capacity :y "; to %;.increase the kiln capacity :y "; to %;.
&he follo#ing additional benefits are possible as #ell:
9ncreased hot gas volume for the e%haust fan to supply to ra# mill
and ( or coal mill system
9ncreased drying efficiency of ra# mill and ( or coal mill system
educed electricity consumption of ra# mill and ( or coal mill
system
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Comparison
Summary of Po(er Savings
conveyin* "(1 k)
dedustin* ( k)
exhaust fan k)
add. e-uipment '2# k)
otal "&+ k)
"(1
(
'2#
#"2
60
0
10
20
30
50
.otal savin*s Example 2 ' kiln capacity
" t!d
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Assessment
/ased on "; capacity increase/ased on "; capacity increase
" t!d x ." x " d!y" t!d x ." x " d!y
+early savings
and additional profit of 0 &. ! tand additional profit of 0 &. ! t3dependin* on country of installation43dependin* on country of installation4
0 2&,&2
0 1$(,
Example 2 5iln capacity " t!dExample 2 5iln capacity " t!d
7oer avin* of "&+ k) and increased kiln capacity7oer avin* of "&+ k) and increased kiln capacity
/ased on &2 h ! year operation/ased on &2 h ! year operation
and 0 .1 ! k)h 3dependin* onand 0 .1 ! k)h 3dependin* on
country of installation4country of installation4
2,&&,2 k)h
2&, t ! y
In totalIn total 0 #%(,&2
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Assessment
/I Assessment
E)ample " , kiln capacity ### t$d
Investment costsInvestment costs
8early savin*s 8early savin*s
0 $$#,0 $$#,
0 #%(,&20 #%(,&2
ROIROI 2 years
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Assessment
ummary of advanta*es and disadvanta*esummary of advanta*es and disadvanta*es
Energy consumption
;edusting volume
*apital investment
/elt :ucket elevator /elt :ucket elevator AirliftAirlift
< <
<3loer volume4
'
'3hi*her volume4
' '
<
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0aintenance1 !elt !ucket elevator vs. airlift
Assessment
-irlift < lubrication =oil filling control> of
blo#ers
< filter cleaning at air blo#er inlet
Bucket elevator < lubrication of drive bearings
< control of belt shore hardness
once a year
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Special Features
/rimarily installed in the cement industry
and designed to suit the
demand for :
? high availability
? long service life of the chain or belt
? temperature resistance
? reduced #ear and maintenance
A0=0>9 hi*h capacity :ucket elevatorsA0=0>9 hi*h capacity :ucket elevators
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Special Features
*istinguising Features of te A2023* Belt
Bucket Elevator
longitudinal steel ropes #ith close
spacing + high tensile strength
less belt thickness
smaller drum diameter
teel re'inforced :eltteel re'inforced :elt
additional cross #ires + high strength for bucket fi%ing
tear6off resistance
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Special Features
9istin*uishin* ?eatures of the A0=0>9 /elt /ucket9istin*uishin* ?eatures of the A0=0>9 /elt /ucket
ElevatorElevator
/elt splicin* – 6lampin* connection/elt splicin* – 6lampin* connection
*lamped steel ropes
.teel ropes cast in a resin
compound
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Special Features
9istin*uishin* ?eatures of the A0=0>9 /elt /ucket9istin*uishin* ?eatures of the A0=0>9 /elt /ucket
ElevatorElevator
/enefits of the steel re'inforced :elt/enefits of the steel re'inforced :elt
@ /elt ends prepared in the orkshop
@ ?ixed rate of elon*ation 3max. .2% ;4
@ >o need for :elt shortenin* on site
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Special Features
9istin*uishin* ?eatures of the A0=0>9 /elt /ucket9istin*uishin* ?eatures of the A0=0>9 /elt /ucket
ElevatorElevator
&ensioning unit for uniform and stable belt
run, no off6track, tolerance only 1 mm
9rive drum and tensionin* unit9rive drum and tensionin* unit
)lat drive drum surface for even load
distribution bet#een belt drum
Belt centering achieved #ith minimum slope at
drum edges
emovable segmented friction lining for easy
maintenance
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Special Features
A0=0>9 /elt /ucket Elevators 9evelopment overA0=0>9 /elt /ucket Elevators 9evelopment over
the past 2 yearsthe past 2 years
$
+2
2
("
$1
22
12
1."
2$
1#
1.%
"+
2
#
+
$
1
12
1#
1+
1($'1($% 1($+'1(( 1((1'1((% 1((+'2
CC m Capacity t/h Installed power kW
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Special Features
>um:er of A0=0>9 /elt /ucket Elevators installed>um:er of A0=0>9 /elt /ucket Elevators installed
over the past 2 yearsover the past 2 years
total number installed in 2001: 12(
S i l F t
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Special Features
&he trend for large belt bucket elevators for feeding of ra# meal silos and&he trend for large belt bucket elevators for feeding of ra# meal silos and
preheaters is steadily increasingpreheaters is steadily increasing
since kiln capacities no#adays often reach 10,000 t(daysince kiln capacities no#adays often reach 10,000 t(day
and lifting heights of 130 m and more are re$uired for multi6stageand lifting heights of 130 m and more are re$uired for multi6stage
preheater and pre6calcining systempreheater and pre6calcining system
A2023* (ill !e tere to meet te callengeA2023* (ill !e tere to meet te callenge
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