CEMENT PLANTS – CHAIN EQUIPMENT SYSTEMS
Quarry & Limestone Mines
Raw Mill & Preparation
Pre Clinkerization (Pre heater & Kiln Feed)
Kiln Feed & Rotary Kiln
Post‑Clinkerization & Grinding
Packing & Dispatch
Transition from Chain to Belt Bucket Elevators in Cement Plants
In modern cement plants, there's a growing shift from chain bucket elevators (central chain or round link) to steel cord belt bucket elevators, especially in applications involving raw meal, cement, and clinker silo feeding. This transition is driven by the need for higher efficiency, reduced maintenance, and smoother operation.
| Parameter | Chain Bucket Elevator | Steel Cord Belt Elevator |
| Speed | 0.6 – 1.2 m/s | 1.2 – 1.8 m/s |
| Lift Height | Up to 70 m (typical), max ~90 m | Up to 175 m |
| Capacity | 100 – 600 TPH | 150 – 1200 TPH |
| Noise & Vibration | Moderate to high | Very low |
| Maintenance Needs | Frequent lubrication, chain elongation check | Minimal; belt stretch negligible in steel cord |
| Temperature Limit | Up to 250–400°C (clinker) | Up to 150°C standard, 200°C for short-term HR grades |
| Service Life | Chain wear after 2–4 years | Belt life 4–8 years (if aligned & tensioned) |
Key Benefits of Belt Elevators in Cement Industry
Higher Lifting Heights: Steel cord belts can comfortably reach vertical lifts up to 175 m — ideal for tall preheater towers or cement silos.
Lower Dynamic Load: Smooth and continuous motion reduces wear on structure, head shaft, and motor.
Quieter Operation: Significant noise reduction benefits cement mills and urban plants.
Reduced Downtime: No lubrication or pin-bushing checks; eliminates chain sag issues.
Application Zones Best Suited for Belt Elevators
Cement Mill to Cement Silo Feeders
Raw Meal Feeding to Preheater Tower
Gypsum and Additive Feeding Lines
Finished Product Elevation for Packing Units
Key Technical Parameters for Belt Design
Steel Cord Belt Strength: ST800 to ST3150 (1000–3150 N/mm) (Higher customizable sizes available).
Bucket Fixing: Through-bolted (steel-backed buckets) or moulded recesses
Belt Speed: 1.4–1.8 m/s (Higher customizable speeds available) (Higher customizable speeds available).
Bucket Pitch: 300–500 mm depending on material & speed (Higher customizable sizes available).
Belt Width: 500–1600 mm (Higher customizable sizes available).
CONSTROMECH Capabilities
Turnkey upgrades from chain to belt elevators, including:
Drive station modifications
Belt selection and supply (DIN/ISO grades)
Head pulley, bottom pulley, take-up, and bucket fixing kits
Custom elevator casing designs for belt conversion
Engineering support for lift >100 m and capacities >1000 TPH
| Chain Type | Applications | Key Characteristics |
| Round Link Chain | Bucket elevators (raw meal, clinker feed, packing), reclaimer chains | Compliant with DIN 764/22252; surface-hardened up to 62 HRC; suited for abrasive duty |
| Central Forged Chain | Bucket elevators (hot clinker), deep pan conveyors, drag conveyors | Precise pitch control, wear-resistant links, heavy load-bearing, works up to 400°C |
| Drop-Forged Scraper Chain | Drag conveyors, clinker dust flow conveyors, ESP ash conveying | Robust scraper design; dust-sealed operation; custom scraper flights (flat/U-type) |
| Plate Link Chain | Clinker pan conveyors, apron conveyors, heavy-duty clinker transport | Built for hot, sharp clinker (300–500°C); sidebars with thick pin and bush assembly |
| Toothless & Toothed Sprockets | All above systems; paired with above chain types | Machined or segmented tooth rings; surface-hardened; precision aligned with chain pitch |
| U-Shackles / DIN Attachments | Bucket-to-chain connection points (elevators and reclaimers) | Forged alloy steel, heat treated, with spring-locked pins for vibration-prone areas |
CONSTROMECH ADVANTAGES FOR CEMENT INDUSTRY
- Full DIN-compliant chain manufacturing: Round link and central forged chains conforming to DIN 764, DIN 22252, and ISO 1977 standards.
- Heat-treated and case-hardened components: Chain surfaces up to 62–64 HRC; depth of hardening optimized for long wear life under abrasion.
- Complete kits supplied for chain bucket elevators: chain strands, shackles, buckets, sprockets, guide wheels, and fasteners—all aligned for perfect pitch matching.
- Retrofit-ready designs: Chains and sprockets engineered to directly replace leading OEMs, with matching PCDs and dimensions.
- Specialized material grades: Chains available in 31CrMoV9, 42CrMo4, or MnCr-based alloys for high-temperature and dusty clinker environments.
- High-capacity designs: Elevator configurations capable of handling up to 1800 m³/h and 90m vertical lift with minimal elongation and maintenance.
- On-site technical support: CONSTROMECH offers joint inspections, wear audits, and failure diagnosis at cement plants for proactive replacement scheduling.
- Customized chain pitch and length: Engineered to meet unique layouts in raw mill elevators, preheater feed lifts, and clinker cooler discharges.
- Surface options: Phosphate-coated, manganese plated or shot-blasted finishes to reduce corrosion and material build-up in sticky material areas.
| Parameter | Typical Range / Specification | Description / Remarks |
| Belt Width | 400 mm to 1600 mm | Depends on elevator capacity and bucket size; wider belts for clinker or high TPH |
| Belt Construction | Steel Cord Reinforced with rubber cover | High tensile strength with low elongation, stable in long vertical lifts |
| Tensile Strength | 1000 N/mm to 3150 N/mm (DIN ST1000 – ST3150) | Higher grades used for clinker or tall elevators (≥ 60 m) |
| Number of Steel Cords | 7–24 (based on width and load) | Arranged in parallel, embedded in rubber; zinc-plated for corrosion resistance |
| Cover Grade | Wear Resistant (W), Heat Resistant (HR), Oil Resistant (OR) | HR preferred for clinker and hot cement; OR for gypsum and additives |
| Cover Thickness (Top/Bottom) | 4+2 mm to 8+4 mm | Thicker covers for high abrasion zones; bottom cover may be reduced for drive traction |
| Bucket Fixing Method | Through-bolt (punch hole) or moulded recessed holes | Steel-backed buckets bolted through belt; ensures minimal slippage |
| Belt Speed | 1.2 – 1.8 m/s | Optimized for throughput vs. belt tension and wear |
| Max Lifting Height | Up to 175 meters | For raw meal, cement, or preheater feeding |
| Capacity Range | 150 – 1200 TPH | Based on material density, speed, and bucket arrangement |
| Splice Type | Hot vulcanized (preferred) or mechanical clamp (temporary) | Hot vulcanized preferred for long-term reliability |
| Pulley Diameter | Min. 630 mm to 1600 mm | Sized as per DIN 22101 and belt manufacturer recommendation |
| Temperature Resistance | Up to 150°C (HR), optionally 200°C for short durations | Required for hot clinker or preheater feeding |
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