Mod 2 Elevator

DATE: Kenmare Moma Mining (Mauritius) Limited PAGE:
Kenmare Moma Processing

April 2010 (Mauritius)Limited 1 OF 16
ISSUE: NO.2 REVISION: NO. 1
EFF. DATE OF DOCUMENT TITLE
SUPERSEDED REV. RELEASED BY
Training module on the Operation of an ADMINISTRATION
Last saved by DJ Rowland Elevator
MODULE 2
ELEVATORS
INTRODUCTION:
Within the MSP Dry separation circuits, material is transferred from

one separation stage to another by materials handling equipment.
The Dry Circuits are specifically designed so that the majority of the
separation equipment is located at a high level all on a common
operating floor.
Mineral products are transported by means of conveyors and elevators.
Conveyors are used to transport mineral from one area to another on a
horizontal plane.
Bucket elevators on the other hand are used to transport mineral
vertically to the next stage of separation equipment.
Elevators are designed solely for elevating dry mineral as wet material
will choke up the inlet and discharge chutes and cause the elevator to
trip out.
Figure 1: General arrangement of an Elevator in the Dry Circuit:
PRINCIPLE OF OPERATION:
PRINCIPLE OF OPERATION
Bucket Elevator with Components:
The units consist of a head and a tail pulley, supported in between by

two large diameter steel pipes
The drive pulley (head) is located at the top of the unit. A continuous
conveyor belt runs between the two pulleys.
Attached to the outside of the belt are steel buckets.

Mineral is fed into a feed chute at the boot of the
elevator, on the side where the buckets are moving
up.
Mineral slides down a feed plate and falls into the
rising buckets.
Some mineral also falls passed the buckets into the
boot, which is picked up by the buckets as they pass
underneath the tail pulley. Feed Chute
The mineral is then transported vertically in the buckets by the moving

belt.
The buckets fill to approx 75% capacity.
As the buckets reach the top of the elevator and travel over the head
pulley, mineral is flung out of the buckets into a discharge chute.
The speed of travel of the buckets causes the mineral to totally
discharge from the buckets.
The speed is critical i.e.: too slow a speed does not generate the flinging
action, while too fast a speed can cause the material to discharge prior
to the discharge point and fall back down into the elevator boot.
At the discharge point is a rubber skirt flap, placed very close to the
edge of the bucket, to prevent mineral from falling back down into the
elevator boot.
The unit is further described in the following sections:

Elevator Boot Section (refer to fig 3):
To tension a elevator belt, the total tail pulley, housing and support
assembly sits within a slide cradle. This allows the tail pulley to be
either lifted or lowered.
Access doors are provided on either side of the boot, for easy access
when the elevator stops (drive motor trips). Material can be removed
quickly (via shovel) and the boot cleared, to ensure the elevator does
not re-start under load.
Figure 3: Elevator Boot:
Elevator Head Section (refer to fig 4)

The drive assembly consists of a motor, pulleys and v- belts connected
to a gearbox which is connected to the head pulley shaft.
The head chute is split so that it can be readily removed for
maintenance access.
An inspection door is also provided so that the discharge of the material
can be observed during operation.
An inspection hatch is located opposite the material discharge point of
the buckets, which also allows the mineral flow to be viewed during
operation.
Buckets/Belt
The buckets are fixed on to the belt at equal distances using special
elevator bolts. Methods used to join an elevator belt.
Angle Iron plates Elevator Bucket Elevator Belt
Belt But Joint.
Belt overlapped.
The bucket bolts have a flat head on the inside of the belt so that there
is a smooth passage of the belt over the head and tail pulleys.
The elevators, within the plant, are of various heights depending on the
required elevation at the discharge point. The units can also handle a
wide range of solids (TPH) rates.
Figure 5: Attachment of buckets to elevator belt:

OPERATING CHECKS:
The following checks, must be done on a regular basis:

Are any buckets loose or missing.
Is the elevator belt tension correct, no slippage observed.
(If the tension is too loose the belt will stop on a low speed
interlock.
The belt must be tracking correctly and not run off to the one
side, at the head of tail pulley. (Tracking adjustments are made by
a competent artisan
Under feed conditions, the mineral must discharge so that
minimal material falls down into the boot.
The deflector flap at the discharge point must be just touching the
buckets as they pass it.
Ensure that the temperature of the mineral does not exceed the set
point.
The belting used is heat resistant and can withstand mineral
temperatures of up to 140oC.
If excessively hot material is fed into the elevator the rubber part of
the belt will harden and crack and eventually break.
VARIABLES AND CONTROLS:
The tonnage of mineral to be handled dictates the following:
Speed of the belt.

Number of buckets on the belt.
Sizes of the buckets.
The above variables are incorporated as per the circuits mass flow.
The following will influence the amount of mineral that an elevator can
handle
Any overloads from upstream separators such as broken H.T
wires, incorrect splitter settings and product hopper chokes can
cause excessive tonnage to discharge in to the elevator
The equipment upstream must be operated in a manner so as to

limit excessive surges of mineral to the elevator feed chute.
The discharge rate from the elevator is influenced by the
availability of the down stream separating equipment. If one or
more of the separators are off line (machine maintenance, feed
gates closed),
To prevent the elevator from tripping out a discharge pipe is
connected to the elevator distribution box(distributor) which
feeds into a surge bin.
If a number of down stream separators go off line the distributor
will fill up and overflow into the surge bin.
Figure 6: Arrangement of Elevator Discharge System with Surge

Bin and HTR Machine:
TROUBLE SHOOTING:
TROUBLE SHOOTING:
In other words if the feed to an elevator goes above its design tonnage
or the elevator surge bin is allowed to fill up the elevator will trip out on
overload.
The draining of an elevator surge bin onto the floor should only be
carried out in an emergency.
Instead elevator surge bin levels must be monitored on a regular
basis and if they start to rise, prompt action must be taken:
Reduce the respective circuits feed rate.
If downstream separators are off line, priority must be
given to get them back on line.
If down stream HTR Separators are all running check feed
gates not closed and clean machine feed slides
Operating problems are due to two main areas:

Components Malfunctioning.
Main belt too loose and even stationary. Requires

tensioning at the tail pulley (boot section).
Buckets missing from the belt. Requires system shutdown
and bucket replacement.
Main belt speed too slow. Requires inspection of drive vee
belts to ensure non-slippage.
Main belt not tracking effectively. This can be observed at
the head pulley and adjusted at the tail pulley.
TROUBLE SHOOTING:
Components Malfunctioning.
Worn deflector flap.

If the edge of the flap is too far away from the
discharging buckets, mineral will fall back down in to
the boot, causing excessive re-circulation of solids and
eventually the elevator will trip out.
Requires system shut down and flap replacements.
Operating problems:
Outlets of Elevator discharge distributor

blocked with trash eg: scrap steel, cloth,
cans etc.
Elevator discharge screen blocked
remove and clean, make sure that it is
put back in place.
Pipe work or screens/feed slides on
machines blocked with trash.
Pipe work to surge bin blocked with trash.
Problems with HTR machines and feed
gates to machines closed. Elevator
Distributor
Elevator Distributor
Screen
SAFETY
To un-bog an elevator: (To clean material from the boot so that the
unit can be restarted requires):
Isolate/lock-out the elevator drive motor as per the MSP Lockout

procedure.
Ensure feed from up stream machines is diverted to the
appropriate surge bins.
Open doors at elevator boot and shovel out the material.
Seal and close doors, unlock/De-Isolate drive motor and re-start.
Check the elevators belt tension and for missing bucket.
Re-introduce feed to elevator boot.
Note: Elevators are extremely dangerous, do put your hands or any

object into an inspection panel, feed or discharge chute.
No work may be carried out on an elevator unless it has been
isolated and locked out as per the MSP Lockout Procedure.
SAFETY
Proximity Switch Steel Blade
Motion Detector (On tail pulley shaft)

monitors belt slippage.
The motion detector consists of a self-

contained sensor known as a proximity
switch.
The sensor is placed to sense the blades on

the tail pulley shaft.
Switching (counting) is activated as each

blade passes the sensor head.
If the counts drop below a set point the sensor de-activates and stops the
motor. (This usually happens when the belt is slipping).
NOTE: All alarms and interlocking devices are activated once

the above occurs.

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DATE: Kenmare Moma Mining (Mauritius) Limited PAGE:

Kenmare Moma Processing

Within the MSP Dry separation circuits, material is transferred from

Figure 1: General arrangement of an Elevator in the Dry Circuit:

Bucket Elevator with Components:

The units consist of a head and a tail pulley, supported in between by

Attached to the outside of the belt are steel buckets.

The mineral is then transported vertically in the buckets by the moving

The unit is further described in the following sections:

Elevator Head Section (refer to fig 4)

Angle Iron plates Elevator Bucket Elevator Belt

Belt But Joint.

Figure 5: Attachment of buckets to elevator belt:

The following checks, must be done on a regular basis:

VARIABLES AND CONTROLS:

The tonnage of mineral to be handled dictates the following:

Speed of the belt.

The equipment upstream must be operated in a manner so as to

Figure 6: Arrangement of Elevator Discharge System with Surge

Operating problems are due to two main areas:

Main belt too loose and even stationary. Requires

Worn deflector flap.

Outlets of Elevator discharge distributor

Isolate/lock-out the elevator drive motor as per the MSP Lockout

Note: Elevators are extremely dangerous, do put your hands or any

Motion Detector (On tail pulley shaft)

The motion detector consists of a self-

The sensor is placed to sense the blades on

Switching (counting) is activated as each

NOTE: All alarms and interlocking devices are activated once

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