Belt Bucket Elevator Design Notes

FEED FORWARD PUBLICATIONS
BELT BUCKET ELEVATOR DESIGN NOTES

DISCLAIMER
These notes are intended to assist and provide direction in the process of designing belt bucket elevators. They are
not a substitute for conducting a thorough engineering analysis of the design requirements. Because the author
and publisher do not know the context in which the notes are to be used and cannot review the resulting design
they accept no responsibility for the consequences of using them.
The author claims copyright over all the material in these notes – 15 March 2001.
CONTENTS OF DESIGN NOTES
1.0 Overview of belt bucket elevators and their use.
2.0 Determine throughput capacity.
3.0 Determine belt speed and throw.
4.0 Calculate motor power.
5.0 Calculate top and bottom pulley shaft sizing.
6.0 Drive arrangement and design.
7.0 Shaft bearing and seal arrangement.
8.0 Selecting elevator frame structural members.
9.0 Inlet and outlet chute design.
10.0 Considerations in choosing panel materials.
11.0 Selecting belts and buckets.
12.0 Methods to take-up belt tension.
13.0 Protection against bogging the buckets.
14.0 Clean-out considerations.
15.0 Dust extraction requirements.
16.0 Installing the bucket elevator in place.
17.0 Correct operation of belt bucket elevators.
18.0 Maintenance of belt bucket elevators.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 1
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DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
OVERVIEW OF BELT BUCKET ELEVATORS
PURPOSE OF BUCKET ELEVATORS
Bucket elevators are used to lift bulk materials from one height to another. They are a reliable and well-
proven piece of equipment.
METHOD OF OPERATION
Bucket elevators operate by using an endless belt or chain on which rectangular buckets are mounted. The
belt or chain revolves between a top and bottom pulley and the buckets move with it. At the bottom the
buckets pick up product fed into the elevator boot and at the top the product is discharged as the bucket
turns downward over the head pulley.
TYPES OF BUCKET ELEVATORS

Bucket elevators come in several standard forms with numerous variations to suit the characteristics of the
products being moved.
The most common forms of bucket elevator are -

- centrifugal discharge where the speed of the belt around the top pulley flings the product out of the
bucket,
- positive discharge, for product requiring slower, less aggressive handling, where a snub pulley below
the top pulley orients the buckets downward for emptying,
- continuous discharge, for large lumpy products or very friable products, where the buckets are placed
in contact with each other, and
- pivoted bucket for transporting materials horizontally.
Along with each type of elevator, different styles of buckets have been developed which better suit the
elevator or the materials to be handled.
The left-hand column provides descriptive text. The right-hand column provides an example.
NECESSARY INFORMATION NECESSARY INFORMATION
Required product parameters. Product parameters.
Service use. Raise crushed product from mill outlet to storage silo.
Material chemical name. Aluminium Sulphate.
Bulk density – mass/volume – kg/m3 1700 kg/m3
Maximum duty – kg/hr or m3/hr 5,000 kg/hr
Maximum lump size - dimensions 3 mm max
average size 2 mm
percentage of lumps in total Nil
Height product is to be raised (meters) and angle of incline 5.5 m including length of discharge chute into 4 m high
if any. Provide enough height at the outlet of the discharge storage silo.
chute so the product is always falling following discharge.
Product characteristics – abrasiveness Sharp edges
flowability – free/cohesive/slug Free
dampness – % moisture Less than 2%
friability – firm/breaks/powders Firm
particle shape – Consistent
length/size/volume Ambient
temperature of product 30 degrees
angle of repose Corrosive if damp
corrosiveness Dry and airy
Operating environment, location and conditions –
corrosive/damp
Service required – continuous/intermittent. Intermittent – up to 12 hours per day 6 days a week
Open or closed boot design. Open boot bottom, elevator will sit on a concrete floor.
SELECT BUCKET SIZE AND SPACING SELECT BUCKET SIZE AND SPACING
The size and number of buckets is determined from the 5,000 kg/hr throughput.
required throughput using an iteration process. Select a bucket 150 mm wide x 100 mm projection with a
volume of 0.78 litre.
Select the bucket from the range in the bucket supplier’s
Using 2/3 of the volume give a capacity of 0.5 litre.
catalogue. Only 2/3 (67%) of the bucket’s design capacity
0.5 lt. is 0.0005 m3 and holds 0.85 kg of product. (0.0005
is used in calculations.
m3 x 1700 kg/m3).
Centrifugal discharge conveys usually have a spacing To move 5000 kg/hr using 150 x 100 buckets requires
between buckets that is 2 to 3 times the bucket projection, 6,000 buckets per hour or 100 buckets per minute.
though the spacing can be greater for free-flowing Select a bucket spacing of 300 mm.
products.
DETERMINE BELT SPEED
DETERMINE BELT SPEED 100 buckets per minute/60 sec per minute = 1.7 bucket/sec.
The bucket spacing times the number of buckets per 1.7 bucket/sec x 0.3 m = 0.5 m/sec. This is too low and
second determines the required belt speed. The speed for will prove to be insufficient for a clearance throw into the
centrifugal bucket elevators is usually in the range of 1 m/s discharge chute. The bucket spacing will need to be
to 2 m/s to insure the product throws into the chute at the increased and the calculation repeated.
head pulley.
CALCULATE HEAD PULLEY DIAMETER
CALCULATE HEAD PULLEY DIAMETER v2 (0.5m) 2
A simplifying assumption is made that the throw r (radius ) = = = 25mm
g 9.8m / sec 2
commences at the top of the head pulley. At this point the
centrifugal force and gravity force are balanced. The head pulley diameter is 50 mm. This size, though
cos b accurately calculated, is not practical. It is far too small.
Centrifugal force = m ⋅ v 2 ⋅ where The buckets cannot deform sufficiently to go around the
r pulley without over-stressing both buckets and belt.
m = mass in kg
v = belt speed in m/s The solution is to increase the bucket spacing or to use
b = angle from top dead centre smaller buckets. This then requires a proportionate speed
r = pulley radius in m increase to maintain the throughput. The greater velocity
Gravity force = m ⋅ g where needs a larger head pulley revolving at the same RPM.
g = gravity constant 9.8 m/sec2. However as we are using the smallest buckets available it
Putting both forces equal to each other - is necessary to increase the bucket spacing.
v 2 = g ⋅ r ⋅ cos b The belt velocity using a bucket spacing of 700 mm with
the removal rate of 1.7 bucket/sec x 0.7 m = 1.2 m/sec.
cos b = 1 at top dead centre.
The pulley diameter is now
v2 d = r ⋅ 2 = (1.2 2 ⋅ 9.8) ⋅ 2 = 300mm . The diameter could be
Therefore r = and diameter (d ) = 2 ⋅ r
g made slightly larger if so desired.
CALCULATE THROW INTO CHUTE AND CHUTE

SIZE
Calculate the horizontal and vertical position of the product
for every 0.1 seconds of flight time.
TIME HOR. DIST. VERT. DIST
(sec) (mm) (mm)
CALCULATE THROW INTO CHUTE AND CHUTE 0.1 120 50
SIZE 0.2 240 195
Using the standard trajectory formula s = u ⋅ t + 0.5 ⋅ a ⋅ t 2 0.3 360 440
Where s = displacement (m) 0.4 480 780
u = initial velocity (m/s) 0.5 600 1220
a = acceleration (m/s2) = gravity constant g = 9.8 From the table it is noted that after 0.2 seconds of flight the
m/s2 product has traveled 240 mm horizontally from top dead
t = time (sec) centre and 195 mm vertically. The pulley radius is 150
The trajectory after the product leaves the bucket can be mm which means the product is clear of the pulley by 90
graphed and the chute height determined. mm. But it is not yet clear of the 270 mm radius circle
scribed by the lip of the bucket (allowing for belt
The horizontal component at top dead centre of the pulley thickness).
where acceleration due to gravity in the horizontal
direction is zero is given by s h = u ⋅ t meters. This distance is reached shortly after 0.2 seconds. A
satisfactory chute depth would be 600 mm, with the chute
The vertical component at top dead centre where velocity opening starting 350 mm from the vertical centre of the
in the vertical direction is zero is given by s v = 0.5 ⋅ a ⋅ t 2 head pulley. This makes the bucket elevator 700 mm deep.
meters. Because of the 150 mm width of the buckets a 175 mm
wide belt on 200 mm wide head pulley will be used. To
The distance of the chute from the vertical center of the provide clearance to the wall the elevator it will be 250
head pulley must be sufficient to allow the buckets to clear mm wide.
the wall of the elevator on the downward leg.
DETERMINE THE DRIVE ARRANGEMENT
1.2
RPM = ⋅ 60 = 38
2 ⋅ p ⋅ 0.3
It will be necessary to select sprocket sizes for the motor
DETERMINE THE DRIVE ARRANGEMENT and head pulley to produce the required rotational speed.
With the head pulley size determined and the linear belt
speed known, the RPM of the head pulley can be A gearbox can be selected to reduce from 1450 RPM input
calculated. shaft speed to 38 RPM output shaft speed. Alternatively
the sprocket sizes can be used to produce some of the
V (m / s) reduction and the gearbox the remainder. Limit reduction
RPM = ⋅ 60
2 ⋅ p ⋅ r ( m) via the sprockets to around a 3:1 ratio to not over-stress the
chain.
Usually a 4-pole motor at 1450 RPM with a reduction
gearbox of suitable ratio is selected to drive the head
pulley. The gearbox can be a direct drive or shaft-mounted
unit depending on the available space and access.
Chain and sprocket drives are preferred to vee-belt and The first iteration gearbox output RPM can be determined
pulley drives because of their more positive transfer of from the knowledge of the head pulley RPM and use of the
power. Setting the motor current overload protection to the 3:1 sprocket reduction suggested above.
upper limit of the motor accommodates overload
situations. The head pulley speed is 38 RPM. A 3:1 reduction
produces 114 RPM at the gear motor output shaft.
The selection of the gearbox sprocket size is dependent on Check the gear motor ratios available from the
the maximum allowable torque. This value can be found manufacturer and select the closest next higher shaft speed
from the gear motor manufacturer’s catalogue. Once the gearbox.
limiting torque at the gear motor output shaft is known the
allowable force for different sprocket sizes can be Often it is necessary to choose a sprocket size and number
calculated from the equation T = F ⋅ r where of teeth and then to confirm the selection through an
iterative process of checking calculated against allowable
F = force (N) and r = sprocket or pulley radius (m). torque.
Start with a 25-tooth _” simplex chain 101 mm diameter
Select a sprocket size that is well within the torque rating sprocket on the gearbox output shaft and a 76-tooth 307
of the gear motor and has more than 20 teeth. A lesser mm diameter sprocket on the head pulley.
number of teeth cause excessive forces in the chain links as
they come around a tight radius. Less torque is needed The selection of sprockets and chain will be confirmed
with a larger sprocket radius on the gearbox output shaft. later.
CALCULATE POWER REQUIRED CALCULATE POWER REQUIRED

2 ⋅p ⋅ N ⋅ F ⋅ r T ⋅w The linear height of the bucket elevator is 5.5 m and bucket
Power (kW ) = = spacing is 0.7 m. This means there are 16 buckets in total,
60 ⋅ 1000 ⋅ h 1000
with 8 buckets on the upward and 8 on the downward legs.
Where N = revs per minute
The load from the material weight is calculated by
F = force at outer edge of the head pulley (N)
multiplying the bulk density of the product by the volume
r = radius to force (m)
in each bucket by the number of buckets.
T = torque (Nm)
h = drive efficiency
v = radians per second Bucket load = Lb = 1700kg / m 3 ⋅ 0.0005m 3 ⋅ 8 ⋅ 9.8 = 67 N
The load on the belt results from the weight of product 90 ⋅ 1700kg / m 3 ⋅ 0.0005m 3
lifted plus the dredging drag as the bucket scoops up the The dredging load = = 109 N
0.7 m
product. A duty factor is used to accommodate start-up
loads. Total pulley load = (67 N + 109 N) = 176 N
Belt Load = (total bucket load + dredge load) This load acts at the centre of the buckets, which have a
projection of 100 mm. The radial distance to the bucket
The bucket load is the sum of the loaded buckets on the centers is 150 mm + 50 mm = 200 mm
upward side. The dredging load can be estimated either by
adding an equivalent length (5m for continuous buckets, 2 ⋅ p ⋅ 38 ⋅ 176 ⋅ 0.2
12m for spaced buckets) to the belt or by use of the Power pulley = = 147W
60 ⋅ 1000 ⋅ 0.98
following formula.
As a check on the calculation -
90 ⋅ Wb
Dredge load (N) =
Ps To lift 5,000 kg/hr to a height of 5.5 m allowing for 50%
efficiency overall.
where Wb = weight of material in each bucket (kg) 5000 ⋅ 9.81 ⋅ 5.5
W= = 540kNm
Ps = Bucket spacing on belt (m) 0.5
W 540,000
A quick check on the load can be done using the formulas P= = = 150W (which is close to the previous
t 3600
for work and power. W = F.s (Nm) and P = W/t = F.v (W).
answer considering the actual efficiency is unknown).
CONFIRM DRIVE ARRANGEMENT POWER CONFIRM DRIVE ARRANGEMENT POWER
The load on the motor is transferred through the drive from Power at the head pulley is 147 W. Torque at the head
the head pulley. Simple ratio calculations back to the gear pulley sprocket is directly proportional to the inverse of the
motor shaft will allow determination of the torque at the diameters at which the torque acts.
output shaft. This torque is then compared to the allowable
torque to confirm the suitability of the gear motor. In this calculation the gearbox service factor is 2 and chain
drive efficiency is 0.98.
The power through the gearbox must be increased in
147 ⋅ 2
accordance with - Gear motor power = = 300W
- The manufacturer’s service factors requirement for 0.98
intermittent operation and shock loading.
- Drive efficiency. The logical choice is to select a small 0.55 kW or 1.1 kW
4-pole motor. For the calculation use a 1.1 kW motor, as
With the power through the drive train known, the chain this will permit altering sprocket sizes if operating duties
selection can be confirmed by the chain supplier or change in future.
calculations performed using appropriate formula.
DETERMINE PULLEY DRIVE SHAFT SIZE DETERMINE PULLEY DRIVE SHAFT SIZE
The drive shaft size is calculated to handle the stresses The conceptual sketch for the head pulley is shown below.
generated by a bogged or jammed conveyor. Allowance is
made for stress concentrations causing metal fatigue and
service factor corrections are also applied. The diameter of
the shaft is selected so that the stresses are well within the
shaft material’s metallurgical capacity.
By this stage initial dimensioned drawings can be sketched
using the information compiled from the previous
calculations.
Commence by constructing a free-body diagram of the
head pulley located in its bearings with the drive sprocket
mounted at the drive end. The head pulley will be
mounted to the shaft using hubs at each end. This allows
the uniform load produced across the pulley by the belt to
be drawn as point loads on the shaft at the mid point
position of each hub.
The forces are oriented in the vertical, including the drive
The position and orientation of the gearbox drive has not sprocket force. This arrangement produces the highest
yet been determined. It is best to design for the loading loads on the shaft. The gearbox can be oriented in the
arrangement that produces the greatest stresses and size the horizontal. Such an arrangement would not have vertical
shaft accordingly. This permits the gearbox to be located loads at the sprocket. The sprocket load would then be at
in any orientation in future. 90 degrees to the belt tension. This would produce less
The loads on the shaft are its own self-weight, the belt and overall stress in the shaft and a smaller shaft could be used.
bucket weights, the belt tension load (from product weight However in this design the worst-case orientation will be
and friction drive requirements) and the drive sprocket used.
force generated by a bogged or jammed conveyor. The
bearings counter all these forces and keep the shaft in It is necessary to determine the tension in the belt to lift the
place. full buckets and overcome the dredging load.
Power = (T1 - T2 ) ⋅ v (Watt) The power through the head pulley is 1.1 kW.
where T1= tight side tension (N)
T2 = loose side tension (N) P 1100
v = belt speed (m/sec) v 1.2
T1 = = = 1.68kN
1 1
T1 1 - mq 1 - 0.25⋅p
Also = e mq where e = 2.718 (base of natural logs) e e
T2
m = Coefficient of friction T2 = 0.77 kN
q = arc of contact in radians
The coefficient of friction for rubber on steel is 0.25 and
for rubber on rubber 0.35. The arc of contact is 180
degrees for bucket elevators provided the bottom pulley is
the same diameter as the head pulley.
Combining the above tension equations allows T1 to be The force at the head pulley drive sprocket is in the
determined. proportionate ratio of drive train sprocket diameters.
P 2 ⋅p ⋅ N ⋅ F ⋅ r P ⋅ 60 ⋅ 1000 ⋅ h
Power (kW ) = and F =
v 60 ⋅ 1000 ⋅ h 2 ⋅p ⋅ N ⋅ r
T1 = Newton
1 1.1 ⋅ 60 ⋅ 1000
1 - mq Fgearbox = = 1.84kN
e 2 ⋅ p ⋅ 114 ⋅ 0.05
1.84 ⋅ 101
The weight of the rubber belt depends on the ply of the Fheadshaft = = 606 N
307
belt, its width and length. Since the belt tension is know
The load on the bearings is the sum of the belt tension and
the belt can be selected. The belt supplier can advise the
the drive force considering their direction of action.
belt to be used. Select a belt specifically for bucket
elevators and not horizontal conveyors. Those used on The pulley and shaft self self-load and the belt material
bucket elevators contain more weaving than those for loads will need to estimated and later checked if suitably
horizontal conveyors. Select the belt with a safety factor accurate.
beyond the calculated loads for long life under intermittent
and shock load conditions. The buckets are 150 mm wide so the belt will be 175 mm
wide inside a 225 mm wide elevator frame. The elevator
height is 5.5 m and the belt length about 12 m. For the
purpose of the example a 4-ply 36-oz belt will be used with
a mass of 0.0018 kg/mm width/metre length/ply.
A 12-metre, 175 mm wide, 4 ply belt weighs 15 kg and

produces 150 N downward force.
The mass of the head pulley can be estimated by assuming
it will be made of 300 mm diameter steel pipe of 12 mm
thickness with end plates of 12 mm thick flat plate. The
shaft will be assumed to be 50 mm solid bright steel bar
400 mm long. The head pulley mass is calculated at 22 kg
and 220 N force. It can be seen that the self-load forces are
minor when compared to the product load generated
The shaft undergoes both bending and torsion
forces.
simultaneously.
The free-body diagram can now be completed with all the
The bending and torsional stresses are combined into an forces acting on the shaft. With the drive and load forces
equivalent stress Se in the formula - known the reactions at the bearings can be determined by
balancing the moments at each bearing. The shear force
S e = K b ⋅ K cb ⋅ M 2 + K t ⋅ K ct ⋅ T 2 = Fs ⋅ Z p and bending moment diagrams for the shaft can be drawn
to indicate the position of the highest bending stress.
where M = largest bending moment Nm The highest bending stress is at drive-end head pulley hub.
T = shaft torque At the same time the shaft is undergoing torsional stress
Kb = shock factor bending from the drive. The worst case under torsion would be if
Kt = shock factor torsion the buckets were bogged and the geared motor applied full
Kcb = stress concentration factor bending power of 1.1 kW. This produces a torque T at the pulley
Kct = stress concentration factor torsion shaft of -
Fs = allowable shear stress (MPa) 1000 ⋅ P 1000 ⋅ 1.1
T= = = 31Nm
Zp = polar section modulus = pd3/16 for a solid bar 2 ⋅ p ⋅ RPM 2 ⋅ p ⋅ 38
60 60
The maximum allowable shear stress is half the maximum
principle stress. In addition a factor of safety of 2 for S e = K b ⋅ K cb ⋅ M 2 + K t ⋅ K ct ⋅ T 2
shock loading and stress raisers is included. = 1.5 ⋅ 129.5 2 + 1.5 ⋅ 312 = 163 Nm = 163,000 Nmm
For rotating shafts under minor shock loads Kb varies from No allowance was made for stress concentration since the
1.5 to 2.0 and Kt varies form 1.0 to 1.5. In heavy shock shaft will be mounted to the pulley by taper locks, which
load conditions Kb varies from 2.0 to 3.0 and Kt varies do not require the shaft to be machined. If the shaft is
form 1.5 to 3.0. Stress concentration factors can be found stepped it will be necessary to factor in stress concentration
from stress concentration graphs for the form of stress effects.
raiser involved.
Fs F pd 3 Fs F p ⋅d3 16 ⋅ S e Fs
Se = ⋅Zp = s ⋅ Se = ⋅Zp = s ⋅ and d = 3 ⋅
2+2 2 + 2 16 4 4 16 p 4
16 ⋅ S e For the calculation CS 1030 steel will be used. Fs = 225

d (mm) = ⋅p MPa
3 Fs
4
16 ⋅ 163,000
d= ⋅ p = 25mm
The allowable stress for the steel selected is found in the 3 225
steel manufacturer’s catalogue. If a key way is used in the 4
shaft, the allowable stress for the shaft is reduced by 0.75.
This shaft is on the small side and a 40 mm solid shaft will
be used for ease of assembly and future maintenance.
SHAFT BEARING AND SEAL ARRANGEMENT
Once the shaft size is determined the bearing size can be

selected. Follow the bearing manufacturer’s selection
process for calculating the required bearing type and
configuration for the equipment design life and service
factors.
The best bearing arrangement design is to stand the bearing

off the elevator frame with a clearance of around 25 mm.
Provide shaft seals for the bearing at the bearing housing
and at the penetration into the elevator frame. The bearing
must never be exposed to dust or dirt or moisture while in
the production environment. Do everything necessary to
protect the bearing. The bearing and seal suppliers can
advise other ways of mounting and protecting the bearing.
ELEVATOR FRAME MEMBERS
The frame can either be made of an angle iron skeleton to
which sheets of steel are attached or from sheets of steel
pressed to the required rectangular shape that are flanged
and bolted together.
The thickness and lengths of section used in the frame

must be sufficient to prevent buckling under load.
INLET AND DISCHARGE CHUTE DESIGN

The inlet chute should be designed to promote product
flow and to minimise the amount of bucket drag.
Preferably the product feed falls into the buckets as they
come around the tail pulley without being dragged through
a fully plugged boot.
The feed chute should be made with a slightly smaller

width than the buckets. It should be sufficiently steep to
insure product always flows and does not build back. Test
the product’s flowability if possible by putting some on a
bent sheet of the elevator chute material shaped into a ‘U’
the same width as the chute. Tilt it to find the angle that
produces flow.
Insure there are no restrictions or protrusions into the chute

that will cause the product to build back.
The discharge chute size is known from the initial design.

The angle at which it is set must meet the same criteria as
the inlet.
HEAD AND TAIL PULLEY DESIGN

The head pulley dimensions have been determined. For
simplicity the tail pulley should be to the same dimensions
as the head pulley. This will keep the buckets a constant
distance off the elevator wall and aid product pick-up and
simplify chute design and fabrication. Both head and tail
pulleys need to be crowned to centralise the belt and permit
the belt to be tracked if it wanders. The crowning should
be 2 degrees both left and right from the center of the
drum.
The head pulley could be rubber lagged if desired to

increase the coefficient of friction and lower the belt
tension. This will allow use of a lighter duty belt. But
there is always the possibility the lagging will be stripped
off during operation. It is best to design for a metal drum
and use lagged pulleys only when detection of bogged
conditions is installed.
Ribbing can also be mounted on the top pulley to increase

friction and act by ‘digging’ into the rubber belt and
producing a grabbing effect. The ribs are placed across the
full axial length of the drum and positioned so that at least
two ribs are always in contact with the belt. The rigs
should be 3 mm to 4 mm high and contoured into the drum
so as not to rip the belt.
The tail pulley should be a self-cleaning design. This can
be achieved in two ways –
- constructing the pulley drum of 20 mm or 25 mm
round bars of length wider than the belt. The bars are
spaced around the end plates with gaps for product to
fall through. Size the spacing between ribs with
sufficient clearance for small product to fall through.
Larger product will not fit through the gaps.
- provide a twin opposed-cone hub with the cone’s base

starting at the center and tapering to the shaft at the
ends of the pulley. 20 mm or 25 mm round bars are
welded to the outer rim of the cones and gussetted
back to the cone wall for stiffness.
The pulley can be mounted to the shaft using taper locks

fitted to suitably sized hub, interference press fits, retainers
screwed and doweled to the shaft, hubs screwed and
doweled to the shaft or key way in the hub and shaft.
CONSIDERATIONS IN CHOOSING FRAME AND

PANEL MATERIAL
The materials selected for the frame and panels must
consider the corrosive nature of the product, the dampness
of both product and environment and the protective coating
system requirements to be applied to the finished elevator.
SELECTING BELTS AND BUCKETS

The materials selected for the belt and buckets must be
compatible with the product.
The product’s abrasiveness will influence the choice of

bucket material. Plastic and metal buckets are available. It
is often a good idea when plastic buckets are used, to
install an occasional metal bucket that acts to scrape away
solid build-up in the elevator boot. A steel bucket every 6
–8 plastic buckets is a good place to start.
Use belts specifically designed for bucket elevators as they

constructed in a way to take more stress that similar ply
horizontal conveyor belts.
METHODS TO TAKE-UP BELT TENSION

The belt will stretch when in use after a period of time.
Unless there is a method to take-up the stretch the pulleys
will eventually start slipping.
The take-up moves one pulley further away from the other.
The pulley to be moved can be either the top or bottom
pulley. If it is the top pulley the drive must also permit the
pulley to move.
One way is to mount the pulley shaft bearing housing on

movable plates running in slides. They are positioned by
jacking bolts in both directions. Another method is to have
the entire top portion of the elevator on jacking bolts and
slide it in and out of the lower section. A rubber skirt is used to seal the gay between the two sections.
PROTECTION AGAINST BOGGING THE BUCKETS
To protect against bogging install a proximity sensor to
detect rotation of the non-drive pulley and stop the motor
and in-feed system when motion is no longer present.
Signal to the operator that a problem exists.
CLEAN-OUT CONSIDERATIONS
At times the elevator boot will need to be accessed for
cleaning, especially if multiple products are put through
the elevator.
Whether a floor is required in the boot as part of the

elevator or whether the bottom of the boot is open and sits
on the plant floor is dependent on the product
characteristics and operating environment.
With fully sealed boots removable flanged doors, either

bolted or wedged in place using restraining bars and
retaining hooks, are mounted to one or both ends of the.
When open bottom boots are used flanged triangular
sliding draws fitted to both sides of the boot at the bottom
is the best alternative.
Operators and maintainers prefer easy methods of access

that do not require large numbers of bolts to be removed.
DUST EXTRACTION AND EXPLOSION

PROTECTION
Dust is generated within the elevator by the bucket loading
process. Dust can be extracted from the bucket elevator by
dust collection systems where necessary. Use methods of
dust removal that allow entrainment air to be drawn
through the elevator, else the dust collection fan may create
a vacuum within the elevator.
Explosive conditions are beyond the scope of these notes.

Should this situation arise tt will be necessary to install
bursting panels venting to a safe place and possibly
pressure and temperature sensing instrumentation to detect
high-risk conditions. The selection of materials suitable
for an explosive environment will also be required. As
will consideration of static charge build-up control.
INSTALLATION OF THE BUCKET ELEVATOR

Consideration will need to be given as to how the elevator
will be restrained in position. Methods of fixing the frame
to the floor and to attached equipment have to be selected.
Installation techniques will need to be designed into the

elevator. Lifting points may be necessary. Will
installation be as a complete unit or in sections? Is crane
access possible at the working site? Are there height
restrictions? How will bracketing and ancillary items and
equipment be mounted once on-site?
CORRECT OPERATION OF BUCKET ELEVATORS
Once an elevator is installed operators will need to know
how to start and stop it. Local power isolation switches are
necessary at both the top and bottom of the bucket for
emergency needs. It is useful to have the power supply to
the motor on a plug and lead so power can be remove
during maintenance access.
The feed to the bucket elevator should always be at a lesser

rate than the elevator can remove it to protect against
bogging and overload conditions.
Reversal prevention will be necessary on tall or heavily

loaded elevators to protect personal and equipment from
damage by a belt running backward during a power failure.
Usually a brake option is available with the gear motor.
MAINTENANCE OF BELT BUCKET ELEVATORS

Access for maintenance will be needed to the motor,
gearbox and drive. Motors mounted at the top of the
elevator will require access platforms.
Inspection and observation openings will be required to the

top and bottom pulleys to observe the belt when tracking it.
Operators should conduct periodic inspections of the belt

and bucket condition and a record made of their
observation.
If the selected bearings require greasing they will need to

be put onto a preventative maintenance route. The bearing
manufacturer can advise the greasing frequency. It is
preferred to select bearings that are greased for life and
remove all greasing points from the bearing housing.
When belts have stretched beyond their take-up limits they

can be cut shorter and spliced together while a replacement
belt is procured.
Overlapping the ends of the belt past two or more buckets

and bolting the buckets through the overlap produce a belt
slice. This lap makes a bump in the belt and stresses the
belt as it runs over the pulleys. Another way to splice is to
butt the end of the belt together and lay a separate piece of
belt spanning two buckets either side of the butt. The
overlay piece is put on the same side as the buckets. This
lay produces a flat belt against the pulley. The buckets
mounted to the overlay piece will stick out further than the
buckets mounted to the belt.
An alternative splice is an oil well splice where the ends of

the belt are brought together and folded outward against
each other on the bucket side. The turned-out ends are
clamped and bolted together.
Authored by Mike Sondalini – Maintenance Engineer.

Belt Bucket Elevator Design Notes

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Belt Bucket Elevator Design Notes

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BELT BUCKET ELEVATOR DESIGN NOTES

2.0 Determine throughput capacity.

3.0 Determine belt speed and throw.

4.0 Calculate motor power.

5.0 Calculate top and bottom pulley shaft sizing.

6.0 Drive arrangement and design.

7.0 Shaft bearing and seal arrangement.

8.0 Selecting elevator frame structural members.

9.0 Inlet and outlet chute design.

10.0 Considerations in choosing panel materials.

11.0 Selecting belts and buckets.

12.0 Methods to take-up belt tension.

13.0 Protection against bogging the buckets.

14.0 Clean-out considerations.

15.0 Dust extraction requirements.

16.0 Installing the bucket elevator in place.

17.0 Correct operation of belt bucket elevators.

18.0 Maintenance of belt bucket elevators.

TYPES OF BUCKET ELEVATORS

The most common forms of bucket elevator are -

CALCULATE THROW INTO CHUTE AND CHUTE

CALCULATE POWER REQUIRED CALCULATE POWER REQUIRED

A 12-metre, 175 mm wide, 4 ply belt weighs 15 kg and

16 ⋅ S e For the calculation CS 1030 steel will be used. Fs = 225

SHAFT BEARING AND SEAL ARRANGEMENT

Once the shaft size is determined the bearing size can be

The best bearing arrangement design is to stand the bearing

The thickness and lengths of section used in the frame

INLET AND DISCHARGE CHUTE DESIGN

The feed chute should be made with a slightly smaller

Insure there are no restrictions or protrusions into the chute

The discharge chute size is known from the initial design.

HEAD AND TAIL PULLEY DESIGN

The head pulley could be rubber lagged if desired to

Ribbing can also be mounted on the top pulley to increase

- provide a twin opposed-cone hub with the cone’s base

The pulley can be mounted to the shaft using taper locks

CONSIDERATIONS IN CHOOSING FRAME AND

SELECTING BELTS AND BUCKETS

The product’s abrasiveness will influence the choice of

Use belts specifically designed for bucket elevators as they

METHODS TO TAKE-UP BELT TENSION

One way is to mount the pulley shaft bearing housing on

PROTECTION AGAINST BOGGING THE BUCKETS

Whether a floor is required in the boot as part of the

With fully sealed boots removable flanged doors, either

Operators and maintainers prefer easy methods of access

DUST EXTRACTION AND EXPLOSION

Explosive conditions are beyond the scope of these notes.

INSTALLATION OF THE BUCKET ELEVATOR

Installation techniques will need to be designed into the

The feed to the bucket elevator should always be at a lesser

Reversal prevention will be necessary on tall or heavily

MAINTENANCE OF BELT BUCKET ELEVATORS

Inspection and observation openings will be required to the

Operators should conduct periodic inspections of the belt

If the selected bearings require greasing they will need to

When belts have stretched beyond their take-up limits they

Overlapping the ends of the belt past two or more buckets

An alternative splice is an oil well splice where the ends of

Authored by Mike Sondalini – Maintenance Engineer.

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