Reliable energy supply in outdoor use with dust and dirt

Energy chains defy the harsh environment in alumina production and secure the energy suppl

During the mining and subsequent storage of bauxite, a sedimentary rock for the production of aluminum oxide, a lot of dust is thrown up, which is a major challenge especially for the moving machine parts of the conveyor units. Partly for this reason, the Aluminum Oxid Stade GmbH (AOS), one of the major German alumina producers, decided to use energy chains of igus. For several years now, they have reliably supplied conveyor units and stockpiling equipment with energy, data and media.

Profile

What was needed: "Heavy-duty" rol e-chain® 5050RHD, igus Condition Monitoring System
Requirements: High reliability despite unfavorable environmental conditions (outdoor use, temperature fluctuations, humidity, dust) and high push/pull forces
Industry: Aluminum production
Success for the customer: High reliability due to sophisticated energy chain system, high safety due to i.Sense system, fast and scheduled installation

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The problem

Aluminum Oxid Stade GmbH (AOS) is one of the major alumina producers in Germany. It processes the raw material bauxite into aluminum oxide. The various types of bauxite are stored either in halls or in large open areas and fed into production by an impressive bucket-wheel stockpiling machine that can be seen from afar. In this process, the raw material is transported via an encapsulated conveyor belt system for intermediate storage before it is taken from there for processing. When a complete overhaul of the stockpiling equipment was due, those responsible decided not only to modernize the equipment itself, but also to renew the rail track and the energy supply system of the conveyor.
The particularly difficult environment (outdoor use, temperature fluctuations, humidity, dust) as well as the 366 m long track required a special solution. Since the motorized cable drums used previously required a great deal of maintenance and were always causing problems, Fabian Wilhelm, Head of Electrical Engineering at AOS, decided to use an energy chain system from igus for the first time in 2012.

The solution

Originally, the conveyor was supplied with energy and signals on its 366m long track via a motor cable drum. Now a modern energy chain system from igus performs this task. Since the length of the travel results in push/pull forces that should not be underestimated, the project engineers recommended the use of a rol e-chain that does not glide in the guide trough but rolls over high-strength rollers with stainless steel ball bearings. Due to the unfavorable ambient conditions, a Heavy Duty rol e-chain® type 5050RHD is used. External radius stop-dogs prevent the conveyed material from getting stuck. In addition, the guide trough was equipped with an enclosure as a protection against rising and weather. A floating moving end suspension also ensures lateral tolerance compensation, and an igus Condition Monitoring System ensures the high availability that is indispensable in this application. The system continuously measures the push/pull forces that occur. If obstacles or blockages occur during the movement of the energy chain, they are detected by the i.Sense and the system can then ensure an immediate stop of the conveyor. In this way, major damage, such as tearing off of cables, is avoided.

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Bauxite is fed into production on a 366 m long track. A state-of-the-art energy chain system from igus provides the energy supply.

The dust and dirt load is especially high. An e-chain with external stop-dogs prevents too much dust from accumulating.