Redesign of a bucket elevator for shot-blast media recirculation

• IndustryAluminium production
• EquipmentShot-blast media recirculation bucket elevator (anode rod cleaning)
• DisciplineMechanical design
• Deliverable3D model, fabrication drawings and assembly/disassembly procedure

The challenge

The shot that cleans the anode rods is recirculated by a bucket elevator. The enclosure was deteriorated and the seals on both drums worn: every material leak meant cutting sections of the enclosure and welding plates to restore tightness. The brief was to survey the equipment in order to build a new one, and to fix the weaknesses of the original design along the way.

Scope

• On-site survey of the enclosure and its components
• Assessment of design weaknesses and feasibility of the requested upgrades
• Redesigned feed tray and top overflow
• New shaft sealing system and inverted mounting position of the lower drum housing
• Inspection windows and belt tensioner at the elevator boot
• Modular panel enclosure with wear plate or ceramic lining in critical zones
• Alignment and soft start with variable-frequency drive
• Standard elements and existing stock codes used wherever possible
• Calculation, 3D model and complete fabrication engineering
• Disassembly procedure for the existing unit and assembly procedure for the new one

How we worked

From failure mode to upgrade. Every wear pattern observed on site became a design decision: seals, replaceable panels, lining and tensioning.

Maintainable by design. Inspection windows, modular enclosure and standard spares so that the next intervention is a panel change, not a welded repair.

Delivered by milestones. Survey and proposals, 3D modelling, drawings and close-out, certified stage by stage.