Tubular Drag Conveying: A Cost-Effective, Energy-Efficient Solution for Material Handling
CHALLENGE
Designing efficient conveying systems for modern processors goes beyond simply moving materials from one point to another. Engineers must consider plant and worker safety, environmental impacts, and, increasingly, the protection of materials throughout the process. With rising costs of materials and processing, it’s critical to minimize product loss while maintaining a safe and environmentally conscious operation.
In today’s manufacturing environment, engineers are looking for conveying systems that not only move products efficiently but also integrate seamlessly into existing operations, even in tight spaces. Tubular drag conveyors are rapidly becoming the preferred solution due to their versatility, low energy consumption, and ability to protect both materials and workers.
How Tubular Drag Conveying Works
A tubular drag conveyor consists of a stationary outer casing through which a chain is driven by a sprocket. The chain is fitted with flights that carry bulk material from an infeed point to a discharge port. Conveying capacity can reach up to 50 CFM by adjusting the size of the casing, flight, and chain speed.
While tubular drag conveyors share some characteristics with cable and aero-mechanical systems, they offer several advantages. They use a heavy-duty chain to move materials at low speeds, making them both rugged and gentle on a wide range of materials. This low-velocity operation minimizes wear and tear, reduces maintenance, and lowers power consumption.
Key Advantages
1. Low Speed for Material Protection and Energy Efficiency
Tubular drag conveyors are powered by a single, low-horsepower electric motor, making them one of the most energy-efficient conveying systems available. The slow, positive displacement motion of the chain ensures that even fragile materials are handled gently without degradation. This reduces material loss and ensures a longer conveyor lifespan, all while minimizing noise and energy consumption. These conveyors can run continuously or intermittently, depending on the application.
2. Fully Enclosed Design for Safety and Protection
The most significant feature of tubular drag conveyors is their fully enclosed construction. With male/female ends and gaskets at each section, this design protects the conveyed material from contamination and shields both workers and the plant environment from potentially hazardous substances. It is also effective at containing odors, making it an ideal solution for handling a variety of sensitive or hazardous materials.
Additionally, these conveyors can operate under an inert purge, preventing reactions that might occur when materials are exposed to air. This makes tubular drag conveyors an excellent choice for handling hygroscopic materials, especially when combined with dry air or inert gas purging systems. As a result, costly product/air separation or filtration systems can be eliminated.
3. Flexible Circuit Design and Integration
Tubular drag conveyors are highly flexible due to their customizable chain and casing design. They can be adapted to create virtually any conveyor circuit, allowing easy integration into existing production processes. These conveyors can transfer materials over distances up to 400 feet (122 meters) and accommodate multiple direction changes, making them ideal for complex layouts.
Moreover, the system can include multiple inlets and discharge points, allowing a single conveyor to replace multiple traditional conveyors. Manual or pneumatic gates can be used to control selective discharge points, and a self-cleaning discharge gate offers additional convenience.
4. Material Construction and Durability
Tubular drag conveyors are available in a range of materials to meet specific application needs. The casing can be made from carbon steel or stainless steel, with diameters ranging from 3 to 12 inches (76 to 305 millimeters). For more specialized applications, additional liners can be used.
The conveyors use a round-link chain, which is less prone to fatigue, wear, and stretch than steel cables. This design allows individual links to be replaced as needed, making maintenance easier and more cost-effective. The round-link chain’s strength-to-weight ratio and flexibility enable it to handle even complex conveyor circuits with ease.
Conclusion
Tubular drag conveyors offer a range of benefits for today’s processors: material protection, worker safety, low operating and maintenance costs, easy integration with existing systems, and gentle material handling. These factors make them an increasingly popular choice for businesses seeking a cost-effective, energy-efficient, and reliable material handling solution. With their ability to protect both materials and personnel, and to operate efficiently in demanding environments, tubular drag conveyors are poised to play a key role in the future of manufacturing and processing operations.