Each granary must ensure the following operations with grain: reception, processing (cleaning and drying), storage, internal movements, release. All elevators, regardless of their types and purposes, operate according to the following principle:
Each granary must ensure the following operations with grain: reception, processing (cleaning and drying), storage, internal movements, release. All elevators, regardless of their types and purposes, operate according to the following principle:
1 - receiving belt conveyor; 2 - receiving hoppers: 3 - release device; 4 - elevator; 5 — overhead bunker; 6 — scales (bucket or portion); 7 - distribution pipes; 8 - over-silo conveyor; 9 — above-separator bunker; 10 - separator; 11 — silos for grain storage; 12 — silo conveyor; 13 - sub-separator bunker.
Grain and its processed products are one of the foundations of human nutrition, therefore this storage option is the most relevant among all possible grain storage facilities. The grain elevator is considered the most reliable, and therefore entire networks of such grain receivers are installed near producing areas. This makes it possible to level out grain losses during remote transportation from harvest sites.
Grain and its processed products are one of the foundations of human nutrition, therefore this storage option is the most relevant among all possible grain storage facilities. The grain elevator is considered the most reliable, and therefore entire networks of such grain receivers are installed near producing areas. This makes it possible to level out grain losses during remote transportation from harvest sites.
An elevator is understood as a special structure designed for storing large quantities of grain, taking into account bringing the grain to a condition. In addition to the storage facilities themselves, such a warehouse is equipped with a complex of special devices that weigh, receive, clean, dry and ship grain.
Alternatively, such a complex can be implemented in a mechanized silo-type device, which significantly saves space and ensures complete mechanization of the process. The first elevators appeared in Russia at the end of the 19th century; currently they are highly mechanized, efficient storage systems for grain crops.
Grain and products made from it are the basis of people's lives. The issue of their safety until transportation is very important. Grain elevators simplify it.
Grain and products made from it are the basis of people's lives. The issue of their safety until transportation is very important. Grain elevators simplify it.
The grain elevator is designed to store grain in large quantities and bring it to condition. The elevator inside includes mechanisms for loading and unloading grain and dryers. Work buildings, etc. Usually, organizations build entire turnkey elevator complexes.
In the grain harvesting and processing industry, a structure such as an elevator is often used. In other words, this structure is high-tech equipment for storing grain in special conditions and through such storage the grain is brought to a certain, required stage of condition.
Elevator equipment
Elevators are certainly equipped with equipment such as elevators, which are vertical lifts that are needed to lift grain for weighing, cleaning from various impurities, and further drying it. After this, the grain is delivered through a conveyor system onto conveyors, which discharge the grain into a silo. All these elements for carrying out the described work are included in one structure - the elevator.
The elevator also includes another structure in which the grain crop is directly disinfected and ventilated, but today not all elevators are equipped with such working devices.
However, it is worth noting that today an increasing number of elevator installations are equipped with special points that receive grain from road, rail and air transport. This greatly facilitates all loading and unloading operations, because just some time ago, elevators were operated exclusively by hand, and all work on unloading grain was carried out directly using manual labor.
Work towers, silos and grain dryers are important technological units of elevators. Their optimal location relative to each other ensures the circulation of large volumes of bulk products, thanks to the streamlined operation of internal transport arteries.
Loss during storage
Despite compliance with all standards and the creation of ideal conditions at elevators, it is still not possible to preserve grain 100%. There is such a thing as the rate of natural grain loss. For example, when storing grain for longer than 3 months, the following formula is used: x=a+b>c/g, in which:
- a – loss for the previous period;
- b – the difference between the current and previous standards;
- c – the difference between the average and previous storage standards;
- g - number of months of storage.
Natural loss is a natural process that occurs due to loss of moisture, grain cleaning, sedimentation of mineral impurities to the bottom of the storage facility, etc.
Elevator components and equipment
An elevator is not one building, it is a complex of interconnected objects. The objects are as follows:
The list of equipment necessary for the operation of the elevator includes:
- elevators, which are necessary for delivering grain for weighing, cleaning from impurities and drying. The vertical belt continuously makes a cyclic movement, at the bottom it scoops up grain with buckets, at the top point the buckets tip over, pouring out the contents;
- a screw conveyor, with the help of which the grain crop is transferred to conveyors that dump it into a silo;
- equipment for loading and unloading grain crops.
Old style elevator
Storage requirements
To guarantee the safety of grain raw materials, elevators must be equipped in accordance with all technical requirements of grain storage facilities. The technologies for acceptance, unloading, storage and subsequent delivery of grain for transportation must also be observed.
Grain is placed in bunkers or warehouses according to the plans of previous years. But with all the previously gained positive experience, the possibility of quickly shipping grain of the required variety for transportation to its destination is also taken into account.
Tanks and premises of grain warehouses must be in good condition. If necessary, scheduled repairs and disinfection of premises are carried out.
Construction of a grain elevator
The bucket elevator consists of the following elements:
Shoe
– this is the lower part of the elevator, it is intended for loading and unloading grain masses. Grain is poured into it through the windows. Inside, the shoe consists of a cover, walls, a rod, a gate, a hatch, as well as a tension drum on the rod, which tensions the tape. The tension drum comes with a solid rim, as well as a lattice or with an open rotor and 10-12 blades. The lattice design and the rotor benefit from the fact that the grain mass does not stick to the drum, which rubs against the belt cloth and wears it out.
The shoe is the support of the entire structure; it is made with a durable body made of steel sheet from 2 to 5 mm thick. The gate at the bottom of the shoe provides convenient cleaning and unloading of the lower part. There is also a hatch in the shoe for servicing the tension drum.
Shafts (or pipes)
- These are cavities with steel walls that protect buckets and their contents from external influences.
Drive unit
located in the head, it consists of a motor, transmission and gearbox. The cylindrical gearbox is connected to the electric motor via a V-belt drive.
Elevator belt
tensioned between the drive and tension drums. Its purpose is to pull the load upward. The buckets are attached to it using bolts. The bucket elevator belt has low movement resistance and high tensile strength, and also moves silently.
They have from 3 to 8 pads made of special fabric with a breaking force of 60-80 kg per cm of width.
The movement speed is optimized according to the volumetric weight of the materials being moved. To work with wet raw materials, belts with rubber linings on both sides are used. The width of the web is 2.5-5 cm larger than the dimensions of the buckets and 2.5-5 cm smaller than the width of the drums. Thus, in case of belt misalignment, the buckets do not collide with the walls and are not pinched.
Elevator buckets
made of steel, plastic, polymers. They are placed at different intervals depending on the width of the tape. The shape must ensure complete loading and unloading of containers when inverted.
The belt bucket elevator also has a number of sensors: current speed, bearing temperature and belt deflection. For example, a speed sensor reports a change in feed speed, which may indicate a problem with the mechanism. This can happen due to clogging of areas with raw materials, entry of a foreign object into the shaft, or rupture of the belt. If this happens, the sensor will send a command to the electrical panel and the movement will stop.
Operating principle of the elevator
quite simple: after turning on the drive, the drive drum begins to rotate, which begins to move the belt. Grain enters the shoe below, it fills the buckets, which rush upward. At the top point of the head they turn over, and their contents are thrown out into the outlet; along the return shaft they go empty, upside down.
Grain cleaning and drying complex.
An elevator is a special structure designed to store sufficiently large volumes of grain crops, as well as to bring them to the required condition.
Its complex includes: a grain cleaning and drying apparatus, a granary, as well as additional truck scales, grain cleaning machines, grain loaders, auxiliary facilities, etc.
- linear (30-40 thousand tons);
- procurement (15-100 thousand tons);
- port (50-150 thousand tons);
- state (150-300 thousand tons).
- near-mill (production) (10-150 thousand tons);
Grain cleaning and drying complex.
Granary.
Modern elevators boast a huge range of services for storing, processing and loading grain crops. Thanks to this range of measures, the strategic grain reserve of a particular country will be satisfied 100%. The latest technologies and the knowledge of specialists have honed the work of elevators to impeccable results, so more and more agricultural enterprises want to build improved elevators on their territory.
Farm elevators. They allow you to store the crop throughout the year and have 3-4 containers with a total volume of up to 8 thousand tons. Receiving grain from heavy-duty vehicles, the elevator sends it for drying and processing, after which it is unloaded. Elevators can be equipped with the necessary machines for cleaning, sorting, multi-mode drying and slicing of the product. They imply a ventilation system to preserve grain.
Silo installation
With the classic approach to the installation of silos, the structure is assembled from a ready-made kit, including metal sections. Most often, bolts and welding are used for connections. After this, the facility is supplemented with a set of technological equipment.
It is worth noting that bolted connections are the most vulnerable part of silos. That is why experts recommend paying special attention to initial calculations . For example, if the body is made of thick steel, and the screw has minimal strength indicators, then when installing silos with a similar combination of elements, the durability of the structure will not be ensured.
Industrial and farm elevators
These designs are used directly in grain processing enterprises. Their role is to place grain for a long time at all stages of processing.
Primelnichnye. Installed at mill farms for storing wheat and rye. On average, such elevators have grain reserves necessary to operate the mill for a quarter. Capacity – from 5 to 15 thousand tons. Grains and grinding batches are stored in climate-controlled tanks, and square silos are installed to store flour.
Compound feed. Control over the processes of mixing and production of various types of feed, enrichment of products with minerals is fully automated. Elevator control can be integrated into the overall feed mill control panel system. The capacity is variable: from 7 to 40 thousand tons, depending on how much product needs to be stored in production to ensure its uninterrupted operation for 3 months.
Farm elevators. They allow you to store the crop throughout the year and have 3-4 containers with a total volume of up to 8 thousand tons. Receiving grain from heavy-duty vehicles, the elevator sends it for drying and processing, after which it is unloaded. Elevators can be equipped with the necessary machines for cleaning, sorting, multi-mode drying and slicing of the product. They imply a ventilation system to preserve grain.
Whatever type of elevator we are talking about, its composition is determined by specific goals, features and location of production. Depending on the volume of your production, we will design and install “turnkey” high-quality and reliable silos to ensure optimal storage of the product!
- working tower,
- receiving and releasing devices,
- elevator tower,
- silo building,
- grain drying department.
Grain elevator (grain complex)
The grain elevator with automated control of all processes has compactly located large containers. The storage conditions for products in grain elevators are designed to ensure the complete safety of grain here and even improve the quality of grain crops stored in this building for some long time.
A grain elevator (compared to conventional warehouses) has its advantages:
- grain complexes occupy a smaller area of territory for the location of grain crops on it,
- ease of working with pests (primarily rodents),
- the possibility of constant regular monitoring of the condition of products,
- complete mechanization of grain operations,
- an effective active product ventilation system.
Among the advantages of such grain elevators are also less labor intensive work to ensure complete safety (including cleaning and drying) of grain, the presence of a thermometry system, less grain loss, and better isolation of the product from the external environment. Moreover, the service life of the structure is much longer than that of simple warehouses, and operating costs are lower.
The grain elevator structure consists of the following parts and departments:
- working tower,
- receiving and releasing devices,
- elevator tower,
- silo building,
- grain drying department.
Let's take a closer look at them.
Working tower of the grain complex
Receiving and releasing devices of a grain elevator
They are intended for external operations (reception of arrived products and release to consumers). These parts of the system are connected with road, water and rail transport. Those grain elevators that perform production functions have devices for dispensing grain to the enterprise.
Silo building
The department is designed for storing grain in silos. Its task is to ensure the quantitative and qualitative safety of products. The silo body of the elevator consists of three main parts: the silos themselves for storing the product, the above-silo gallery with conveyors for loading the silos, and, finally, the sub-silo gallery with conveyors for unloading the silos. The buildings may differ in the method of construction, the relative position (grid) of the silos, the material of construction, shape, and size.
Grain drying department
This part of the entire structure is a very important component of every grain elevator . Grain dryers are placed in the working tower of the elevator or in a separate room attached to it. There are also separate buildings in the form of workshops where waste obtained from grain cleaning can be stored, processed and released.
Port elevators
The function of port elevators is to receive grain from base and transshipment grain storage facilities, prepare it in batches for export and ship the products to sea vessels. The department’s tasks also include receiving grain imported from sea vessels and shipping it to consumers within the country. Port elevators have a large capacity. They are equipped with particularly reliable, high-performance transport equipment.
Manufacturing technology
Traditional commercial granary production uses steel panels.
Usually they are thin-sheet corrugated sections, which make it possible to reduce the cost of grain production and at the same time ensure practical installation of the storage facility. This approach to making silos has another advantage.
It consists in the possibility of providing customers with a basic kit, which can be delivered to the site without any special difficulties and a ready-made grain storage structure can be installed there .
However, such proposals also have disadvantages. The main one is that in this case, the production of the silo is carried out at the factory, and the quality of the already assembled structure is not checked. That is, the customer has the opportunity to buy a kit and then enter into an agreement with a third-party company for its assembly. In this case, the warranty obligations will be divided between several parties who have the right to shift responsibility for the quality of the final product to each other.
To prevent such situations, it is initially recommended to contact manufacturers who assemble spiral silos. These installations make it possible to ensure the reliability of the granary during its operation, as well as easy maintenance of the facility. In this case, the customer gets the opportunity to assess the quality of the object before its commissioning.
