How to make a conveyor chain last in hot and abrasive conditions?

Hot dusts, abrasive material, and occasional large material build-ups are a demanding combination for a conveyor chain. Particularly with the mechanical transport of smelter dusts, the chain's lifespan isn't determined by a single “super-material,” but by a complete approach: a suitable operating temperature range, particle size control, structural protection, thermal movement compensation, and correctly selected operating parameters.

Our half a century of accumulated experience has taught us how to ensure chain durability in hot and abrasive conditions – read on if you're interested!

1. Design a conveyor with conditions in mind

Keep the conveyor's operating temperature as constant as possible. In excessive heat, the chain quickly loses its tensile strength, while a temperature that is too low can easily lead to problems caused by the acid dew point.

Control the particle size before the conveyor. Mechanical damage to the chain often occurs in situations where excessive material accumulation enters the conveyor.

Take thermal expansion seriously. In hot processes, thermal movement is a fact, and careless thermal compensation can lead to structural damage and dust leaks.

2. Structurally protect the chain from heat and impact

Ensure that the chain guard provides adequate protection against both radiant heat and impact from build-ups.

3. Control the temperature: too hot will break, too cold will corrode

Excessively high temperatures degrade the chain's properties, reducing tensile strength and surface hardness. Large hot build-ups can cause thermal shock to the chains, leading to deformation. The other extreme is equally dangerous: if the conveyor is too “cold”, sulfuric acid can form inside the conveyor (via the acid dew point), which accelerates damage.

That's why the 250–400 °C temperature window is essential: it balances the chain's mechanical properties and the risk of internal corrosion.

Careful insulation is key to controlling the conveyor's temperature.

4. The chosen chain material determines the service interval.

Boron steel has proven to be the best material for the hot and abrasive conditions found in smelters. The lifespan of the chain naturally depends greatly on the process and the properties of the material being transported, but typically at least double the lifespan has been achieved compared to commonly used manganese chain. Manganese chain, or a conveyor chain made from 20MnCr5 steel, works excellently in lighter applications and up to temperatures of approximately 100°C. For hotter and more abrasive conditions, we always recommend choosing a boron chain (27MnCrB5), which is tougher in its properties and tolerates continuous thermal load excellently, up to 400°C.

5. Operating parameters: small choices, big impact

It is important to note that the boron chain also wears down. In addition to the previously mentioned factors, used the transport speed also affects wear.

Wear increases exponentially as transport speed is increased. Therefore, the slowest possible transport speed is recommended.

At Kopar, we understand what constitutes efficient and durable material handling in smelters and we can take the overall picture into account. If you're wondering whether your conveyor chains could last longer, get in touch and let's find out!

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