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Robust energy chains and cables for the mining an bulk handling technology

In the area of bulk handling, equipment must function under tough and dirty conditions and work reliably even in bad weather. We offer polymer components for bulk handling which make that possible and are characterised by their robustness and long service life. These include energy chains, cables and hoses, which are used for example in bucket-wheel excavators, ship loaders, portal scrapers, wagon tipplers, conveyor belts, lifts, silos and funnels. The igus Project Engineering Team will assist you with the sizing, design, construction, project management, reconstruction, installation and commissioning on site.

Benefits of igus products:

Corrosion-free
Cost-effective, modular design
Durability with low maintenance
Resistant to dirt, sea water, chemicals, extreme temperature
Proven, tested material with igus system guarantee
Lightweight and high strength
TÜV tested

Tech up ▲ Cost down ▼

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World's first driven e-chain system for long distances

drive-chain

The e-loop for top drive applications

e-loop

Mobile shore power outlet for container terminals

iMPSO

See all the 2022 news? You can find the overview here.

Suitable products for equipment in bulk handling

e-chain P4.1

Travel lengths of 800 m and more are possible
High fill weight of up to 30 kg/m
Speeds of up to 10 m/s possible
Longer service life due to maintenance-free tribo-polymer plain bearings

Series P4.1 e-chains

e-chain 4040RHD/5050RHD

Travel lengths of 1000 m and more are possible
Cable loads of up to 50 kg/m are possible
Speeds of up to 6 m/s possible
Various roller types for optimum application adaption

Series 4040RHD/5050RHD e-chains

24/7 condition monitoring

Continuous push/pull force measured by a special sensor
If the force is exceeded, report if necessary and shutdown the system to prevent damage

i.Sense EC.P system

Energy supply systems ready for connection

Procurement optimisation: one system, one part number
Save time: 95% less harnessing time
Reduce assembly time: less machine downtime

Energy supply systems ready for connection

Steel guide trough

For long travels
Very tough and reliable
For extreme loads

Steel guide trough

Rotating energy supplies

Rotation angle of 540° (on one level)
Rotation angles of 900° is possible with MRM version
Rotation speed of up to 360°/s

Rotating energy supplies

Motor cable CFCRANE

For maximum voltages and outputs
Flame-retardant
UV resistance
Oil resistance

Motor cable CFCRANE

CFLG.LB fibre optic cable

For heaviest-duty applications with 5 x d
Gliding application (horizontal) of 400 m and more
UV-resistant, with TPE outer jacket

CFLG.LB fibre optic cable

Pneumatic hoses

Abrasion-resistant
Oil-resistant
Coolant-resistant
Halogen-free

Pneumatic hoses

Success stories

e-chain system for bulk goods technology in India

World record with 670m

Longest travel with rol e-chain system

For an international customer, our engineering teams in Germany and India have implemented the world's longest travel with an e-chain system. For years, the customer had recurring problems with the power supply, which was implemented by motor cable reels and ribbon cables on two bucket wheel excavators. This repeatedly led to production downtimes. After the installation of the new e-chain system with smart condition monitoring, the plant has been running perfectly.

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Conveyor system in aluminium oxide production outdoor storage

Energy chains in aluminium oxide production outdoor storage

Reliable power supply in dusty and dirty environments

During the mining and subsequent storage of bauxite, a sedimentary rock for the production of aluminium oxide, a lot of dust is produced, 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.

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e-chain system in Tušimice lignite power plant

Lignite excavator

In operation since 2008 without failure on a 615m travel

At the Czech lignite power plant Tušimice, coal is stored in a lengthy heap on the edge of the power plant site. To pile the coal automatically on the heap, a stacker is used. Originally, a cable reel was used for the power supply but the cables repeatedly froze in the winter, which led to system failures The operators switched to an energy chain system from igus. This has ensured a reliable operation without failure for many years.

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Ship unloader

Travel of 441 m and in operation without failure since 2001

Series 5050R energy chains, CFCrane chainflex cables and fibre optic cables are used in ship unloaders at a modern coal-fired power plant in Malaysia. All energy chains are equipped with stainless steel guide troughs and are able to withstand rough weather conditions.

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