EN

Chains and Sprockets for the

Bulk Material Handling

Industry » Product catalogue
» Special solutions
» Accessories
» Spare parts

Product Catalogue
2|

The Global KettenWulf Group

The core factory in Kückelheim, corporate head-

quarters and KettenWulf competence centre

02 The global KettenWulf Group

06 Partners of the bulk material handling industry
08 Development, production, installation & after sales
12 Quality as the basis of success
13 Production overview
16 Eco Evolution technologies
18 Continued development, specialisation & innovation
24 Specific technical solutions for the bulk material handling industry
 |3

Figure top left:

Warehouse in
Kückelheim, Germany

Figure top right:

Production and sales
site in Ferlach, Austria

Figure bottom left:

Production and sales
site in Hangzhou, China

Figure bottom right:

Warehouse and sales
site near Atlanta, USA

KettenWulf has been synonymous for quality, reliability KettenWulf is your number one strategic partner.
and flexibility for more than 90 years. Founded in 1925 Whether you are located in Europe, Asia, Australia
by the brothers Josef and Johannes Wulf the family- or the Americas, KettenWulf’s global network allows
owned business developed into an internationally us to respond to all your needs in just a short matter
operating and highly-recognized manufacturer in the of time.
chain industry.
Trust, commitment and loyalty are the key values of
From its beginning as a small, local fabricator, our family-owned business. As a medium-sized
KettenWulf’s focus over the past nine decades has enterprise our corporate structure is based on trust
evolved to the development, manufacturing and and strong personal relationships with both our
distribution of custom-made conveyor and drive customers and suppliers.
chain systems and technology. Today, more than
1400 employees at ten locations all across Europe,
North America, Asia and Australia guarantee to
serve our international customer’s needs.

The headquarters in Kückelheim is also home to the

KettenWulf competence center. Here we address,
investigate and answer technical inquiries from all
over the world in order to provide our customers
with the best possible support. With 550 employees
and a production area of 30.000 m² / 320.000 ft²,
this is the largest production site of the worldwide
KettenWulf Group.
4|
 |5

Leading OEM companies in the bulk

handling industry rely on KettenWulf.

Our customers include global plant manufacturers

with whom we work in partnership to develop
and produce innovative and capable products of
top quality.
6|

KettenWulf – The partner of the bulk

material handling industry

As developer, designer and manufacturer of engineered Almost every industry can benefit from our know-how.
chains and sprockets, KettenWulf’s deep experience Wherever conveying or drive technology is required,
allows us to meet our customers’ specific conveyor KettenWulf is your specialist.
and drive technology needs.
We constantly strive to improve the technology of our
Every customer has unique needs and requirements. products to achieve longer service life, and higher
Therefore Kettenwulf’s engineers and technicians take performance under the most extreme conditions.
pride in tailoring customized solutions for every indi-
vidual customer and application.

The high quality of our products is the result of our

DIN EN ISO 9001 certified production and quality
management processes. Highly trained and ex-
perienced engineers at the Kückelheim headquarters
share their expertise with our employees all over the
world, ensuring we develop and supply a first-class
product at every production facility.
 |7

New developments
(extract)

Bucket Elevator Chain

with Forged Link Plates

Feeder chains Reclaimer chains with

Sealed Chain System
8|

Development, production, installation &

after sales: What we can do for you.

Competence, experience, efficiency and a high level

of commitment are the basis of our work. We offer
you individual consultation and the support of your
development and production process from start
to finish. Through an optimal selection process we
guarantee our products and your long term and
sustainable success.

KettenWulf establishes a number of highly special-

ised competences to support your projects. We have
linked all individual services efficiently to obtain op-
timum results for your product solutions. This makes
us your competent and reliable conveying and drive
technology partner.
 |9

We support you as a
competent partner:
Both during initial
consultation and an
intensive support of
the value creation
process and during
the review of existing
resources.

Development:
In line with your requirements and preferences we
design optimum solutions for conveying and drive
technology.

Production:
Using the latest technologies we manufacture con-
veyor chains, drive chains and sprockets for you.

Assembly:
We know our products best. Together with reliable
partners we take care of assembly on site if required.

After sales:
Upon request we inspect and evaluate the condition
of  your chains and sprockets for functionality and
future service life.
10 |
 | 11

The production process on the basis of

guaranteed quality & innovation

Guaranteeing the highest levels of quality

creates satisfaction and trust. On this basis our
products can be developed continuously and
ideas be developed for the future.
12 |

Quality as the basis of success

DIN EN ISO 9001

The quality products

of KettenWulf are
continuously reviewed
and developed in our
research and develop-
ment department.

We supply the highest quality! To achieve this, we The satisfaction and trust of our customers are
only use the latest machines and production meth- a cornerstone of the corporate philosophy of the
ods. With a high manufacturing depth over many KettenWulf Group. To guarantee the consistent
years we can guarantee the consistent quality of our high quality of our products, KettenWulf has been
products and materials at all levels. In addition, the certified in accordance with the strict DIN EN ISO
quality management and our R&D department en- 9001 guidelines. The quality management has been
sure the continuous improvement of our products. implemented in all production and management
processes to ensure highest quality from incoming
The following fundamental inspections/tests are goods to final inspection.
carried out regularly in our extensive test lab:

» Endurance tests for chain components

» Media resistance tests
» Roller wear tests
» High temperature tests
» Fatigue strength tests for chain components
 | 13

Production technology overview

Laser cutting Heat treatment

For the production of link plates, requiring highest In the heat treatment of the components for our
precision, KettenWulf uses laser cutting technolog y. chains and sprockets we use two different methods:
This also allows for the manufacture of plate com- case hardening and inductive hardening. We thereby
ponents with more complex contours. achieve a very high wear resistance for the chain links
and thus an increase service life of the chain. Inductive
hardening of sprockets reduces the wear in the tooth
gaps, ensuring a long operating life between chain
and sprocket.
14 |

Machining Welding technology

In the field of machining KettenWulf uses the latest All welding is carried out in our own welding shop.
CNC technology. This not only permits the turning of The production uses the latest MIG and MAG methods.
bushings, pins and rollers, but also the milling of link To guarantee consistent high quality, we use partly
plates, sprocket teeth and pitch borings with high- and fully robotic welding systems in the manufacture
est precision. The manufacture of variable designs of our chains.
is possible without problems in order to implement
also specific customer preferences quickly and pre-
cisely. In addition, all bushings, pins and rollers for
our chains can be be polished after heat treatment to
narrow tolerances using precise grinding machines
to guarantee an absolute perfect fit.
 | 15

Punching Forming technology

Modern die cutting technology permits the effective To produce lug plates or attachment brackets at chain
serial production of chain link plates and lugs. The links in a bent design, the bending zones of all work
required die cutting tools are manufactured by pieces are first inductively heated. This prevents ben-
KettenWulf directly. This ensures a very high pitch ding fractures and significantly increases the service
accuracy for our chains. All link plates and lugs are life of the chain link.
shot blast after die cutting to further improve their
quality.

Final assembly
In a last step the chain components are assembled
in hydraulic presses into complete chain strands.
Only after the subsequent final inspection will the
products be released for dispatch to our customers.
16 |

Product development in harmony with our environment.

 | 17

KettenWulf lives
environmental protection
Our attachment to nature does not only stem from
our headquarters being at the green heart of the
Sauerland region, but our demand for sustainable
action determines our daily work. We promote this
principle globally at all our locations by meeting
not only statutory requirements but in addition
adhering to further standards defined by ourselves.
The standards in Germany and China are also
certified in accordance with ISO 14001.

The environment as a resource also plays an im-

portant part in our investment considerations and
we always take our decisions with an awareness of
sustainable commerce. The results of this approach
are ultimately also reflected in our product develop-
ments. Here are some examples:

» Energy-efficient chain technology

» Lubrication-free and therefore environmentally
friendly and maintenance-efficient technology
» High noise attenuation for people and the
environment
18 |

Continued development,
specialisation & innovation

Absolute high-tech: In order to meet the ever greater demands of bulk- In order to test the theoretically determined potential
the new high-frequency
pulsator in our
materials conveying technology, KettenWulf is turning for improvement in practice, KettenWulf has recently
main plant to the systematic, technical enhancement of its acquired one of the world’s most modern high-fre-
products. Maximum conveying speeds and large quency pulsators. This enables us to dynamically
conveying heights, in particular, push the products sample both individual components as well as entire
ever more to their limits. It is therefore all the more chain strands of up to several hundred kilonewtons.
important to know the individual products’ maximum
loads and to thereby achieve a corresponding level Reducing maintenance while maintaining a high level
of operating safety. of plant availability is also a key aim in the further
development of the products. KettenWulf has there-
In order to overcome these challenges, KettenWulf fore developed a new sealing system which can per-
deploys state-of-the-art FEM tools, which can be used manently eliminate the need to re-lubricate the chain
to expose and eliminate weak points in the chain joint.
system.
 | 19

Sealed Chain System Permanently Oiled

Deployment in the toughest conditions – alongside An important key aim in the further development of
a large number of flexures, the ingress of abrasive the products is to reduce maintenance while main-
material into the joint area, in particular, has an taining a high level of plant availability. In order to
impact on chain wear. This adversely affects the chain achieve this goal, KettenWulf has developed the new
elongation, which determines the service life of a SCS PO sealing system in cooperation with renowned
conveyor chain. In order to better protect the chain plant manufacturers and has successfully brought it to
joint, it is usually sealed with special components. market. This system permanently eliminates the need
to re-lubricate the chain joint.
Targeted operational lubrication of the chain joint is
also indispensable for maximising conveyor chains’ Using this system enables the chain to be operated
service life. Strongly adhering material and heavy almost maintenance-free. In addition, the use of lu-
contamination often prevents the lubricant from be- bricants is significantly lower. Alongside the reduced
ing applied to the friction points accordingly. Greasing expenditure for operating resources, this technology
nipples, through which lubricant can be inserted thereby enables the plant to be operated sustainably
into the joint area, have therefore proven themselves and in a way that conserves resources.
suitable in practice. The regular re-lubrication of each
individual greasing nipple is often done manually and The SCS PO technology has already proven very
therefore entails long downtime for the plants and successful in practice. (See the comparison of wear
greater manpower requirements. on the following page)

Sealing package Sealing package

Plug screw Plug screw Lubrication channels

20 |

Example of application and areas of use

Reclaimer chain with

Sealed Chain System
Permanently Oiled

Sealing package SCS PO

Video link:

Overview Benefits
» Maintenance-free chain system for conveying » Oil-filled chain link
bulk materials » Contacting sealing elements
» Individual design of the bush conveyor chain » Permanent lubrication
» Detailed selection of sealing components » Protection from external influences
» Application-related selection of lubricants » Maintenance-free
» Easy replaceability of highly stressed components
» Emergency lubrication (optional)

Applications in bulk-material conveying

» Reclaimer systems
» Apron feeders
» Feeder breakers
» Continuous ship unloaders
» Pan conveyors (selective)
» Bucket elevators (selective)

Technological limits SCS PO

» Temperature range: -25 °C to +80 °C
» Chain speed: max. 2.5 m/sec
» Pin diameter: 26 mm to 60 mm
» Link plate height: min. 70 mm
» Total width: 12 mm to 16 mm
 | 21

Comparison of wear of the pins:

KW SCS CR vs KW SCS PO
The comparison of wear once again very clearly rable wear. Installing the new system has therefore
shows the benefits of the new sealing system. Even paid off very quickly, as the maintenance times and
after a high stress of over 18,000 operating hours, the repair costs have been considerably reduced and the
chain pin of the new SCS PO system shows no measu- availability of the plant significantly increased.

KW SCS CR KW SCS PO
(greasable) (maintenance-free)

In the case of Even after 18,000

greasable chains, operating hours, the
the pin sees signifi chain link is perfectly
cantly greater wear. oiled – without
re-lubrication.

2,6

2,4

2,2

2,0
Deterioration of the chain pin [mm]

1,8

1,6

1,4

1,2 CR
S CS
1 KW

0,8

0,6

0,4

0,2 KW SCS PO
0

-0,2
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000

Duration [h]
22 |

Heavy Environment Roller (HE-Roller)

In order to meet the continuously increasing demands The design of the rollers is flexible: depending on the
on outboard rollers in the bulk material handling load and the environment, different ball bearings and
sector, KettenWulf has further developed the proven specific lubricants can be selected.
technology of these rollers. This has resulted in a
significantly improved product that can withstand In conjunction with the new Click-On Mounting
the most difficult environmental conditions. System, fast and error-free installation on site is
also guaranteed. This reduces maintenance and
Thanks to innovative sealing concepts, KettenWulf mounting costs to a minimum.
now offers a lifetime-lubricated outboard roller for
use in highly abrasive and corrosive materials.

1 Roller body with induction hardened outer diameter

2 Special shafts with Click-On technology
3 Roller bearing individually matched to the particular load case
 | 23

Click-On Mounting System

To conserve resources and to save energy as well longer necessary to lubricate and seal the rollers
as maintenance costs, almost all modern reclaimer on site as this is already done at the factory.
chains are equipped with outboard and mainte-
nance-free rollers. However, the initial installation Assembly times are thus reduced by 80%, which
of these rollers on site is often time-consuming means time savings of several days in the case of a
and can only be carried out with specific tools. complete replacement of rollers for medium-sized
systems. Besides, the new Click-On System helps
For this reason, KettenWulf has developed the new prevent problems arising from wrong installation
Click-On Mounting System. Whereas up to five steps or lubrication, which ensures optimized machine
were required to mount the roller in the past this can availability from the start.
now be done with just one click. In particular, it is no

Assembly time Maintenance-free roller with standard mounting system

Initial state:
1
Pin and roller
without seal, cover
and retaining ring

Step 1:
Slide the pre as-
sembled roller
onto the pin

Step 2:
2 3
Secure roller
with circlip

Step 3:
Fill with special
lubricant

Step 4:
4 5
Assemble seal, cover
and retaining ring

Step 5:
Final state

Assembly time Maintenance-free roller with Click-On mounting system

Initial state:
1
Extended pin and
pre assembled
Click-On roller

Step 1:
Roller completely
assembled by simply
sliding the roller
on until it “clicks”
24 |

FEM

In order to know the individual products’ maximum As well as eliminating weak points, the products
loads and to thereby achieve a corresponding level can also be weight-optimised using FEM analyses.
of operating safety, KettenWulf uses state-of-the-art This targeted geometry optimisation means that the
FEM tools. products’ operational weights can be reduced by up
to 30%. In addition to lower handling requirements,
The use of modern FEM tools also allows us to calcu- the reduction in weight also means that energy
late and simulate stresses and deformation in chains consumption is significantly lower and that the plant
and other components as early as their development can be operated in a sustainable manner over the
stage, meaning that possible constructional faults long term.
can be identified and avoided before series produc-
tion starts.

Starting situation New product development

-30%
 | 25

Noise Reduction Technology

During the operation of plant in the bulk material The Noise Reduction Technology developed by
handling industry annoying noise can often arise KettenWulf ensures that the chain links no longer
when the chain enters the sprocket. To reduce this knock against the gaps in the sprocket but are
operational noise and improve the working condi- guided into the tooth gap in defined manner. The
tions, KettenWulf has developed a special Noise infeed noise of the chain is greatly reduced.
Reduction Technology coping with the demands and
ambient conditions of this industry.

Sprocket with Noise

Reduction Technology

1
2

1 KettenWulf Noise Reduction Technology

2 Sprocket in divided design, prepared
for assembly on an individual hub flange body
3 Optimised tooth gap geometry in accordance with
KettenWulf standard, inductively hardened for high
wear resistance (chain - sprocket)

3
26 |
 | 27

Specific technical solutions for every

area of the bulk material handling industry

Transporting bulk material with the aid of special

chains is one of the most efficient transport solutions.
For a multitude of applications in the bulk material
industry KettenWulf offers groundbreaking chain
technologies.
28 |

KettenWulf offers
innovative chain
technologies for various
conveyor systems in the
bulk material handling
industry.

Specific technical solutions for the

bulk material handling industry

For almost any conveying process in the bulk material KettenWulf develops and produces special chains
handling industry, KettenWulf offers optimal chain and sprockets for conveying almost any type of bulk
designs. Jointly with our customers we develop the material:
right solution, whether to transport coarse or fine
grain bulk material or material with corrosive or » clinker, gypsum, marl and clay for cement
abrasive properties production
» granulate in fertiliser production
» coal, coarse-grained ore, crushed stone, limestone
and slate in the mining industry
» biomass, coal, slag and quartzite in power stations
 | 29

Asphalt Port technology

» Bucket elevators » Reclaimer systems

» Continuous ship unloaders

Mining Cement

» Feeder Breaker » Feeder Breaker

» Reclaimer systems » Reclaimer systems

» Bucket wheel reclaimers/

» Pan conveyors
Rotary Breakers

» Bucket elevators

» Bucket wheel reclaimers/

Rotary Breakers

Fertilisers Coal fired plants

» Reclaimer systems » Reclaimer systems

» Bucket elevators » Continuous ship unloaders

30 |

For every application the

perfect solution

Transporting bulk material with the aid of special Since every customer's requirements are basically
special chains is one of the most efficient transport different, KettenWulf offers mainly individual pro-
solutions. For a multitude of applications in the bulk duct solutions for the bulk material handling industry.
material handling industry, such as pan conveyors, Our engineers and technicians develop special chain
slat-band chain conveyors, trough chain conveyors, systems customised to the specific application envi-
reclaimer conveyors in mixing bed technology to ronments.
high performance bucket elevators, KettenWulf offers
groundbreaking chain technology. On the next page is an overview of the transport solu-
tions we offer for various bulk materials together with
In accordance with the plant-specific framework an indication of possible applications in the individu-
conditions, i.e. the local conditions and the transport al industries.
task, KettenWulf offers optimum consultation for the
selection and specification of the chain and sprocket
as well as technical support on site.
 | 31

Feeder Breaker/ Apron Conveyor

Bucket wheel reclaimers/

Rotary Breakers

Reclaimer systems

Pan conveyors

Bucket elevators

Continuous
ship unloaders

Roller units

Sprocket wheels/ Shafts

Service & Accessories

32 |

Chains for feeder breakers

KettenWulf chains for feeder breakers are specifically KettenWulf uses high quality materials which
designed for the high demands of the mining industry. guarantees performance under these extreme
Shock loads, abrasive media, moisture and at times conditions together with high service life.
corrosive media place highest demands on the pro-
ducts used.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 FEEDER BREAKERS
| 33

Specific designs for various mining and

energy industry applications
The processing and crushing of ores and minerals often takes place in
mobile or stationary breaker plants. The raw materials removed in quarries
or mines is fed to the breaker unit using chain conveyors for the material
to be processed and crushed. KettenWulf supplies direct transport chains
both for underground and surface mining.

Feeder breakers
34 |

Feeder chains with extended pins

Advantages

Extended pins
These are used to hold and connect the reclaimer
bars on the conveyor chain.

Thick-walled bushings
Thick-walled bushings guarantee a high resistance to
shock loads. The high surface hardness and ductile
core significantly increase the service life of the con-
veyor chain.

Head pin design

To reduce assembly effort our chains are designed
with head pins.
 FEEDER BREAKERS
| 35

Drawings / product data

h2
p1 p2 p1 p2

d4
t2

t
d2

b1
F1

t
F2

t2

F3

F4

b d

Feeder chain with extended pins

Calculated braking

Height of linkplate

Thickness of outer
Thickness of inner
Bush diameter
Type of chain

Attachment part dimensions

Pin diameter
Inner width

linkplate

linkplate
Pitch 1

Pitch 2
load

Unit

FB p1 p2 b1 d4 d2 h2 t t2 F1 F2 F3 b d F4

inch 3 4 1,87 1,5 1 2,56 0,55 0,47 5,84 3,58 3,15 0,93 0,35 1,56
KWFBE764738 610 kN
mm 76,2 101,6 47,50 38,1 25,4 65 14 12 148,30 90,90 80,00 23,60 9,00 39,60

inch 3,5 2,25 1,75 1,125 2,76 0,55 0,47 6,25 3,84 3,45 1,06 0,35 1,63
KWFBE885744 770 kN
mm 88,90 57,15 44,45 28,58 70 14 12 158,75 97,60 87,70 27,00 8,75 41,30

inch 4,5 2,75 2 1,37 3,54 0,63 0,63 7,51 1,31 2,00
KWFBE1146950 1060 kN
mm 114,30 69,85 50,80 34,87 90 16 16 190,70 33,30 50,80

inch 5,5 2,75 2,476 1,36 3,74 0,79 0,71 8,57 5,44 1.3 1.75
KWFBE1396962 1050 kN
mm 139,70 69,85 62,89 34,62 95 20 18 217,70 138,10 34,1 44,45

Other designs are possible upon request

36 |

Feeder chains with forged lugs

Advantages

Lug as forging blank

These are used to hold and connect the reclaimer
bars on the conveyor chain. The design in a special
forged shape improves the transmission of forces be-
tween the medium and chain.

Thick-walled bushings
Thick-walled bushings guarantee a high resistance
to shock loads. The high surface hardness and ductile
core significantly increase the service life of the
conveyor chain.

Head pin design

To reduce assembly effort our chains are designed
with head pins.
 FEEDER BREAKERS
| 37

Drawings/ product data

h2
p p p p p p

d4
t2

d2

t
b1
t
t2

T2

F2
d

Feeder chains with forged lugs

Calculated breaking

Height of linkplate

Thickness of inner

Thickness of outer
Bush diameter
Type of chain

Attachment part dimensions

Pin diameter
Inner width

linkplate

linkplate
Pitch
Unit
load

FB p b1 d4 d2 h2 t t2 W F2 T2 d

inch 3,50 2,25 1,75 1,13 2,75 0,55 0,47 1,82 5,22 3,97 0,69
KWFBF885744 770 kN
mm 88,90 57,20 44,45 28,60 70 14 12 46,20 132,60 100,80 17,50

inch 6,00 3,63 2,74 1,75 4,50 0,88 0,75 2,75 8,63 7,38 1,25
KWFBF1529269 1600 kN
mm 152,40 92,10 69,60 44,45 115 22 20 69,90 219,10 187,30 31,75

Other designs are possible upon request

38 |

Chains for apron feeders

Advantages

Welded bar
The bar is welded with attachment holes to one side
and used to connect the transport links laterally.

Flanged rollers
Flanged rollers transfer the vertical material load to
the guide rail. The tapered flange also guarantees
optimum lateral guidance of the conveyor chain in
the guiding system.

Bolted pins
Bolted pins with hexagonal nuts facilitate chain
assembly on site.

Relubrication option
Screw-in lubrication nipples in the link pins provide a
relubrication option. Special porting channels in the
pin and bushing allow penetration of the grease at
the bearing points (pin/ bush) of the track roller .
 FEEDER BREAKERS
| 39

Drawings/ product data

h2
p p

d1
t2

t
d2

b1

t
t2

Chains for apron feeders

Calculated breaking

Height of linkplate

Thickness of outer
Thickness of inner
Roller diameter
Type of chain

Pin diameter
Inner width

linkplate

linkplate
Pitch 1
load

Unit

FB p1 b1 d1 d2 h2 t t2
KWAP35087150 600 kN mm 350 87 150 36 100 12 10
KWAP35087150H 900 kN mm 350 87 150 44 100 20 15
KWAP350118180 2000 kN mm 350 118 180 56 155 20 15

Other designs are possible upon request

40 |

KettenWulf offers a
wide selection of
special drive chains
for bucket wheel
reclaimers and
crusher systems.

Chains for bucket wheel reclaimers

and rotary breakers

Large bucket wheel reclaimers move 240,000 tons The design, processing and storage of the most varied
cubic metres of excavated material daily. To guaran- bulk materials takes place using e.g. bucket wheel
tee the smooth conveying of these enormous reclaimers and crusher systems. For these extreme
volumes, roller chains and rotary chains must meet environmental conditions KettenWulf offers a wide
the highest quality requirements to prevent down- selection of conveyor and drive chains designed for
times. high shock loads and abrasive and corrosive media.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 41

Application examples for chain systems

BUCKET WHEEL RECLAIMERS

in bucket wheel reclaimers and rotary breakers

Whether the wheel arm is designed with or without KettenWulf chains and sprockets are designed to
forward feed, whether moving clockwise or anti-clock- operate in the highest demanding and extreme work-
wise: KettenWulf products for bucket wheel reclaimers ing/ environmental conditions to facilitate trouble-
and Rotary Breakers achieve highest quality levels – free operation in your plant.
long service life, lowest maintenance intervals and Especially when used as drive chains in bucket wheel
functional solutions for your plant. reclaimers and crusher systems, maximum force
transmission and fatigue strength are required.

Bucket wheel
reclaimer

Rotary Breakers
42 |

Bucket wheel reclaimers/ rotary breakers

Roller chains

Advantages

Tapered link plates

To optimise the dynamic running characteristics
and reduce weight the link plates are scalloped in
the centre section of the link plate.

Small roller
To protect the chain sprockets against excessive wear
the chains are designed with small rollers. The small
rollers are surface-treated to increase their dynamic
load capacity.

High-strength materials
The selection and heat treatment of materials is
geared towards maximum power transmission.
 | 43

Bucket wheel reclaimers/ rotary breakers

BUCKET WHEEL RECLAIMERS

Roller chains in simplex design

Drawings/ product data

h
p p

Si
b1
l

Si
d1 d4
k

Sa

Basic dimensions of the roller chains according to ISO 606 in simplex design
Min. clearance width

Max. connecting pin

Calculated breaking

Link surface [cm²]

Max. pin length
Max. protective

Weight [kg/ m]
External plate
Type of chain

Internal plate

Plate height
Max. pin Ø

thickness

thickness
overhang
roller Ø
Pitch
Unit
load

FB p b1 d4 d1 l k Si Sa h f ≈q

KW 16B HFS 72,5 kN mm 25,40 17,02 15,88 8,28 36,1 3,1 4,00 3,20 21,00 2,10 2,83

KW 20B HFS 109,9 kN mm 31,75 19,56 19,05 10,19 43,2 4,4 4,50 3,50 26,40 2,96 3,94

KW 24B HFS 178,3 kN mm 38,10 25,40 25,40 14,63 53,4 5,5 6,00 4,70 33,40 5,54 7,21

KW 28B HFS 245 kN mm 44,45 30,99 27,94 15,90 65,1 4,8 7,40 6,00 37,00 7,39 9,58

KW 32B HFS 272,4 kN mm 50,80 30,99 29,21 17,81 67,4 3,9 6,90 6,00 42,20 8,10 9,97

KW 40B HFS 400 kN mm 63,50 38,10 39,37 22,89 81,5 7,0 8,50 8,00 52,90 12,75 17,00

KW 48B HFS 600 kN mm 76,20 45,72 48,20 29,20 99,1 6,9 12,00 10,00 64,00 20,61 27,00

KW 56B HFS 850 kN mm 88,90 53,34 54,00 34,30 113,0 12,0 14,00 12,00 78,00 27,90 38,00

KW 64B HFS 1120 kN mm 101,60 60,96 63,50 39,40 129,0 19,0 15,00 14,00 93,30 36,25 49,50

KW 72B HFS 1400 kN mm 114,30 68,58 72,39 44,50 147,0 14,0 18,00 15,00 103,63 46,19 64,50

Other designs are possible upon request

44 |

Bucket wheel reclaimers/ rotary breakers

Roller chains in duplex design

Drawings/ product data

h
p p p

Si
e
l

b1
Si
d1 d4
Sa
k

Basic dimensions of the roller chains according to ISO 606 in duplex design
Min. clearance width
Calculated breaking

Max. connecting pin

Link surface [cm²]

Transverse pitch
Max. pin length
Max. protective

Weight [kg/ m]
External plate
Type of chain

Internal plate

Plate height
Max. pin Ø

thickness

thickness
overhang
roller Ø
Pitch
load

Unit

FB p b1 d4 d1 l k Si Sa h e f ≈q

KW 16B-2 HFS 145 kN mm 25,40 17,02 15,88 8,28 68,0 3,4 4,00 3,20 21,00 31,88 4,21 5,28

KW 20B-2 HFS 219,8 kN mm 31,75 19,56 19,05 10,19 79,0 5,1 4,50 3,50 26,40 36,45 5,91 7,78

KW 24B-2 HFS 356,6 kN mm 38,10 25,40 25,40 14,63 101,0 6,7 6,00 4,70 33,40 48,36 11,08 14,31

KW 28B-2 HFS 490 kN mm 44,45 30,99 27,94 15,90 124,0 5,5 7,40 6,00 37,00 59,56 14,79 19,00

KW 32B-2 HFS 544,8 kN mm 50,80 30,99 29,21 17,81 126,0 3,8 6,90 6,00 42,20 58,55 16,21 19,59

KW 40B-2 HFS 800 kN mm 63,50 38,10 39,37 22,85 153,0 7,4 8,50 8,00 52,96 72,29 25,50 33,00
KW 48B-2 HFS 1200 kN mm 76,20 45,72 48,20 29,20 190,4 7,6 12,00 10,00 64,00 91,21 41,23 54,00
KW 56B-2 HFS 1600 kN mm 88,90 53,34 54,00 34,30 221,5 11,5 14,00 12,00 78,00 106,6 55,80 75,00

KW 64B-2 HFS 2100 kN mm 101,60 60,96 63,50 39,40 250,0 10,0 15,00 14,00 93,30 119,89 72,50 100,00

KW 72B-2 HFS 2700 kN mm 114,30 68,58 72,39 44,50 282,8 10,7 18,00 15,00 103,63 136,27 92,40 129,00

Other designs are possible upon request

 | 45

Bucket wheel reclaimers/ rotary breakers

BUCKET WHEEL RECLAIMERS

Roller chains in triplex design

Drawings/ product data

h
p p p p
l

Si
e

b1
Si
d1 d4
Sa
k

Basic dimensions of the roller chains according to ISO 606 in triplex design
Min. clearance width
Calculated breaking

Max. connecting pin

Link surface [cm²]

Transverse pitch
Max. pin length
Max. protective

Weight [kg/ m]
External plate
Type of chain

Internal plate

Plate height
Max. pin Ø

thickness

thickness
overhang
roller Ø
Pitch
load

Unit

FB p b1 d4 d1 l k Si Sa h e f ≈q

KW 16B-3 HFS 217,5 kN mm 25,40 17,02 15,88 8,28 99,9 3,6 4,00 3,20 21,00 31,88 6,31 7,88

KW 20B-3 HFS 329,7 kN mm 31,75 19,56 19,05 10,19 116,0 4,6 4,50 3,50 26,40 36,45 8,87 11,66

KW 24B-3 HFS 534,9 kN mm 38,10 25,40 25,40 14,63 150,0 5,8 6,00 4,70 33,40 48,36 16,63 21,10

KW 28B-3 HFS 735 kN mm 44,45 30,99 27,94 15,90 184,0 5,1 7,40 6,00 37,00 59,56 22,18 28,34

KW 32B-3 HFS 817,2 kN mm 50,80 30,99 29,21 17,81 184,0 4,4 6,90 6,00 42,20 58,55 24,31 29,30

KW 40B-3 HFS 1200 kN mm 63,50 38,10 39,37 22,89 226,0 7,0 8,50 8,00 52,90 72,29 38,25 50,00

KW 48B-3 HFS 1800 kN mm 76,20 45,72 48,20 29,20 281,0 8,0 12,00 10,00 64,00 91,21 61,84 80,00

KW 56B-3 HFS 2310 kN mm 88,90 53,34 54,00 34,30 330,0 12,0 14,00 12,00 78,00 106,60 83,71 111,50

KW 64B-3 HFS 3050 kN mm 101,60 60,96 63,50 39,40 370,0 10,0 15,00 14,00 90,17 119,89 108,74 150,00

KW 72B-3 HFS 3930 kN mm 114,30 68,58 72,39 44,50 420,0 14,0 18,00 15,00 103,63 136,27 135,57 194,00

Other designs are possible upon request

46 |

Bucket wheel reclaimers/ rotary breakers

Rotary chains

Advantages

Angulated link plates

The chain link plates are cranked so that a chain link
forms an inner and outer link simultaneously. This is
necessary for an uneven number of links.

Small roller
To protect the sprockets against excessive wear
the chains are designed with small rollers. The
small rollers are surface-treated to increase their
dynamic load capacity.

High-strength materials
The selection and heat treatment of materials is
geared towards maximum power transmission.
 | 47

BUCKET WHEEL RECLAIMERS

Drawings/ product data

h2
p p p p

d1

d2

t
b1
t

Basic dimensions of rotary chains

Calculated breaking

Height of linkplate
Roller diameter
Type of chain

Pin diameter

Thickness of
Inner width

linkplate
Pitch
load

Unit

FB p b1 d2 d1 h2 t
KWRO2510 271 kN mm 78,1 36,9 16,0 31,75 40 8
KWRO2814 556 kN mm 88,9 36,9 22,25 44,45 60 14
KWRO3214 476 kN mm 103,2 48,0 22,0 44,45 55 14
KWRO3618 894 kN mm 114,3 50,8 27,97 57,15 75 15
KWRO4020 1100 kN mm 127,0 68,3 31,78 63,5 90 18

Rotary chains based on DIN 8182

48 |

KettenWulf offers a
wide selection of
special conveyor chains
for reclaimer systems.

Chains for
reclaimer systems

Storing and homogenising bulk material, in particular Here KettenWulf offers a wide selection of conveyor
raw material and coal, is done with the aid of reclaimer chains adapted specially to the extreme environmen-
systems of varying design in the bulk material hand- tal Conditions, such as high shock loads, abrasive
ling industry. media, corrosive product and environmental impacts
are just a few of the technical considerations our
engineers have to consider.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 49

Specific designs for

different storage units

KettenWulf special chains and sprockets permit trou-

ble-free operations in the most varied plant systems
for bulk material storage and under extreme environ-
mental conditions, such as in bridge reclaimer, portal

RECLAIMER SYSTEMS
reclaimer, side reclaimers or round mixing beds.

Bridge reclaimer

Semi-portal reclaimer

Portal reclaimer
50 |

Reclaimer chains – Block Link Design

Advantages

Press-fitted wearing bush

The hardened wearing bush from alloyed case-hard-
ened steel improves the wear resistance of the chain
and increases its service life significantly. The wearing
bush is press-fitted with an excess into the block plate
to protect against torsion.

Milled block plate heads

To optimise the force transmission between the chain
and sprocket and reduce wear, the heads of the block
plates are machined.
 | 51

Versions SCS CR

RECLAIMER SYSTEMS
Reinforced reclaimer attachment

» Reinforcement of the dynamically stressed reclaimer

attachment plates and gusset plate designs
» Optimised force transmission through
component reinforcement

Guide rail

» Guide rail to absorb existing lateral forces

» Guide rail with contact chamfers to reduce friction

Lubrication system

» Lubrication system consisting of lubrication bores

and lubrication nipples in the chain pin
» Optimum lubricant application into the chain link
and cleaning effect through lubrication flow from
inside to outside
52 |

Reclaimer chains as bush conveyor chains

with internal rollers

Advantages

Internal roller
The internal roller permits the chain roll instead of
drag like the Block Link Chain which significantly
reduces the friction and load on the chain and drive
system. The guide rails are also subject to reduced
loads from the rolling of the rollers.

Chain link
The chain link consists of a thick-walled hardened
bearing bush and a hardened chain pin providing
optimum force transmission.

Inner and outer links

The chain link plates of the inner and outer links are
made of flat material and enable the optimum in-
teraction between chain and sprocket and a marked
weight reduction compared to the block plate chain.
 | 53

Versions

Reinforced reclaimer attachment

RECLAIMER SYSTEMS
» Integral design attachment plate with one of
several welded gusset plate designs
» Optimised force transmission

Welded reinforcement element

» Optimised force distribution of the excavating

forces over both chain link plates of the attached
link through welded reinforcement element

Relubrication option via lubrication nipples

» Lubrication system consisting of lubrication bores

and lubrication nipples in the chain pin
» Optimum lubricant application into the chain link

KettenWulf sealing system

» The KettenWulf sealing system protects the

chain link against contamination
» Specifically for abrasive or corrosive conveying media

Weight reduction

» Chain link plates with lightening holes

for weight reduction
» Reduced chain tensile force due to lower
chain weight
54 |

Reclaimer chains as bush conveyor chains

with internal rollers

Drawings

h2
h2

p p

d1
d1
t

t
d2

b1
d2
t

t
t
b1
t

1 Reclaimer chain with internal roller and welded vertical 2 Reclaimer chain with internal roller and angled
attachment bracket attachment bracket

h2
h2

p p
p p

d1
d1
t

d2
t
t

d2
b1

b1
t

t
t

3 Reclaimer chain with internal roller and raised trapezoidal 4 Reclaimer chain with internal roller and vertical raised
attachment plate attachment plate
 | 55

Product data

Basic dimensions of the reclaimer chain with internal roller

RECLAIMER SYSTEMS
Thickness of linkplate
Calculated breaking

Height of linkplate
Roller diameter
Type of chain

Pin diameter
Inner width
Pitch
load

Unit

FB p b1 d1 d2 h2 t

160
KWRCI4080 300 kN mm 250 40 80 22 60 8
315

160
KWRCI50100 500 kN mm 250 50 100 30 80 10
315

250
KWRCI60120 800 kN mm 315 60 120 36 90 12
400

250
KWRCI80130 1000 kN mm 315 80 130 40 100 15
400

315
KWRCI90140 1200 kN mm 400 90 150 42 120 15
500

315
KWRCI110170 2000 kN mm 400 110 170 54 130 20
500

315
KWRCI120190 2500 kN mm 400 120 190 56 150 25
500

Additional information:
» Design of the reclaimer attachment in accordance with individual customer specification
» Pin lock provided by locking collar head pin
56 |

Reclaimer chains as bush conveyor chains

with outboard rollers

Advantages

External low-maintenance roller

The external maintenance-free roller with press-fitted
ball bearings reduces the chain tensile force due to
lower roller friction compared to the reclaimer chain
with internal roller. This achieves an improved chain
utilisation.

Chain link from bushing and pin

The chain link consists of a thick-walled hardened
bearing bush and a hardened chain pin providing
an optimum transmission force.

Inner and outer links

The chain link plates of the inner and outer links are
made of flat material and enable the optimum in-
teraction between chain and sprocket and a marked
weight reduction compared to the block plate chain.
 | 57

Versions SCS CR

RECLAIMER SYSTEMS
Reinforced reclaimer attachment

» Reinforcement of the dynamically stressed reclaimer

attachment through welded reinforcement gussets
» Optimised force transmission

Welded reinforcement element

» Optimised force distribution of the excavating

forces over both chain link plates of the attached
link through welded reinforcement element

Relubrication option via lubrication nipples

» Lubrication system consisting of lubrication bores

and lubrication nipples in the chain pin
» Optimum lubricant application into the chain link
» Cleaning effect of the chain link through lubricant

KettenWulf sealing system

» Protection of the chain link against contamination

through the KettenWulf sealing system
» Specifically for abrasive or corrosive conveying media

Weight reduction

» Chain link plates with lighting contour for

weight reduction
» Reduced chain tensile force due to lower
chain weight
58 |

Reclaimer chains as bush conveyor chains

with outboard rollers

Drawings

h2
p p

h2
p p

d4
t

d2
t

d2

t
b1

b1
l2

l2
t

t
t
l1

l1
d1
d1

1 Reclaimer chain with outboard roller and angled 2 Reclaimer chain with outboard roller and raised
attachment bracket attachment plate
h2

d4
h2

p p
p p

d4
t

d2
t

d2
t

b1
b1
l2

t
t

t
t

l1
l1

d1 d1

3 4
Reclaimer chain with outboard roller and raised trapezoidal Reclaimer chain with outboard roller, link plates raised on both sides
attachment plate and welded attachment plate
 | 59

Product data

Basic dimensions of the reclaimer chain with outboard roller

RECLAIMER SYSTEMS
Thickness of linkplate
Calculated breaking

Chain centre - roller

Height of linkplate
Roller diameter

Bush diameter
Type of chain

Pin diameter

Roller length
Inner width

centre
Pitch
load

Unit

FB p b1 d1 d2 d4 h2 t l1 l2

160
KWRCO4090 300 kN mm 250 40 90 22 38 60 8 73 84
315

160
KWRCO50110 500 kN mm 250 50 110 30 44 80 10 77 95
315

160
KWRCO60110 800 kN mm 250 60 110 36 58 90 12 77 106
315

250
KWRCO80110 1000 kN mm 315 80 110 40 60 100 15 77 122
400

250
KWRCO90130 1200 kN mm 315 90 130 42 65 110 15 95 136
400

315
KWRCO100150 1500 kN mm 400 100 150 44 71 120 15 97 142
500

315
KWRCO110150 2000 kN mm 400 110 150 54 80 130 20 97 161
500

315
KWRCO120180 2500 kN mm 400 120 180 56 85 135 25 113 187
500

315
KWRCO140180 3000 kN mm 400 140 180 60 90 150 25 113 197
500

Additional information:
» Design of the reclaimer attachment in accordance with individual customer specification
» Pin lock provided by locking collar head pin
60 |

KettenWulf supplies
special chains for
the most varied
conveyor systems,
e.g. for hot mate-
rial transport

Chains for pan conveyors

High conveying material flows with temperatures KettenWulf meets these special requirements with
of up to 700 °C, shaft distances of up to 250 metres, the highest degree of precision in component geo-
complex line routing and overcoming large convey- metry, optimum press-fit connections, wear-resistant
ing heights and conveying speeds of more than 1000 and fatigue-resistant materials and highest surface
m³/h: These are the challenges for conveyor systems quality.
in the material handling industry.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 61

Specific designs for

various pan conveyors
The variety of conveyor systems is extensive. Equally To pull the cell conveyors, bush conveyor chains with
extensive is the performance range of KettenWulf. single or double sided attachment brackets are used
We supply customised chain technology for all as single or double strand chains. The quality require-
conveyor systems, such as apron conveyors, hinge ments for our products, which are usually adapted to
apron conveyors, bucket conveyors or deep drawn the individual requirements of the conveyor systems,
pan conveyors. provides our customer with a decisive competitive
edge.

Pan conveyors

PAN CONVEYORS
Wide pan conveyor
62 |

Chains for deep-drawn pan conveyors

Advantages

Anti-Bend Back Design

Chains with back locked design to support
the transport weight on the tight side

Angled bracket plates

Angled bracket plates to hold and
attach the transport flights
 | 63

Versions

Variable geometry of the attachment holes

» Different hole shapes and distances permit the use

of individual attachment elements or carrier cells.
The attachment holes can be either round or square
shaped.

PAN CONVEYORS
weight reduction

» Chain link plates with lightening holes or tapering

to reduce weight

Single or double sided brackets

» Single or double sided bracket design for the

variable connection of the carrier cell
64 |

Chains for deep-drawn pan conveyors

KWCTN chain

Drawings/ product data

h2
p p

d4

d2

t
b1

KWCTN chains for deep-drawn pan conveyors

Thickness of linkplate
Calculated breaking

Height of linkplate
Bush diameter
Type of chain

Pin diameter
Inner width
Pitch
load

Unit

FB p b1 d2 d4 t h2
KWCTN2503032 290 kN mm 250 30 20 32 8 55
KWCTN2504540 510 kN mm 250 45 26 40 10 75

KWCTN2505544 700 kN mm 250 55 30 44 12 85

KWCTN2506052 900 kN mm 250 60 34 52 12 100

Other designs and chain divisions are possible upon request

 | 65

Chains for deep-drawn pan conveyors

KWCTO chain

Drawings/ product data

h2
p p

PAN CONVEYORS
d4

t
d2

b1

KWCTO chains for deep-drawn pan conveyors

Thickness of linkplate
Calculated breaking

Height of linkplate
Bush diameter
Type of chain

Pin diameter
Inner width
Pitch
load

Unit

FB p b1 d2 d4 t h2
KWCTO2503032 220 kN mm 250 30 20 32 8 50
KWCTO2504540 450 kN mm 250 45 26 40 10 70
KWCTO2506040 520 kN mm 250 60 26 40 10 80
KWCTO2506044 700 kN mm 250 60 30 44 12 90
KWCTO2506054 900 kN mm 250 60 36 54 12 90

Other designs and chain divisions are possible upon request

66 |

Chains for wide pan conveyors

Advantages

Movable lug
Movable lug to connect the movable wide pan to
the conveyor chain

Lug link to hold the link axle

Lug link with double sided raised special link plates
as fixed bearing to hold the link axle
 | 67

Versions

Lug link with integrated wear shell

» Lug link with inserted and replaceable wear shell

to reduce wear

PAN CONVEYORS
Lug in solid construction

» Lug in solid construction with hardened contact face

to reduce wear
68 |

Chains for wide pan conveyors

Drawings/ product data

h2

p p p p
t

t
d2
d4

b1
t
t

Cell conveyor chains with movable flap lug

Thickness of linkplate
Calculated breaking

Height of linkplate
Bushing diameter
Type of chain

Pin diameter
Inner width
Pitch
load

Unit

FB p b1 d2 d4 h2 t

KWLC1603032 220 kN mm 160 30 20 32 50 8

KWLC1604540 350 kN mm 160 45 26 40 65 9
KWLC1604540H 450 kN mm 160 45 28 40 80 10
KWLC1605046 550 kN mm 160 50 34 46 80 12
KWLC1605254 650 kN mm 160 52 39 54 90 15
KWLC1606060 800 kN mm 160 60 44 60 100 15
KWLC1606572 1200 kN mm 160 65 52 72 120 20

Other designs are possible upon request

 | 69

Other designs for the chains of pan conveyors

Slat conveyor chain for crusher entry

» Slat conveyor chain for crusher entry with

roller on antifriction bearing

PAN CONVEYORS
Double strand cell conveyor chain

» Double strand cell conveyor chain with welded

attachment element and outboard roller

Back locked deep-drawn pan conveyor chain

» Back locked deep-drawn pan conveyor chain in

sandwich construction with angled bracket to hold
the links
70 |

Products for high

performance
bucket elevators

Chains for bucket elevators

The use of KettenWulf bucket elevator chains for the especially for high performance applications, have
vertical conveying of bulk material has become an been proven worldwide in constant use under diffi-
essential link between production processes in many cult conditions.
industries. Double strand chains and central chains,

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 71

Specific designs for

various chain bucket elevators

Chain bucket elevators are mainly used for the vertical

conveying of bulk material, for silo feeding and in clink-
er milling. KettenWulf bucket elevator chains meet the
highest requirements for wear resistance and dynamic
loads, especially for conveying abrasive media.

Double strand
bucket elevator

BUCKET ELEVATORS
Central chain
bucket elevator
72 |

Chains for double strand bucket elevators

Advantages

Trapezoidal lug plate

Trapezoidal lug plates are used as lateral attachment
element to connect the bucket to the conveyor chain.

Small rollers
To protect the sprockets against excessive wear the
chains are designed with small rollers.

Head pins
To reduce assembly effort our chains are designed
with head pins. The head pin protruding from the
attachment plate side also ensures optimum force
transmission from the bucket to the chain.
 | 73

Versions SCS CR

Sealing

» The KettenWulf sealing system protects the

chain link against contamination
» Specifically for abrasive or corrosive conveying media
» Reduction of the wear characteristics during the
start-up phase

Weight reduction

» Chain link plates with lightening holes or in special

tapered design ensure weight reductions with unal-
tered mechanical chain characteristics

BUCKET ELEVATORS
Lug plate in angled design

» Trapezoidal lug plate in angled design to connect

the buckets to the conveyor chain
74 |

Chains for double strand bucket elevators

KWD chains

Drawings/ product data

l1

h2
l2

p p

d1
t

t
d2

b1

t
t

KWD chains
Thickness of linkplate
Calculated breaking

Height of linkplate
Roller diameter
Type of chain

Pin diameter

Hole pattern
Inner width
Pitch
load

Unit

FB p b1 d1 d2 h2 t l1 x l2
KWD1005144 380 kN mm 100 51,8 44,5 20 50 10 105 x 100
KWD1005748 550 kN mm 100 57,6 48,5 26 75 10 105 x 100
KDW1256763 750 kN mm 125 67,4 63,5 32 90 12 130 x 125
KWD1257570 1000 kN mm 125 75 70 36 100 16 130 x 125
KWD1508275 1200 kN mm 150 82.5 75 39 115 16 150 x 140
KWD1509293 1500 kN mm 150 92.5 83 42 130 18 150 x 150

Other designs are possible upon request

 | 75

Chains for double strand bucket elevators

KWD chains

Drawings/ product data

l1

h2
l2

p p

d1

BUCKET ELEVATORS
t

t
d2

b1

t
t

KWD chains
Thickness of linkplate
Calculated breaking

Height of linkplate
Roller diameter
Type of chain

Pin diameter

Hole pattern
Inner width
Pitch
load

Unit

FB p b1 d1 d2 h2 t l1 x l 2
KWD1523636 240 kN mm 152,4 36,5 36 16 45 8 75 x 70
KWD1005144 380 kN mm 100 51,8 44,5 22 60 10 100 x 80
KWD2005748 550 kN mm 200 57,6 48,5 26 75 10 100 x 80
KWD2506763 750 kN mm 250 67,4 63,5 32 90 12 140 x 100
KWD2507570 1000 kN mm 250 75 70 36 100 16 140 x 100
KWD3007570 1200 kN mm 300 75 70 40 100 16 170 x 120
KWD3008275 1200 kN mm 300 82.5 75 40 115 16 170 x 120

Other designs are possible upon request

 | 77

Versions SCS CR

Sealing

» The KettenWulf sealing system protects the

chain link against contamination
» Specifically for abrasive or corrosive conveying media
» Reduction of the wear characteristics during the
start-up phase

weight reduction

» Chain link plates with lightening holes or in special

tapered design ensure weight reductions with unal-
tered mechanical chain characteristics

BUCKET ELEVATORS
Chain link plates in angled design

» Chain link plates in angled design permit the variable

arrangement of the attachment plates
chains
elevatorsKWE
bucket
strand
double
for
dataChains
product
Drawings/
 78 |

Central chains for bucket elevators

Bucket Elevator Chains with Straight Link Plates

Drawings/ product data

d4 d4

t
t

d2 d2

b1
b1
t

h2
h2

p p p p

Design A Design B

Central chains for bucket elevators Thickness of linkplate

Calculated breaking

Height of linkplate
Bush diameter
Type of chain

Pin diameter
Inner width
Design

Pitch
load

Unit

FB p b1 d4 d2 h2 t

inch 6 3 1,75 1 2,5 0,5

KW1856 500 kN B
mm 152,4 76,2 44,45 25,4 63,5 12,7

inch 6 3 1,75 1 3 0,5

KW1956 650 kN A
mm 152,4 76,2 44,45 25,4 76,2 12,7

inch 6 3 1,75 1 3,25 0,5

KW1857 650 kN B
mm 152,4 76,2 44,45 25,4 82,5 12,7

inch 6 3 2 1,13 3,25 0,5

KW1958 800 kN A
mm 152,4 76,2 50,8 28,7 82,5 12,7

inch 6 3,75 2,38 1,25 4 0,62

KW1859 1000 kN B
mm 152,4 95,3 60,45 31,75 101,6 15,7

inch 7 3,75 2,38 1,25 4 0,62

KW1864 1000 kN B
mm 177,8 95,3 60,45 31,75 101,6 15,7

inch 7 3,75 2,5 1,38 4 0,62

KW1984 1200 kN A
mm 177,8 95,3 63,5 34,9 101,6 15,7

Other designs are possible upon request

Versions
 | 79

Central chains for bucket elevators

Bucket Elevator Chains with Straight Link Plates

Drawings/ product data

H H
A
F

G
A
F
B
D

E
E J
D
T

K
C

BUCKET ELEVATORS
C

Design K24 Design K44/K443

Central chains for bucket elevators, dimensions of the attachment components

Type of chain

Design

Weight
Unit

A B C D E F G H J K T kg/m

inch 7,25 1,75 1,88 0,69 2,50 9,38 6,91 0,50

KW1856 K24
mm 184,15 44,45 47,75 17,50 63,50 238,00 175,50 12,70 32,0

inch 7,25 1,75 1,88 0,69 2,50 9,38 6,91 0,50

KW1956 K24
mm 184,15 44,45 47,75 17,50 63,50 238,00 175,50 12,70 34,0

inch 7,00 1,25 2,50 0,56 3,50 14,00 12,00 5,50 1,25 3,50 0,50
KW1857 K44
mm 177,80 31,75 63,50 14,20 88,90 356,00 304,80 140,00 31,75 88,90 12,70 48,0

inch 7,00 1,25 2,50 0,56 * 3,50 13,68 12,00 5,75 1,25 3,50 0,50
KW1958 K44
mm 177,80 31,75 63,50 14,20 * 88,90 347,00 304,80 146,00 31,75 88,90 12,70 49,0

inch 9,00 1,62 3,00 0,69 * 2,75 15,00 13,00 5,92 0,75 4,50 0,62
KW1859 K44
mm 228,60 41,15 76,20 17,50 * 69,85 378,00 330,20 150,00 19,05 114,30 15,70 75,4

inch 9,00 1,62 3,00 0,69 * 3,75 15,00 13,00 7,00 0,75 5,50 0,62
KW1864 K443
mm 228,60 41,15 76,20 17,50 * 95,30 378,00 330,20 178,00 19,05 139,70 15,70 71,0

inch 9,00 1,62 3,00 0,69 * 3,75 14,88 13,00 7,00 0,75 5,50 0,62
KW1984 K443
mm 228,60 41,15 76,20 17,50 * 95,30 378,00 330,20 178,00 19,05 139,70 15,70 65,0

* Attachment hole designed as slotted hole Other designs are possible upon request
Versions
80 |

Central chains for bucket elevators

Bucket Elevator Chains with Straight Link Plates

Advantages

Weight reduction
Sustainable increase in energy efficiency through
weight reduction. Easy handling of the chain during
installation and removal. Optimization of energy
consumption.

Thick-walled bushings
Thick-walled bushings guarantee a high resistance to
shock loads. The high surface hardness and ductile
core significantly increase the service life of the con-
veyor chain.
 | 81

Central chains for bucket elevators

Bucket Elevator Chains with Straight Link Plates

Drawings/ product data
h

p p p p

i g

d4

b1
f

1
Version Type A (with angle attachment)

h
p p p p

BUCKET ELEVATORS
d4

i
b1
f

1 2
Version Type B (without bucket holder) KW BH 408 for Version Type B

1 Central Bucket Elevator Chains

Calculated breaking

Longitudinal pitch
Bushing diameter

Transverse pitch
Fixation holes

Fixation holes

Fixation holes
Type of chain

Inner width

Diameter
Version

Weight
Pitch
load

Unit

FB p b1 d4 i g f kg/ m

KW404 A 450 kN mm 140 50 38 14 100 140 18,5

KW406 A 630 kN mm 152,4 65 45 18 130 200 28,5

33,6
KW408 B 800 kN mm 177,8 70 52 18 150 250
without bucket holder

2 Bucket holder for Central Bucket Elevator Chains Type B

Longitudinal pitch
Fixation holes

Fixation holes
Bucket holder
Central Edge/

Diameter
Top Edge

Weight
Type

Unit

h i g kg/ pcs.

KWBH408 mm 55 18 150 1,8

82 |

Central chains for bucket elevators

Bucket Elevator Chain with Forged Link Plates

Advantages

Weight reduction
Sustainable increase in energy efficiency
through weight reduction.

Bucket holder
Forged design with highly wear-resistant bore
holes for connection to the chain.

Fatigue strength
Optimized design through research based on
FEM analyses and selection of specific materials
to maximize fatigue strength.
 | 83

Central chains for bucket elevators

Bucket Elevator Chain with Forged Link Plates

Drawings / product data

h
p p p p

d4

b1
i
f

BUCKET ELEVATORS
g

1 2

1 Bucket Elevator Chain with Forged Link Plates (without bucket holder)
Calculated breaking

Bushing diameter

Transverse pitch
Fixation holes
Type of chain

Inner width

Weight
Pitch
load

Unit

FB p b1 d4 f kg/ m

KW412 1200 kN mm 177,8 70 58 250 38,0

KW415 1500 kN mm 177,8 85 63 300 49,9

KW418 1800 kN mm 177,8 95 71 300 65,9

2 Bucket holder for Central Bucket Elevator Chains

Longitudinal pitch
Fixation holes

Fixation holes
Bucket holder
Central Edge/

diameter
Top Edge

Weight
Type

Unit

h i g kg/ pcs.

KWBH412 mm 60 18,5 150 1,7

KWBH415 mm 65 18,5 150 2,0

KWBH418 mm 70 18,5 150 2,4

84 |

Bucket elevator
base for continu-
ous ship unloader

Chains for continuous

ship unloaders

The mass transfer of various bulk materials from river KettenWulf products for unloading bulk material op-
and sea vessels in the medium to large performance erate environmentally friendly, economic and reliably
range is mainly handled through continuously operat- under all climatic conditions.
ing unloading systems. These permit an effective
ship unloading which protects the material as well as
being dust-free and low in noise for coal, ores, phos-
phates, sulphurs and fertiliser.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 85

Low maintenance chain technology (SCS CR)

in continuous ship unloaders

At KettenWulf, innovation means making good pro- A special seal embedded in two corrosion-resistant
ducts even better: For years KettenWulf has success- labyrinth covers ensures that neither environmental
fully developed groundbreaking innovation in the contamination can enter the chain link nor can special
field of low-maintenance chain technology. The cata- lubricant introduced escape uncontrolled from the
lyst for this is our drive to continually innovate and chain link. This results in optimum lubrication for the
develop products with our customers to meet their bushing and pin in the chain link, ensuring the long-
market demands. term sound operation of the entire conveyor system.

Abrasive media, such as coal, ores or fertilisers cause With its low use of resources this innovation not only
high wear in the chain link which is mainly respon- contributes actively to protect the environment but
sible for an early failure of the chain. The results are also ensures high product efficiency for our customers.
usually very expensive: Increased maintenance or
the complete replacement of the conveyor chain and
resulting plant downtime. To ensure high plant availa-
bility with simultaneously reduced maintenance costs,
KettenWulf has developed a special multiple seal sys-
tem (sandwich seal system) for the chain link.

Multiple seal system

for the chain link

SHIP UNLOADERS
86 |

Continuous ship unloader

Advantages

Link plate design

Optimised link plate design for weight reduction to
reduce wear and drive energy

Attachment
Optimised attachment for simple assembly and
removal of the buckets
 | 87

Drawings/ product data

h2
p p p p

d1
t1

t
b1
t
t1

SHIP UNLOADERS
Chains for continuous ship unloaders
Calculated breaking

Height of linkplate
Thickness of outer
Thickness of inner
Roller diameter
Type of chain

Inner width

linkplate

linkplate
Pitch
load

Unit

FB p b1 d1 t t2 h2

KWCSU2507264 600 kN mm 250 72 64 12 12 90

KWCSU2009495 1800 kN mm 200 94 95 19 19 135

KWCSU250136130 3085 kN mm 250 136 130 25 25 175

KWCSU350158165 4585 kN mm 350 158 165 28 28 230

Other designs are possible upon request

88 |

Reclaimer system with

central guide roller

Roller units for bulk material

handling systems

Roller units in bulk material handling systems meet Support rollers in deep-drawn pan conveyors transfer
the most varied requirements. Central guide rollers the vertical loads of the medium onto the guide rail and
in reclaimer systems ensure the correct guidance of ensure an optimum lateral guidance via the flange.
the reclaimer buckets and reduce the axial loads on
the conveyor chain.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 89

Application examples for roller units

in bulk material handling systems
The use of rollers on antifriction bearings reduces
the roll resistance in the plant and reduces the stress
on the conveyor chain. A special sealing system can
reduce the maintenance effort to a minimum.

Central guide roller

for reclaimer buckets

Support roller
for deep-drawn
pan conveyor

ROLLER UNITS
90 |

Central guide rollers

Advantages

Guide roller
The guide roller is made of tempered steel. To optimize
wear resistance, the running surface is inductively
hardened.

Ball bearing
To reduce friction and noise the central guide rollers
are equipped with ball bearings.

Seal
Special seals protect the ball bearings of the rollers
against environmental influences. This makes the
roller maintenance-free and permanently lubricated.
 | 91

Drawings/ product data

l1

d1

Central guide roller with locating pins to connect the reclaimer bucket

Central guide rollers basic dimensions

Roller diameter

Roller length
Type

Unit

ROLLER UNITS
d1 l1

KWGRS90 mm 90 55

KWGRS110 mm 110 65

KWGRS130 mm 130 80

KWGRS150 mm 150 95

KWGRS180 mm 180 110

Locating pins according to customer preferences

92 |

Rollers for pan conveyors

Advantages

Sealing
To protect against environmental influences the
flanged roller is sealed on both sides. The utilisation
of a rubber seal back face and cover plate on the front
face the unit is protected. Relubrication of the ball
bearing is via a grease nipple.

Flanged roller
The flanged roller is made from heat-treated steel
and induction harden to optimise the wear resistance
at the roller diameter and roller flange.

Antifriction bearing
To reduce wear friction, heating and noise, the rollers
are equipped with standardised grooved ball bearings.
 | 93

Drawings/ product data

d1

d2

Rollers for pan conveyors

Roller diameter

Roller diameter
Type

Unit

ROLLER UNITS
d1 d2

KWSRC108 mm 108 160

KWSRC140 mm 140 200

KWSRC160 mm 160 220

Locating pins according to customer preferences

94 |

Assembly of
drive shaft and
sprocket used
in the bulk
material han-
dling industry

Sprockets for complete

drive systems

Sprockets are a decisive factor in the capability and dual solutions with optimal tooth shapes and wheel
service life of every chain system. KettenWulf there- sizes. Using high quality heat-treated tempered steel we
fore produces its own sprockets to ensure the high set quality standards for wear-resistant sprockets and
quality of all products. Our product range covers in drive components.
addition to sprockets in all DIN gearings also indivi-

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 95

Optimum tooth shape for all designs

We supply the corresponding sprockets for all chains. Our production range covers all designs of sprockets,
In addition to sprockets with DIN gearing sprockets such as sprockets with single and double sided hub,
with optimised tooth shapes and milled surfaces can divided sprockets, sprockets with bolted on segments
also be produced on our CNC machines. Designs in or tooth shells, shear-pin sprockets, pinion sprockets
high quality materials with tempered and additionally and noise-attenuated special sprockets as well as hard-
inductively hardened teeth are part of our standard ened drive and tensioning wheels for chain bucket ele-
product programme. vators without gearing.

Figure 1: 1 2
Sprocket with
bolted-on tooth shells

Figure 2:
Sprocket with
intermediate gap
for welded chain
reinforcement tube

Figure 3: 3 4
Sprocket with
special gearing for
forged link chains

Figure 4:
Double sprocket for
block plate chain

Figure 5: 5 6
Drive wheel without
gearing for bucket
elevator chain

Figure 6:
Drive shaft fully
assembled with
sprockets
SPROCKET WHEELS

Figure 7: 7 8
Sprocket with 3-part
sprocket wheel and
lightening holes

Figure 8:
Sprocket with double
sided screw-on noise
attenuation elements
96 |

Maintenance work
on a sprocket

Service & Accessories

In addition to a comprehensive range of specific trans- vice life can only be guaranteed if a customised offer
port solutions for the most varied bulk materials in is accompanied by an individual service. We offer you
different industries, service relating to the use of our accessories beyond the basic equipment as well as
products is also included. Sustainability and long ser- various services for the ongoing use of our products.

Asphalt

Port technology

Mining

Cement

Fertilisers

Coal fired plants

 | 97

Service & Accessories

Service

Sample and wear analysis

» KettenWulf has the test facilities to perform com-

prehensive examinations of its chains and drive
components in operation We also offer the option
to prepare expert evidence relating to the causes
of an accident.

Supervision

» On site assembly of the chains often required

in-depth chain technology know-how to prevent
early damage of the supplied products due to
faulty assembly or to instruct your employees in the
correct handling of the supplied assembly tools.
We can provide experienced site installation staff to
assists and support your maintenance team during
the installation process.

Tensile tests

» In our test lab we can in addition to comprehensive

component tests also carry out tensile tests for
chains with a breaking force up to 3000 kN.

SERVICE & ACCESSORIES

98 |

Service & Accessories

Accessories

Assembly tools

» To ensure easy and professional assembly KettenWulf

supplies the matching assembly and removal tools for
the chain upon request. The tool design complies with
the statutory standards and safety regulations. The
scope of delivery includes also the corresponding user
manual for the tool.

Tooth gap template

» Once a sprocket reaches its limit of wear it must be

replaced. The wear of the tooth gap can be checked
using the tooth shape template supplied.
 | 99

Accessories

Locking collar pliers

» KettenWulf locking collar pliers with their powerful

lever arm enable the easy assembly of the KettenWulf
locking rings for securing the pins.
» With the special pliers both locking rings made from
steel as well as stainless steel of all designs and sizes
can be easily fitted."

Tension pin assembly press

» For the easier assembly and removal of sprocket

wheels which can be attached to the flange using
clamping sleeves, a special draw-out device is used
which has been developed to match the supplied
sprocket wheel.

SERVICE & ACCESSORIES

Contacts worldwide

KettenWulf Betriebs GmbH KettenWulf, Inc. KettenWulf Betriebs GmbH KettenWulf Canada Inc.
Zum Hohenstein 15 322 Thornton Road Liaison Office Turkey 480 University Avenue
D-59889 Eslohe-Kückelheim Suite 101 Varyap Meridian Grand Tower Suite 1500
Germany Lithia Springs, GA 30122 A-Block No: 58 Toronto, ON M5G 1V2
T + 49.(0) 2973.801 0 USA 34746 Atasehir - Istanbul Canada
F + 49.(0) 2973.801 228 T +1.(0) 678.4330 210 Turkey T +1.(0) 416.598 70 72
[email protected] F +1.(0) 678.4330 215 T +90.(0) 216.510 47 94 [email protected]
[email protected] F +90.(0) 216.510 47 94
[email protected]

KettenWulf GmbH KettenWulf KettenWulf Pty Ltd

Division Ferlacher Förderketten Representative Office Poland Level 6, 8 Spring Street
A-9163 Unterbergen 25 ul. Ogrodowa 34 B\ 4 Sydney NSW 2000
Austria PL-65-001 Zielona Góra Australia
T + 43.(0) 4227.25 27 Poland T +61.(0)2 8296 0498
F + 43.(0) 4227.35 94 T + 48.(0) 68.325 43 37 F +61.(0)2 8296 0411
[email protected] F + 48.(0) 68.325 43 37 [email protected]
[email protected]

Hangzhou Wulf Chain Co. Ltd. KettenWulf Betriebs GmbH KettenWulf NV

40 Tangning Road, Yunhe Town A-104, Samarth Carina, Business Centre
Yuhang District Near Aditya Birla Hospital, Esplanade 1/85
311102 Hangzhou Thergaon 1020 Brussels
P.R. of China Pune-411033 Belgium
T + 86.(0) 571.861 899 00 India T + 32.(0)2 486 6516
F + 86.(0) 571.861 899 50 M + 91.(0) 98.905 031 64 [email protected]
[email protected] [email protected]

Modifications and further developments in the interest of technical progress reserved. Your are responsible for checking the use
of the catalogue data for their suitability. No liability is accepted for printing errors, mistakes and changes. All information
© KettenWulf, Stand: Januar 2020, Design: tooldesign, Photos: Erik Hinz, Münster; KettenWulf, Kückelheim, Ontrak;

is offered without warranties. Reprints, including of extracts, require the written permission of KettenWulf.

www.kettenwulf.com