Forged vs Round Link Chains: Choosing the Right Conveyor for Ash Handling

Ash handling is one of the most abrasive jobs in thermal plants and incineration facilities. Fine particles, heat and corrosive residues combine to shorten component life. A poor chain choice means frequent shutdowns and higher operating cost. Matching chain geometry to duty is essential for steady, reliable operation.

The Importance of Using the Right Chain

Not all chains behave the same under abrasion, impact and fatigue. The difference between a forged chain link and a round link chain shows up in wear patterns, fatigue resistance and the way the chain engages sprockets and scrapers. In heavy-duty material handling installations these differences drive maintenance frequency and total ownership cost.

Forged Chain Link: Durability and Shock Resistance

Forged links are made from solid steel that is hot worked and heat treated. The forging process aligns the metal grain and produces a part that resists bending fatigue and heavy impacts. Where ash compacts around scrapers or where tramp metal can strike the chain, forged chain link components hold shape and alignment longer. That means fewer sudden elongation issues and fewer unscheduled stops. If you think a forged chain link meets your needs better, consider the RUD Forky, a simple, heavy duty forged chain link that is reliable and will get the job done.

Round Link Chain: Flexibility and simple service

Round link chain uses formed or welded round links and tends to offer smooth articulation and simple inspection. Its rounded profile engages sprockets gently, which suits lower speed conveyors and lighter ash loads. For plants with predictable, light ash flow and regular maintenance windows, round link chain can be a cost effective, straightforward choice.

How Chain Type Pairs with Conveyor design

A submerged scraper conveyor positions the chain and scraper flights beneath the ash bed. This protects the chain from airborne dust but increases abrasive contact with compacted material. In such conveyors, pairing robust chain geometry with a well designed scraper flight is crucial. Many operators choose forged chain link with reinforced scrapers to keep the trough aligned and to resist abrasive wear.

Practical Trade Offs to Consider

If you expect impact loads, tramp material or heavy compaction, forged chain link is often worth the extra initial investment. If ash is lighter, slower and maintenance is simple, round link chain may be sufficient. Decide on life cycle cost rather than purchase price alone. A chain with a longer service life and fewer emergency repairs usually lowers overall cost and increases plant uptime.

Consider the RUD Submerged Scraper Conveyor

RUD India supplies conveyor equipment designed for continuous, heavy work. The RUD Submerged Scraper Conveyor supports forged chain link options and modular scraper assemblies. It offers accessible inspection points, proven sealing for bearings and drives, and serviceable components that shorten maintenance windows. Local RUD India support helps teams match chain grade, heat treatment and sprocket profile to site conditions.

Selection and Maintenance: Best Practices

Choose chain grade and heat treatment based on ash chemistry and operating temperature. Verify sprocket geometry and tooth profile for the chosen chain type. Keep a record of chain elongation and replace links before they cause misalignment. Fit proper seals and gaskets to limit ash ingress into bearings. Regular inspection and planned part swaps keep unplanned outages to a minimum.

A Use Case Scenario

At a coal fired facility with compacted ash, switching to a submerged scraper conveyor with forged chain link and reinforced scraper flights can reduce chain repairs and improve trough alignment. Fewer unscheduled stops and lower spare part consumption across a full season lead to improved productivity.

Conclusion

Selecting the correct chain for ash handling is a technical decision with financial consequences. Forged chain link provides superior fatigue resistance and impact strength. Round link chain can suit lighter duties and simpler systems. For long term, predictable performance in ash systems, a properly configured RUD Submerged Scraper Conveyor combined with matched chain type and disciplined maintenance offers a reliable solution.