BELT BUCKET ELEVATOR DESIGN NOTES

DISCLAIMER
These notes are i ntended to assi and provde di ti i the proc st i rec on n ess ofdesi ng belt buc et elev gni k ators.Theyare not a substi f c tute or onduc ng a thorough engi ti neeri analy s ofthe desi requi ents. Bec ng si gn rem ause the author and publi sher do not k now the c ontex i whih the notes are to be used and c t n c annot revew the resulti desi i ng gn theyac ept no responsi li f the c c bity or onsequenc ofusi them . es ng The author c m s c ri ov all the m ateri i these notes 15 Marc 2001. lai opy ght er al n h

CONTENTS OF DESIGN NOTES 1.0 2.0 3.0 4 .0 5.0 6 .0 7 .0 8.0 9.0 Overview of belt bucket elevators and their use. Determine throug hput capacity . Determine belt speed and throw. Calculate motor power. Calculate top and bottom pulleyshaft siz . ing Drive arrang ement and desig n. S haft bearingand seal arrang ement. S electingelevator frame structural members. I and outlet chute desig nlet n.

10.0 Considerations in choosingpanel materials. 11.0 S electingbelts and buckets. 12.0 M ethods to take-up belt tension. 13.0 P rotection ag ainst bog ingthe buckets. g 14 Clean-out considerations. .0 15.0 Dust ex traction req uirements. 16 I .0 nstallingthe bucket elevator in place. 17 Correct operation of belt bucket elevators. .0 18.0 M aintenance of belt bucket elevators.

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Th lf- a dc l mnp o i e d s rp ietx . e eth n ou r vd s e c i tv e t NECES ARY I S NFORM ATI ON Req uired product parameters. S ervice use. M aterial chemical name. Bulk densitymass/volume kg 3 /m M ax imum dutykg or m3/hr /hr M ax imum lump siz - dimensions e averag siz e e percentag of lumps in total e Heig product is to be raised (meters) and ang of incline ht le if any P . rovide enoug heig at the outlet of the discharg h ht e chute so the product is alway fallingfollowingdischarg s e. P roduct characteristics abrasiveness flowabilityfree/cohesive/slug dampness % moisture friabilityfirm/breaks/powders particle shape leng th/siz e/volume temperature of product ang of repose le corrosiveness Operatingenvironment, location and conditions corrosive/damp S ervice req uired continuous/intermittent. Open or closed boot desig n. S ELECT BUCKET S ZE AND S ACI I P NG The siz and number of buckets is determined from the e req uired throug hput usingan iteration process. S elect the bucket from the rang in the bucket supplier e s catalog Only2/3 (6 %) of the bucket desig capacity ue. 7 s n is used in calculations. Centrifug discharg convey usuallyhave a spacing al e s between buckets that is 2 to 3 times the bucket proj ection, thoug the spacingcan be g h reater for free-flowing products. DETERM I BELT S EED NE P The bucket spacingtimes the number of buckets per second determines the req uired belt speed. The speed for centrifug bucket elevators is usuallyin the rang of 1 m/s al e to 2 m/s to insure the product throws into the chute at the head pulley . CALCULATE HEAD P ULLEY DI ETER AM A simplify assumption is made that the throw ing commences at the top of the head pulley At this point the . centrifug force and g al ravityforce are balanced. cos where Centrifug force = m v 2 al r m = mass in kg v = belt speed in m/s = ang from top dead centre le r = pulleyradius in m Gravityforce = m g where g= g ravityconstant 9.8 m/sec2. P uttingboth forces eq to each other ual The rig ht-hand column provides an ex ample.

Th rg th n c l mnp o i e a e a l. e ih - a d ou r vd s n x mp e NECES ARY I S NFORM ATI ON P roduct parameters. Raise crushed product from mill outlet to storag silo. e Aluminium S ulphate. 17 kg 3 00 /m 5,000 kg /hr 3 mm max 2 mm Nil 5.5 m includingleng of discharg chute into 4m hig th e h storag silo. e S harp edg es Free Less than 2% Firm Consistent Ambient 30 deg rees Corrosive if damp Dryand airy

I ntermittent up to 12 hours per day6day a week s Open boot bottom, elevator will sit on a concrete floor. S ELECT BUCKET S ZE AND S ACI I P NG 5,000 kg throug /hr hput. S elect a bucket 150 mm wide x100 mm proj ection with a volume of 0.7 litre. 8 Using2/3 of the volume g a capacityof 0.5 litre. ive 0.5 lt. is 0.0005 m3 and holds 0.85 kgof product. (0.0005 m3 x17 kg 3). 00 /m To move 5000 kg using150 x100 buckets req /hr uires 6 ,000 buckets per hour or 100 buckets per minute. S elect a bucket spacingof 300 mm. DETERM I BELT S EED NE P 100 buckets per minute/6 sec per minute = 1.7bucket/sec. 0 1.7bucket/sec x0.3 m = 0.5 m/sec. This is too low and will prove to be insufficient for a clearance throw into the discharg chute. The bucket spacingwill need to be e increased and the calculation repeated. CALCULATE HEAD P ULLEY DI ETER AM v2 (0.5m) 2 = = 25mm r (radi ) = us g 9.8m / sec 2 The head pulleydiameter is 50 mm. This siz thoug e, h accuratelycalculated, is not practical. I is far too small. t The buckets cannot deform sufficientlyto g around the o pulleywithout over-stressingboth buckets and belt. The solution is to increase the bucket spacingor to use smaller buckets. This then req uires a proportionate speed increase to maintain the throug hput. The g reater velocity needs a larg head pulleyrevolvingat the same RP . er M However as we are usingthe smallest buckets available it is necessaryto increase the bucket spacing .

Postal Address:FEED FORW ARD PUBL CATI I ONS,PO Box578, BENTL EY, est Au W strali 6102 E- l Address:f orward@ bi a, . mai eedf gpond. om c Bec se the authors and publi au sher do not k now the c ontex i whih the i orm ati presented i the f er i to be used theyac ep no t n c nf on n ly s c t responsi li f the c sequenc ofu ng the i ormati c tai or i pli i anyartiles bity or on es si nf on on ned m ed n c

v 2 = g r cos cos = 1 at top dead centre.

Therefore r = v2 and diameter (d ) = 2 r g

The belt velocityusinga bucket spacingof 7 mm with 00 the removal rate of 1.7bucket/sec x0.7m = 1.2 m/sec. The pulleydiameter is now d = r 2 = (1.2 2 9.8) 2 = 300mm . The diameter could be made slig htlylarg if so desired. er

CALCULATE THROW I NTO CHUTE AND CHUTE S ZE I Usingthe standard traj ectoryformula s = u t + 0.5 a t 2 W here s = displacement (m) u =initial velocity(m/s) a = acceleration (m/s2) = g ravityconstant g= 9.8 m/s2 t =time (sec) The traj ectoryafter the product leaves the bucket can be g raphed and the chute heig determined. ht The horiz ontal component at top dead centre of the pulley where acceleration due to g ravityin the horiz ontal direction is z is g ero iven by s h = u t meters. The vertical component at top dead centre where velocity in the vertical direction is z is g ero iven by s v = 0.5 a t 2 meters. The distance of the chute from the vertical center of the head pulleymust be sufficient to allow the buckets to clear the wall of the elevator on the downward leg .

CALCULATE THROW I NTO CHUTE AND CHUTE S ZE I Calculate the horiz ontal and vertical position of the product for every0.1 seconds of flig time. ht
TI E M (sec) HOR. DI T. S (mm) VERT. DI T S (mm)

0.1 120 50 0.2 24 0 195 0.3 36 0 40 4 0.4 4 80 7 80 0.5 6 00 1220 From the table it is noted that after 0.2 seconds of flig the ht product has traveled 24 mm horiz 0 ontallyfrom top dead centre and 195 mm vertically The pulleyradius is 150 . mm which means the product is clear of the pulleyby90 mm. But it is not y clear of the 27 mm radius circle et 0 scribed bythe lip of the bucket (allowingfor belt thickness). This distance is reached shortlyafter 0.2 seconds. A satisfactorychute depth would be 6 mm, with the chute 00 openingstarting350 mm from the vertical centre of the head pulley This makes the bucket elevator 7 mm deep. . 00 Because of the 150 mm width of the buckets a 17 mm 5 wide belt on 200 mm wide head pulleywill be used. To provide clearance to the wall the elevator it will be 250 mm wide.

DETERM I THE DRI ARRANGEM ENT NE VE W ith the head pulleysiz determined and the linear belt e speed known, the RP of the head pulleycan be M calculated. V (m / s) 0 RPM = 6 2 r ( m) Usuallya 4 -pole motor at 14 RP with a reduction 50 M g earboxof suitable ratio is selected to drive the head pulley The g . earboxcan be a direct drive or shaft-mounted unit dependingon the available space and access.

DETERM I THE DRI ARRANGEM ENT NE VE 1 .2 RPM = 0 6 = 38 2 0.3 I will be necessaryto select sprocket siz for the motor t es and head pulleyto produce the req uired rotational speed. Ag earboxcan be selected to reduce from 14 RP input 50 M shaft speed to 38 RP output shaft speed. Alternatively M the sprocket siz can be used to produce some of the es reduction and the g earboxthe remainder. Limit reduction via the sprockets to around a 3: ratio to not over-stress the 1 chain.

Postal Address:FEED FORW ARD PUBL CATI I ONS,PO Box578, BENTL EY, est Au W strali 6102 E- l Address:f orward@ bi a, . mai eedf gpond. om c Bec se the authors and publi au sher do not k now the c ontex i whih the i orm ati presented i the f er i to be used theyac ep no t n c nf on n ly s c t responsi li f the c sequenc ofu ng the i ormati c tai or i pli i anyartiles bity or on es si nf on on ned m ed n c

Combiningthe above tension eq uations allows T1 to be determined. P v Newton T1 = 1 1 e The weig of the rubber belt depends on the plyof the ht belt, its width and leng S th. ince the belt tension is know the belt can be selected. The belt supplier can advise the belt to be used. S elect a belt specificallyfor bucket elevators and not horiz ontal convey ors. Those used on bucket elevators contain more weavingthan those for horiz ontal convey ors. S elect the belt with a safetyfactor bey the calculated loads for longlife under intermittent ond and shock load conditions.

The force at the head pulleydrive sprocket is in the proportionate ratio of drive train sprocket diameters. 2 N F r P 6 1000 0 Po (k ) = wer W and F = 6 1000 0 2 N r 1.1 6 1000 0 Fgearbox = k = 1.84 N 2 114 0.05 1.84 101 Fheadshaf = 06 =6 N t 307 The load on the bearing is the sum of the belt tension and s the drive force consideringtheir direction of action. The pulleyand shaft self self-load and the belt material loads will need to estimated and later checked if suitably accurate. The buckets are 150 mm wide so the belt will be 17 mm 5 wide inside a 225 mm wide elevator frame. The elevator heig is 5.5 m and the belt leng about 12 m. For the ht th purpose of the ex ample a 4 -ply36 belt will be used with -oz a mass of 0.0018 kg /mm width/metre leng th/ply . A 12-metre, 17 mm wide, 4plybelt weig 15 kgand 5 hs produces 150 N downward force. The mass of the head pulleycan be estimated byassuming it will be made of 300 mm diameter steel pipe of 12 mm thickness with end plates of 12 mm thick flat plate. The shaft will be assumed to be 50 mm solid brig steel bar ht 4 mm long The head pulleymass is calculated at 22 kg 00 . and 220 N force. I can be seen that the self-load forces are t minor when compared to the product load g enerated forces. The free-bodydiag ram can now be completed with all the forces actingon the shaft. W ith the drive and load forces known the reactions at the bearing can be determined by s balancingthe moments at each bearing The shear force . and bendingmoment diag rams for the shaft can be drawn to indicate the position of the hig hest bendingstress. The hig hest bendingstress is at the drive-end head pulley hub. At the same time the shaft is underg oingtorsional stress from the drive. The worst case under torsion would be if the buckets were bog ed and the g g eared motor applied full power of 1.1 kW . This produces a torq T at the pulley ue shaft of 1000 P 1000 1.1 T = = = 31Nm 2 RPM 2 38 6 0 6 0

The shaft underg both bendingand torsion oes simultaneously . The bendingand torsional stresses are combined into an eq uivalent stress S in the formula e

S e = K b K c M 2 + K t K ct T 2 = Fs Z p b
where M =larg bendingmoment Nm est T = shaft torq ue Kb = shock factor bending Kt = shock factor torsion Kcb = stress concentration factor bending Kct = stress concentration factor torsion Fs = allowable shear stress (M P a) Zp = polar section modulus = d3/16for a solid bar The max imum allowable shear stress is half the max imum principle stress. I addition a factor of safetyof 2 for n shock loadingand stress raisers is included. For rotatingshafts under minor shock loads Kb varies from 1.5 to 2.0 and Kt varies form 1.0 to 1.5. I heavyshock n load conditions Kb varies from 2.0 to 3.0 and Kt varies form 1.5 to 3.0. S tress concentration factors can be found from stress concentration g raphs for the form of stress raiser involved.

S e = K b K c M 2 + K t K ct T 2 b
3 3 = 1.5 129.5 2 + 1.5 312 = 16 Nm = 16 ,000 Nmm No allowance was made for stress concentration since the shaft will be mounted to the pulleybytaper locks, which do not req uire the shaft to be machined. I the shaft is f stepped it will be necessaryto factor in stress concentration effects.

Postal Address:FEED FORW ARD PUBL CATI I ONS,PO Box578, BENTL EY, est Au W strali 6102 E- l Address:f orward@ bi a, . mai eedf gpond. om c Bec se the authors and publi au sher do not k now the c ontex i whih the i orm ati presented i the f er i to be used theyac ep no t n c nf on n ly s c t responsi li f the c sequenc ofu ng the i ormati c tai or i pli i anyartiles bity or on es si nf on on ned m ed n c

S HAFT BEARI AND S NG EAL ARRANGEM ENT Once the shaft siz is determined the bearingsiz can be selected. Follow the bearingmanufacturer selection process for e e s calculatingthe req uired bearingty and config pe uration for the eq uipment desig life and service factors. n P rovide shaft seals for the bearingat the bearinghousingand at the penetration into the elevator frame. The bearingmust ne ver be ex posed to dust or dirt or moisture while in the production environment. Do every thingnecessaryto protect the bearing . The bearingand seal suppliers can advise other way of mountingand protectingthe bearing s . The best bearingarrang ement desig is to stand the bearingoff the elevator frame with a clearance of around 25 mm. n ELEVATOR FRAM E M EM BERS The frame can either be made of an ang iron skeleton to which sheets of steel are attached or from sheets of steel pressed to le the req uired rectang ular shape that are flang and bolted tog ed ether. The thickness and leng of section used in the frame must be sufficient to prevent bucklingunder load. ths I NLET AND DI CHARGE CHUTE DES GN S I The inlet chute should be desig to promote product flow and to minimise the amount of bucket drag P ned . referablythe product feed falls into the buckets as theycome around the tail pulleywithout beingdrag ed throug a fullyplug ed boot. g h g The feed chute should be made with a slig htlysmaller width than the buckets. I should be sufficientlysteep to insure product t alway flows and does not build back. Test the product flowabilityif possible byputtingsome on a bent sheet of the elevator s s chute material shaped into a the same width as the chute. Tilt it to find the ang that produces flow. U le I nsure there are no restrictions or protrusions into the chute that will cause the product to build back. The discharg chute siz is known from the initial desig The ang at which it is set must meet the same criteria as the inlet. e e n. le HEAD AND TAI P L ULLEY DES GN I The head pulleydimensions have been determined. For simplicitythe tail pulleyshould be to the same dimensions as the head pulley This will keep the buckets a constant distance off the elevator wall and aid product pick-up and simplifychute desig . n and fabrication. Both head and tail pulley need to be crowned to centralise the belt and permit the belt to be tracked if it s wanders. The crowningshould be 2 deg rees both left and rig from the center of the drum. ht The head pulleycould be rubber lag ed if desired to increase the coefficient of friction and lower the belt tension. This will g allow use of a lig hter dutybelt. But there is alway the possibilitythe lag ingwill be stripped off duringoperation. I is best to s g t desig for a metal drum and use lag ed pulley onlywhen detection of bog ed conditions is installed. n g s g Ribbingcan also be mounted on the top pulleyto increase friction and act by g into the rubber belt and producinga dig ing g rabbingeffect. The ribs are placed across the full ax leng of the drum and positioned so that at least two ribs are alway in ial th s contact with the belt. The rig should be 3 mm to 4mm hig and contoured into the drum so as not to rip the belt. s h The tail pulleyshould be a self-cleaningdesig This can be achieved in two way n. s constructingthe pulleydrum of 20 mm or 25 mm round bars of leng wider than the belt. The bars are spaced around the th end plates with g for product to fall throug S e the spacingbetween ribs with sufficient clearance for small product aps h. iz to fall throug Larg product will not fit throug the g h. er h aps. provide a twin opposed-cone hub with the cone base startingat the center and taperingto the shaft at the ends of the s pulley 20 mm or 25 mm round bars are welded to the outer rim of the cones and g . ussetted back to the cone wall for stiffness.

The pulleycan be mounted to the shaft usingtaper locks fitted to suitablysiz hub, interference press fits, retainers screwed ed and doweled to the shaft, hubs screwed and doweled to the shaft or keywayin the hub and shaft.

Postal Address:FEED FORW ARD PUBL CATI I ONS,PO Box578, BENTL EY, est Au W strali 6102 E- l Address:f orward@ bi a, . mai eedf gpond. om c Bec se the authors and publi au sher do not k now the c ontex i whih the i orm ati presented i the f er i to beu t n c nf on n ly s sed theyac ept no c responsi li f the c sequenc ofu ng the i ormati c tai or i pli i anyartiles bity or on es si nf on on ned m ed n c

HAZARDOUS ZONES The desig nation (naming of the z ) ones reflect whether the haz is a flammable g or an ex ard as plosive dust and the likelihood that a haz will be present. For a g ard as/vapour the z ones and their definition are listed below. Zone 0 a volume of space an ex plosive g atmosphere is continuouslypresent. An ex as ample is the vapour space in a fuel storag tank. e Zone 1 a volume of space an ex plosive g atmosphere occurs periodicallyin normal operation. An ex as ample is while fillingthe fuel tank of a car. Zone 2 a volume of space an ex plosive g atmosphere is not normally ex as pected and if it does occur, it will only be present for a short period of time. An ex ample is a spill from overfillinga car fuel tank.
R3. 0 VENT BUND W AL L 4. 0 1. 0 4. 0 3. 0

BUND W AL L GROUND

15. 0

15. 0

*ALL DI ENSI M ONS I METERS N SOURCE OF REL EASE ZONE 0 ZONE 1 ZONE 2

ABOVE GROUND FI XED ROOF VENTED STORAGE TANKS, ADEQUATELY VENTI ATED L

Fig No. 1 Zone classification for a flammables tank. ure For dusts the z desig one nations are noted below and reflect the probabilityof the occurrence of an ex plosive mix ture. Zone 20 a volume of space where a combustible dust cloud is present for leng periods during normal operation or thy lay of combustible dust will form. An ex ers ample is inside a dust collector. Zone 21 a volume of space where a combustible dust cloud is likely to occur during normal operation or lay of ers combustible dust will g ather duringoperation. An ex ample is beside a 25-kgbagfilling -head. Zone 22 a volume of space where due to abnormal conditions a combustible dust cloud mayoccur infreq uentlyand for short periods of time or lay of combustible will g ers ather over an ex tended period of time. An ex ample is inside a g rain millingroom that g raduallyaccumulates dust over y ears of operation. Once the z is desig one nated the appropriate haz protection measures suited to the z mu tbe applied. ard one s M INIM ISING SURFACE TEM PERATURES To prevent hot surfaces from causingg ases and dusts to ig nite, their temperatures must be kept below the ig nition temperature. Electrical apparatus, like motors, build up heat in operation. Their surface temperature rises and unless they are properly selected for the haz ardous area theymayintroduce an ex plosion risk. Electrical eq uipment can be desig ned and built to a specific temperature class that limits the max imum surface temperature. There are two desig nations within the surface temperature classification sy stem. Group Iapparatus are used in the mining industry and Group I eq I uipment are used every where else. W ithin Group I there is a second rating sy I stem known as the max imum surface temperature desig nation and is shown in Table No. 1. T1 T2 T3 T4 T5 T6 4 oC 300oC 200oC 135oC 100oC 50 85oC Table No. 1. M ax imum S urface Temperature EXPLOSION PROTECTION TECHNIQUES As alreadynoted the three req uirements that must coincide for an ex plosion to occur are - the presence of a fuel, at the rig ht concentration to burn, when ig nition is present. One ex plosion control principle is to purposelyintroduce a non-flammable atmosphere into the process. An ex ample is the use of inert nitrog or carbon diox g to replace air inside reactors mix flammable chemicals or inside mills g en ide as ing rinding ex plosive powders.

Postal Address:FEED FORW ARD PUBL CATI I ONS,PO Box578, BENTL EY, est Au W strali 6102 E- l Address:f orward@ bi a, . mai eedf gpond. om c Bec se the authors and publi au sher do not k now the c ontex i whih the i orm ati presented i the f er i to beu t n c nf on n ly s sed theyac ept no c responsi li f the c sequenc ofu ng the i ormati c tai or i pli i anyartiles bity or on es si nf on on ned m ed n c

B el conveyor tuni t ng.

ABSTRACT Belt convey tuning A belt convey is a movingsurface used to transport product from one end to the other. I its basic form it consists or . or n of a drivinghead pulley a tail pulley the movingbelt, support rollers, cleaningdevices, tensioningmechanisms and a structural frame. , , Thoug simple in concept its manycomponents need to work tog h ether as a sy stem to g the best performance and operatinglife. Critical to et that is an understandingof how to care for a belt convey and tune it for successful operation. or Key words: materials handling bulk material transport ,

Belt convey are used to transport any ors thingfrom matches to bulk material such as iron ore and q uarried stone. The belt can be made of natural fibres, rubber, plastic or metal. Reg ardless of its construction and purpose there are basic req uirements to its successful operation that must be met. Ho aBet n e o W o k w l Co v y r r s Fig No 1 is a simple sketch of a belt convey An electric motor and g ure or. earboxturn the head drum (or head pulley The belt ). is pulled tig to produce friction between it and the head drum. The friction overcomes the load and dragforces and the belt ht moves around the circuit from the head pulleyto the tail pulleyand back to the head pulley .

Fig No. 1. A Basic Belt Convey ure or Onlyfriction is used to drive the belt. I the friction falls the belt will slip or stop movingeven thoug the head pulleykeeps f h turning The friction between the belt and pulleydepends on the friction properties of the surfaces in contact, the amount of . surface in contact (the arc and width in contact) and the tension in the two leng of the belt. ths The loaded side of the belt is the tig side and the return side is the loose side. The tig side needs to carryas much tension as ht ht possible to minimise the load on the drums, the shafts and the bearing Getting the max s. imum friction possible between belt and head pulleydoes this. Often a head pulleywill be herring bone g rooved or coated in rubber (or other such treatment) to increase the friction. Another option is to increase the arc of contact. A j ockey(snubber) pulleyis placed under the slack side close to the drum. Bylifting the return belt hig so it comes off the head pulleyfurther around the circumference the contact area and hence the friction is her increased. Tensioning the belt also increases friction. This can be byj acking the head and tail pulley further apart and forcing the belt s harder ag ainst the drums or bymakingthe slack (loose) side tig hter. Tig hteningthe slack side g ag oes ainst the ideal of keeping the slack side tension low and the tig side tension hig I the loose side is used for tensioning the load carry components ht h. f , ing are made larg to take g er reater forces. M a i sn Bet n e o Op r tn Lie xmii g l Co v y r e a i g f. Once a belt convey is desig and installed it is there for y or ned ears to come! The verybest practice to adopt to promote long , trouble-free life is to be sure that the desig has desig it with q ner ned ualitycomponents that can handle the entire rang of forces e g enerated in its use. One wayto insure that is to eng ineer everypart takinga load and then review the desig calculations and n the component selection using independent, ex perienced eq uipment users and maintainers q ing the desig uery ner for the assumptions, reasons and proof behind each desig selection. n The list below hig hts some of the issues and problems with belt convey installations. Once y are aware of them y hlig or ou ou can be on the watch-out and g to them fast. et
Postal Address:FEED FORW ARD PUBL CATI I ONS,PO Box578, BENTL EY, est Au W strali 6102 E- l Address:f orward@ bi a, . mai eedf gpond. om c Bec se the authors and publi au sher do not k now the c ontex i whih the i orm ati presented i the f er i to beu t n c nf on n ly s sed theyac ept no c responsi li f the c sequenc ofu ng the i ormati c tai or i pli i anyartiles bity or on es si nf on on ned m ed n c