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Belt Conveyor 2
Belt Conveyor 2
K. Pathak
The belt conveyor is an endless belt moving over two end pulleys at fixed positions
and used for transporting material horizontally or at an incline up or down. The main
components of a belt conveyor are:
1. The belt that forms the moving and supporting surface on which the
conveyed material rides. It is the tractive element. The belt should be
selected considering the material to be transported.
2. The idlers, which form the supports for the carrying and return stands of the
belt.
3. The pulleys that support and move the belt and controls its tension.
4. The drive that imparts power to one or more pulleys to move the belt and its
loads.
5. The structure that supports and maintains the alignments of the idlers and
pulleys and support the driving machinery.
Other components include:
1. Loading chute or feeder chute that organises the flow of material and directs it on
the belt conveyor.
2. Take-up-device which is used to maintain the proper tension of the belt for
effective power transmission.
3. Belt cleaner that keeps the belt free from materials sticking to the belt.
4. Tramp removal device, which is optionally used in case the conveyed material
bears the chance of having tramp iron mixed with it and subsequent handling of the
material, demands its removal.
5. Continuous weighing device for constantly measuring the load being carried by
the conveyor belt.
6. Discharge chutes to guide the discharged projectile to subsequent conveyor or
other receiving point.
7. Surge hopper and feeder, which is essential for supplying material to the conveyor
at uniform rate when the supply of material is intermittent.
8. Tripper arrangement to discharge material at different point or to other device.
Application
Conveyor belts are widely used in mineral industry. Underground mine transport,
opencast mine transport and processing plants deploy conveyor belts of different
kinds to adopt the specific job requirements. The main advantages of conveyor belt
system are:
1. A wider range of material can be handled which pause problems in other
transportation means. Belt conveyor can be used for abrasive, wet, dry, sticky or
dirty material. The lump size of the transported material is limited by the width of
the belt. Belts up to 2500 mm wide are used in mining industry.
2. Higher capacity can be handled than any other form of conveyor at a considerably
lower cost per tonne kilometre. Conveyor belts with capacity of 11000t/h and even
higher can be deployed to match with higher capacity mining machinery.
3. Longer distances can be covered more economically than any other transportation
system. A single belt conveyor or a series of belt conveyors can do this. Belt
conveyors can be adopted for cross-country laying.
4. By the use of many forms of ancillary equipment such as mobile trippers or
spreaders bulk material can be distributed and deposited whenever required.
5. Many other functions can be performed with the basic conveying like weighing,
sorting, picking, sampling, blending, spraying, cooling, drying etc.
6. Structurally it is one of the lightest forms of conveying machine. It is
comparatively cheaper and supporting structures can be used for many otherwise
impossible structures such as crossing rivers, streets and valleys.
7. The belt conveyor can be adopted for special purposes (fire resistant, wear
resistant, corrosion resistant, high angle negotiation etc.) and can be integrated
with other equipment.
8. It can be horizontal, incline or decline or combination of all.
9. Minimum labour is required for the operation and maintenance of belt conveyor
system.
10.
In underground mine transport, belt conveyor can be used in thin seams as it
eliminates the rock works that might otherwise be required to gain haulage height.
Moreover, belt conveyor can provide continuous haulage service from pit bottom
to the surface.
The limitations of conveyor belt are:
1. The loading and transfer points need to be properly designed.
2. Numbers of protective devices have to be incorporated to save the belt from getting
damaged by operational problems.
3. The belt needs higher initial tension (40-200% of useful pull).
4. The use of belt is restricted by the lump size. If the maximum diagonal of a
irregular lump is X then the belt width (B) is approximately given by:
B Xa 200
6. Higher elongation of the belt (4% elongation may take place at the working load).
Some of the applications of belt conveyors are shown in Figures below:
Level or inclined Conveyor receiving material at tail end and discharging at head end.
Level Conveyor receiving material at any point through travelling Hopper and
discharging at head end.
Level and inclined Conveyor receiving material at and near tail end, having vertical
curve to incline, and discharging at head end.
Level and inclined Conveyor with chute. Material received from bins too close to
elevated head end to permit use of vertical curve.
Inclined and level Conveyor receiving material at tail end and discharging from level
section through a movable Tripper.
Level Conveyor on raised structure with double-wing Tripper forming storage piles
on both sides of Conveyor.
Inclined Conveyor receiving material at tail end and discharging at several points
through a series of fixed Trippers.
12. Power available for driving. If by A.C. electric motor, state voltage, phase and
frequency. If D.C. motor state voltage.
Items 1 and 2 determine the suitability of belt conveyors, since inclination is a
limiting factor. Items 1-7 determine the speed and width of the conveyor belt, the
power needed for the drive, the type of drive, the number of belt plies, size of pulleys,
shafts and spacing of idlers. Items 8-10 determine the quality and thickness of the
rubber cover on the belt.
Angle
Rise in Material
m per
100 m
Angle
Rise in
m
per
100 m
Cement-Loose
22
40.4
Coal-Bit Slack
23
42.4
Clay-Fine Dry
23
42.4
Coal-Anthracite
16
28.6
Clay-Wet
18
32.5
18
32.5
Coal-Mine Run
16
28.6
Coke-Sized
16
28.6
Coal-Sized
16
28.6
Coke-Breeze
18
32.5
Concrete-Wet
15
26.8
Ore-Sized
18
32.5
Earth-Loose
20
36.4
Packages-Paper
Wrap.
16
28.6
Glass-Batch
21
38.4
Rock-Fine
Crushed
22
40.4
Grain
16
28.6
Rock-Mixed
18
32.5
Gravel-Bank Run
18
32.5
Rock-Sized
18
32.5
Gravel-Screened
15
26.8
Salt
20
36.4
Gypsum-Powdered 23
42.4
Sand-Dry
15
26.8
lime-Powdered.
23
42.4
Sand-Damp
20
36.4
limestone
18
32.5
Sand-Tempered
Foundry
24
44.5
Ore-Fine
20
36.4
SulphurPowdered
23 42.4
Ore-Crushed
18
32.5
Wood-Chips
2r 50.9- G
Should the horizontal distance be more than sufficient for the required rise, it may be
more economical to run the first section of the conveyor horizontally, and incline it
upwards at the discharge end, rather than use a smaller angle of inclination for the
entire length.
In such a case, the transition from the horizontal to the inclined sections must be made
by a vertical curve, to ensure that the belt does not lift off the idlers.
Belt Conveyor Types
Permanent:
This type of conveyors is installed for the life of the
mine. They are used in main line, slope, long overland installation,
preparation plants and stockpiles.
Portable: These are characterised by relative ease of assembling and
disassembling to facilitate advances and recovery in development and
retreat operations in underground mining. Portable conveyors mounted
on crawler or wheels are also used in mechanised quarries and surface
mines.
Shiftable: Used in continuous surface mining this type of conveyor is
mounted on skid or supporting structures aligned together and the
whole can be shifted transversely to follow the advancing working face.
High Angle Conveyor: These are special type of conveyor belt
arrangement used for negotiating steeper angle of inclination. Such
belts can work in slope up to 70-800. Sandwich belt conveyor is a type
of such belt conveyor.
Cable Belt Conveyor: Where the belt is carried on moving wire ropes and
the tractive force is applied through the rope to the belt is known as
cable belt conveyor. NALCO (in collaboration with France) is using
such system for long distance conveying of bauxite in their mines in
Orissa.
Description of Components
Belt
The belt consists of a carcass covered from all sides with a filler material like PVC
and neoprene as shown in Figure 1.
End Cover
End Cover
Carcass
Bottom Cover (Non-Carrying Side)
The belt works as a tractive element as well as load-carrying element. It may be used
for different kind of material transportation at a higher speed ( 6-8 m/s). For this
purpose the belt need to have the following essential properties:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Flexibility
Transverse rigidity
Low mass per unit length
High strength
Simplicity and inexpensive
Longer life
Should not stretch under normal working stresses ,i.e., low relative elongation.
Wear resistant
Fire resistant
Speed
(fpm)
Width (mm)
Width
(inches)
400
457.2
18
600
609.6-914.4
24-36
800
1066.8-1524
42-60
1000
1828.8-2413
72-95
350
457.2
18
500
609.6-914.4
24-36
3.048
600
over 914.4
over 36
The carcass can absorb the longitudinal tensile stresses and make the belt rigid
transversely. Filler protects carcass against moisture, mechanical damage, abrasion
and combine the carcass into an integral body forming top cover and bottom cover.
The filler can be synthetic rubber or polymer like PVC with adequate additives for
getting particular expected characteristics. The carcass can be a fabric type with plies
of fabric or steel chord type.
A fabric ply has a longitudinal thread called warp and a transverse thread called weft.
The fabric plies are made of capron, nylon or lavsan etc. The longitudinal member of
the carcass transfers the tension. Both the warp and weft carry the load via the cover.
The cover while protecting the carcass from external damage bear the impact and
abrasion at the feeding points and wear at the cleaning points. Figure 2 shows the
cross section of the types of conveyor belt.
Rubber Interply
Twin-bladed plow ( Figure 3b) is designed to clean belt in both directions of travel.
This cleaner discharges material to either side of the belt. It is installed securely to
conveyor structure and can work on conveyors with severe belt vibration.
CONVEYOR BELT FASTENERS
One of the important components that require attention in maintaining services of belt
conveyor is the conveyor belt fasteners. Selection of fasteners should consider
required performance, expected life and ease of installation and maintenance so that
higher availability of the belt conveyor is ensured.
There are different types of fasteners. Mechanical fasteners are commonly used in
underground coal mining. The required rating of the mechanincal fasteners is
calculated based on the required belt tension and it may be upto 263 kN/m of belt
width.
One such fastener is Flexco SR Scalloped Edge RAR8 belt fastener, designed
for use on mainline and panel belts with mechanical fastener ratings up to 1,500 PIW
(263kN/m). The 8-rivet pattern, along with the scalloped edge design, ensures quality
performance in high-tension applications.
Idlers
In a conveyor belt installation different types of idlers or roller supports are used. The
idlers are required for proper support and protection of the belt and proper support of
the load being conveyed.Idlers are designed with different diameters and are provided
with antifriction bearings and seals, and are mounted on shafts. Frictional resistance
of idlers influences the belt tension and consequently the power requirement.
10
Idlers are mounted on a support frame, which can be shiftable or permanent. The
carrying side of the belt is supported on the carrier rollers sets. A set of three rollers
are arranged to form a trough for the troughed belt conveyor. The return side of the
belt is supported on straight return idlers. The spacing of the idlers is determined
based on the belt sag between the idlers. The sag depends on the belt tension, belt
width, belt properties and the pay-load per meter of the belt. The idlers are specified
by its length and diameter. These parameters are selected based on the required belt
speed for the particular width of the belt.
11
Diameter (inches)
Description
B4
18 48
Light duty
B5
18 48
Light Duty
C4
18 60
Medium Duty
C5
18 60
Medium Duty
C6
24 60
Medium Duty
D5
24 72
Medium Duty
D6
24 72
Medium Duty
E6
36 96
Heavy Duty
12
E7
36 96
Heavy Duty
Closely spaced impact idlers with rubber cushions are used the support the belt at the
loading point, below the skirt board. Figure 7.
DISCHARGE HOOD
TRIPPER
SKIRT BOARD
END PULLEY
SCRAPER
END PULLEY
IMPACT IDLERS
BEND PULLEY
SNUB PULLEY
CARRYING IDLERS
RETURN IDLERS
BELT CLEANER
GRAVITY TAKE-UP
Return
Idler
50
75
100
13
150
200
18
5.5
5.0
5.0
5.0
4.5
4.5
10.0
24
5.0
4.5
4.5
4.0
4.0
4.0
10.0
30
5.0
4.5
4.5
4.0
4.0
4.0
10.0
36
5.0
4.5
4.0
4.0
3.5
3.5
10.0
42
4.5
4.5
4.0
3.5
3.0
3.0
10.0
48
4.5
4.0
4.0
3.5
3.0
3.0
10.0
54
4.5
4.0
3.5
3.5
3.0
3.0
10.0
60
4.0
4.0
3.5
3.0
3.0
3.0
10.0
72
4.0
3.5
3.5
3.0
2.5
2.5
8.0
84
3.5
3.5
3.0
2.5
2.5
2.0
8.0
96
3.5
3.5
3.0
2.5
2.0
2.0
8.0
Pulley
A conveyor belt system uses different types of pulleys like end pulley, snub pulley,
bend pulley etc. as shown in the Figure 3. The end pulleys are used for driving and
sometimes for making tensioning arrangements. Snub pulleys increase the angle of
wrap thereby increasing the effective tension in the belt. The pulley diameter depends
on the belt width and belt speed.
Pulleys are used for providing the drive to the belt as well as for maintaining the
proper tension to the belt.
Minimum transition distance as shown in Table 4 should be followed while placing
idlers in front of pulleys.
200
350
%
Rated
Tension
Fabric Belt
Fabric Belt
(for
half
trough
depth).
(for
full
trough
depth)
Steel
Cord Belt
Steel
Cord Belt
(for half
trough
depth).
(for
ful
trough
depth)
>90
0.9b
2.0b
60 90
0.8b
1.6b
1.6b
3.2b
<60
0.6b
1.2b
1.ob
2.8
>90
1.6b
3.2b
3.4b
6.8b
60 90
1.3b
2.4b
2.6b
5.2b
14
450
<60
1.0b
1.8b
1.8b
3.6b
>90
2.0b
4.0b
4.0b
8.0b
60 90
1.6b
3.2b
3.2b
6.4b
<60
1.3b
2.4b
2.3b
4.4b
Loose Snub
Tight Snub
Figure 8
The angle of wrap is increased by using tandem drive as shown in Figure below:
Drive
Belt drive is provided normally at the discharge ends, however, it may be provided
through the head end or through intermediate pulley by coupling the pulley shaft to
the reducing gears output shaft. The coupling is selected based on the load
characteristics and applications. Flexible coupling or fluid couplings are often used.
Various drive arrangements are shown in the Figures below:
Take-up
The purposes of take-up are:
1. To allow for stretch and shrinkage of the belt.
2. To ensure that the minimum tension in the belt is sufficient to prevent undue
sag between idlers.
15
3. To ensure that the tension in the belt in the rear of the drive pulley is sufficient
to permit such pulley to transmit the load.
There are different types of take-up systems as shown in the Figures below:
16
17
18
Skirt clamps,
Skirt clamps are used for eliminating loading point spillage at the conveyor loading and
transfer points. The skirt rubber used for this should be selected considering its hardness with
respect to the top cover of the belt. As it will be requiring adjustments after wear so the fixing
arrangement should be simple, easily accessible and less time consuming.
Pulley lagging
Pulley laggings are necessary for better traction and to eliminate belt slippage.
This tool is used for mechanical belt fastening. ( Flexco produces MSRT AND
MSRT8 ).This easy-to-use, portable tool makes multiple rivet driving simple and fast.
Some tools have drive rods that can drive five rivets simultaneously.
BELT CUTTER
Belt cutters are designed to enhance operator safety. Some belt cutters are chaindriven, double-edged safety blade and are shielded from operator contact. Such blade
can be driven from either end of the cutter and cuts in both directions.
19
For variable speed conveyor belt slip monitoring consists of a speed sensor
that measures the belt speed and compares with the speed reference sent to the
drive system. When the belt speed is below 80% of the intended speed the
conveyor drive is tripped. A method to adjust and test belt slip is normally
provided in the belt control system.
4. Take-up Overtravel : Overtravel limit switches can be placed at the far
extremes of the counterweight or take up device travel. In a gravity
counterweight take-up, the top overtravel switch trip may suggest a jammed
conveyor belt condition. A bottom overtravel switch may indicate belt stretch,
or a broken belt fabric flight. Excessive take-up motion during starting and
stopping indicate that the type of drive control is either inadequate or that is
not working properly.
5. Transfer Chute Plug: If the conveyor transfers material through a transfer
chute, the transfer chute plug monitors blocked flow as blocked flow may
damage the conveyor belt. Under blocked condition the transfer chute plug
switch trips the conveyor drive.
6. Bin Level Control: If the conveyor belt is used to fill bins or stock piles over
dumping may damage the belt. Bin level sensors protect the belt from
probable beltdamage. Simple hanging tilt switch or analogue devices like
ultrasonic, radar or laser devices may be used.
7. Pull-chord Stop Switches: These are emergency switches that can be actuated
by pulling a chord provided along the belt conveyor.
8. Rip Detectors: Rip detectors provide belt protection in case of a rip or tear of
the belt. Simple rip detector is spill switch located below the conveyor near the
loading point. There are complex rip switches available, which require
periodic maintenance.
9. Fire Detection: Thermal trip switches are provided with smoke sensors, CO
sensors or fibre optic temperature sensors.
10. Dust Sprays: Water or chemical based dust suppressing system can eliminate
or reduce dust problems in certain special conveyor belt installations
Belt Controls
The belt control involves the following:
Stop/start: At single or multiple stations.
Start warning: Audible or visual signal for pre-start warning
Interlock: The sequence control between the master and slave conveyors.
Telemetry: Distribution of belt control and information over significant distance.
Lockout: Physical lockout of the all motive power sources.
Regulatory Provisions
For use of belt conveyors in special applications like under ground coal mining state
imposed regulations must be followed. DGMS circulars and CMR should be
considered during installation, running and maintenance of belt conveyor in
underground coal mines.
20
Cause
Complaint
Cause
In order of probable
occurrences
In order of probable
occurrences
7 15 14 17 21
Excessive
wear
cover
2, 11, 1
Excessive
edge
broken edges
wear,
26, 4, 17, 8, 1, 21
8, 23, 22, 18
Belt slip
8, 18
19, 7, 22, 10
Longitudinal grooving or
cracking of top cover
14, 21, 22
Longitudinal grooving or
cracking of bottom cover
14, 21, 22
Fabric
decay,
carcass
cracks, ruptures, soft spots
in belt(gouges)
Vulcanised
separation
Ply separation
splice
bottom
1. Belt bowed: Avoid telescoping belt rolls or storing them in damp locations.
2. Belt improperly spliced or wrong fasteners: Use correct fasteners. Retighten
after running for a short while. If temporarily spliced remove belt splice and
make new splice. Set up regular inspetion schedule.
3. Belt speed too fast: Reduce belt speed
4. Belt strained on one side: Allow time for new belt to break in. If belt does
not break in properly or is not new, remove strained section and splice in a
new piece.
5. Breaker strip missing or inadequate: When service is lost, install proper
breaker strip ( Breakers are woven fabric of nylon &/or polyster placed above
the carcass to dissipate impact energy and to prevent belt puncture)
6. Counterweight too heavy: Recalculate weight required and adjust
counterweight accordingly. Reduce take-up tension to point of slip then
lighten slightly.
21
27. Skirts improperly Placed: Use adjustable skirtboards and check that it does not
rub the belt.
Depending on the scheme of arrangement of the tractive element (of the carrying and
return run), it is distinguished between vertically closed conveyers ( a to d in the
above figure), horizontally closed (e), and those with a combined path. In the last
type, the terminal sprockets are arranged at an angle of 45 0 to the horizontal. The
flights are attached to the chain at an angle of 45 0 and are oriented in the horizontal
plane in the carrying run and in the vertical plane, in the return run.
Vertically closed conveyers are made (with one, two or three parallel hauling chains
(a, b, and c respectively). A three-chain conveyer may have a greater length and
higher reliability, since breakage of. a chain does not disturb the stability of flights
and the operating capability of the conveyer. Their application is however limited by
23
their higher cost and large mass. In single-chain conveyers, the flights may have
symmetrical (the chain at the centre of flight) or unsymmetrical and rigidly fixed or
hinged attachment to the hauling chain.
The path of a vertically closed conveyer for coal transportation in curved drifts may
be either straight (horizontal, inclined or horizontal-inclined) or bending in the
horizontal plane (spatial).
The tractive element is in the form of one, two or three detachable chains of elevated
strength with the pitch 80 mm or round-link chains with the chain pitch of 50 or 64 mm and
rod links. of a diametet of 14 or 18 mm. The chains are made of steel of specified grade and
heat-treated.
The flights are made of steel and have a height roughly equal to the height of chain.
The pitch of flights is 480,640 or 1024 mm, and the linear mass of a chain with flights
is 10- 18 kg/m on the average.
The trough is stamped from steel sheets (steel grades 35 or 30f) in sections of a
length of 2-2.5 m; the working portion (bottom) is hardened.
The drive is electrical, pneumatic or electro-hydraulic in an explosion-safe
embodiment. Drives with one or two motors at the front end and one motor at the rear
end of a conveyer have found wide application. The transmission mechanism is of the
reducer type; the electric motor is connected with the reducer gear through a hydraulic
coupling.
24
Conveyor Calculation
Initial Data:
1. Characteristic of material like lumpiness, density, moistue content, angle of
repose, particle flowability, abrasiveness, particle strength, slumping (losing of
mobility on long storage, e.g. lime, cement etc.), stickyness etc.
2. The average and maximum load carrying capacity
3. Diagram of the designed conveyor with its principal dimensions
4. Data on the exceptional working conditions
5. Arrangements of the operation of the conveyors.
Determining Belt Width
The belt width depends on maximum rated capacity and lump size. The cross
sectional profile of the bulk material on the conveyor belt is determined by the profile
of the load carried on the belt. On straight roller this area is :
A
1
bh
2
h 0.5b tan
A 0.25b 2 tan
25
l1 l
m sin
2
As
r 2 2
sin 2
r2
360
2
(A)
If belt width is B and area of cross section of material is A, it is often taken that:
A
B2
10
(B)
Thus from equation (A) and (B) the belt width can be calculated.
To test the calculated belt width for suitability with lump size the following relation is
used:
B Xa 200
26
S 2W
8T
where,
H: sag, in feet
S: Spacing in feet
T: Tension in pound
W: Weight of the loaded belt in lb/ft.
Idler spacing in the mid portion of the conveyor in meter for different material is
given in the following table.
Belt Width
Density t/m3 Density t/m3 Density t/m3 Density t/m3 Density t/m3
mm
<0.8
0.81-1.6
1.61-2
2.1- 2.5
>2.5
400
1.5
1.4
1.4
1.3
1.2
500
1.5
1.4
1.4
1.3
1.2
650
1.4
1.3
1.3
1.2
1.2
800
1.4
1.3
1.3
1.2
1.1
1000
1.3
1.2
1.2
1.1
1.1
1200
1.3
1.2
1.2
1.1
1.1
1400
1.3
1.2
1.2
1.1
1.1
1600
1.3
1.2
1.2
1.1
1.1
2000
1.3
1.2
1.1
1.1
1.0
The return idlers are spaced at 2 to 2.5 times the spacing of carryng idler subject to the
condition that it is not more than 3.5 m.
27