PDHonline Course M360 (1 PDH)

Chain Conveyors
Practical Calculations
Jurandir Primo, P.E.

2009

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Chain
n Conveyoors - Practtical Calcu
ulations

1 INTRODU
1.
UCTION:
Roller Chain Conveyors or
R
o Apron Chaain Conveyorrs are used to
t transfer heeavy bulk maaterials from one point too
a
another.
This manual
m
for prractical appliccation indicattes the chain conveyor
c
basiic calculationns for Bulk Materials
M
in thee
m
metric
and impperial system
m.
The main funnction is infformative forr both experiienced professionals and beginners innterested in knowing thee
T
d
dynamics
of thhis segment of
o Material Haandling.
A
Arrangement
t:
D
Drive
chains are
a ideally insstalled with thhe shaft in thee horizontal position, as shhown below:

P
Position
of Sp
prockets:
The sprocketss should be "k
T
key-wayed and
a matched in pairs. Sincce the tail shaaft is an idlinng shaft, key it
i to only onee
spprocket. In thhis way the sp
procket can poosition itself if
i uneven weaar takes placee in the chain strands.
The two shaftts should be parallel
T
p
and the
t sprockets should be firrmly installedd. Use a straiight edge to check
c
that thee
tw
wo sprockets are installed along the sam
me horizontal level. This iss illustrated inn Figure 1 andd 2 below:

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C
Chain
Conveyyor Speed:
Commonly thhe Chain Con
C
nveyor speed is dictated by
b how it is loaded and unloaded
u
andd what is donne to the loadd
d
during
conveyying. The tablle below show
ws the basic conveyors andd their typical operating speeds.
CONVEYOR
Continuous Bucket
B
Elevattor
Centrifugal Bucket
B
Elevattor
Slat or flat toop Conveyor
Assembly linne Conveyor
Drag and Scrraper Convey
yors
Apron Conveeyors

SP
PEED (fpm)
75 to150
2200 to 300
50 to 150
5 to 15
50 to 100
10 to 60

2 APRON CH
2.
HAIN CONV
VEYORS
Apron feederss are used in the
A
t mining inndustry for thee transportatioon of heavy and
a lumpy maaterials. Theyy are designedd
fo the most hard condition
for
ns of exploatation to feed thhe crushers att quarry and storage
s
bins.
These types of conveyors have
T
h
capacitiees up to 60000 t/h and are able
a
to transpport materialss with maxim
mum lump sizee
u to 2000 mm
up
m. The large size of materiial lumps is thhe cause for the
t increase of
o the width of the aprons and
a the height
o the skirts. The
of
T presence of fixed skirtss cause additiional resistancces due to skiirt friction.
The presence of receiving
T
g hopper causses additionaal resistance due
d to the prressure of thee material inn it. The hardd
c
conditions
of exploatation and the great starting reesistances aree the cause for
f the introdduction of a coefficient
c
off
reeserve of mottor power.

The basic formulae for Apron

T
A
Chainn Feeders caalculation aree given for references, since
s
that eaach companyy
m
manufacturing
g has its own
n methodologyy for calculattion.
V
Velocity,
Wid
dth an Heigh
ht of Skirts
A the transpoorted materiall is lumpy, its maximum luump size willl determine thhe apron widtth B [m]:
As

C
Considering
thhe following data:
d
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T formula for
The
fo the determ
mination of thee height of thee skirts h, is given h for appron conveyoors, as:
(1 m = 3.28
8 ft)
When width B and height of the skirts h are determ
W
mined, the aprron speed v iss determined by the know
wn formula forr
thhe capacity:

(1 m/s = 3.228 ft/s)

w
where:
Qh = capacityy in t/h
Q
= density off the transportted material inn t/m (t/ft)
= 0,75 exttraction efficiiency factor
c = 100 - inclination
i
facctor ( angle of inclinatiion).
100

The coefficiennt c, as indiicated above, must be takeen into accounnt, when feedding are inclinned (usually = 15 - 25).
T
T reason foor the inclinaation is the faacilitation off truck dischaarge and the protection off the equipm
The
ment when thee
m
material
will fall
f directly on
n it.
Speed is limited to 0.25 m//s (0.82 ft/s), and in somee cases to 0,4 m/s (1.3 ft/s)). The reasonns for the limiitation are thee
S
g
great
dynamicc loads in the track chains and
a the high abrasion
a
wearr of the apronns.
Iff the calculated speed is greater
g
than lim
mited, the skkirt height h must be inccreased. The contemporary
c
y drives allow
w
v
variation
of thhe speed in th
he work diapaason v = 0.033 0.16 m/s (0.1
(
0.5 ft/ss) for differennt capacities, realized withh
thhe use of variable speed DC,
D AC and hydraulic
h
mootors.

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Apron Chain and Rollers:

Apron feeders use heavy duty crawler tractor chains (Caterpillar tractor type), commonly sized to suit the
application. The chain links are forged for increased load capacity. Pins and bushes are hardened on the wearing
surface.
The carrying rollers are spaced to eliminate the sag, mounted on support frames to permit easy removal for
maintenance and replacement. The apron plates are bolted on flat top of the chain links, as shown below:

Special design and exclusive metal to metal allows continuous pan contact through articulation minimizes spillage
and leakage, as indicated below:

Drag and Flight Conveyors

Drag conveyors are used where multiple loading or discharge points are required and a totally enclosed conveyor is
needed for dust containment, capable of handling fine materials ranging from dust to 6 inch (150 mm) lumps, where
capacity requirements are high, 200 - 400 TPH.

They are used and when the material is somewhat fluid. The typical materials conveyed are TSP (fertilizer), raw meal,
and finish cement.
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3. FORMULAS FOR EASY CALCULATIONS:

1) Chain conveyor or apron chain conveyor calculation system. The load tensions are calculated as indicated below:
T = Fs + Fi + Fk (Kgf) (lbf)

Fs = (Qt x L) + (Pch x L) x f =

Fi = Pch x L x f1 =
2

Fk = (Qt + Pch) x L1 x sen x f2

2) To calculate the driving power (CV or HP), use the following formulas:
N = T x v (m/s) (metric) and
75

T x v (fpm) (imperial).
33000

Where:
T = Total chain force or total work chain tension (kgf) (lbf);
Fs = Upper chain tension (kgf) (lbf)
Fi = Under chain tension (kgf) (lbf)
Fk = Lift chain tension (kgf) (lbf)
Q = Conveyor total load - (t/h) (tph)
Qt = Conveyed material weight (kg/m) (lb/ft)
L = Total conveyor direct length (including inclined/declined) - (m) (ft)
L1 = Conveyor horizontal direct length (m) (ft)
L2 = Conveyor slope (inclined / declined) extension direct length (m) (ft)
Pch = Total chain weight (see manufacturers tables according to chain types);
N = Driving power (kW) - (HP)
f = Upper chain friction factor 0.25 ~ 0.35;
f1 = Down chain friction factor 0.10 ~ 0.15;
f2 = Lift chain friction factor 0.25 ~ 0.35;
v = Chain conveyor speed (m/s) - (fpm)
= Driving sprocket diameter (mm) - (in)
= Conveyor slope angle;
= Bulk density of conveyed material (kg/m) - (lb/ft)

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4. PRACTICAL EXAMPLE:
Calculate the driving power of a Drag Roller Chain Conveyor, commonly used in Sugar Plants considering the
following sketch below:

CONVEYOR CAPACITY = 90 tph

PESO DO MATERIAL = 300 kg/m
DRIVING PULLEY DIA = 270 mm
SPROCKETS DIAMETER = 270 mm
70

14

CONVEYOR SPEED = 6 m/min

50

(4

7,

TOTAL CHAIN WEIGHT = 160 kg/m

5

f t)

28

2500 (8,2 ft)

Where:
Q - Chain conveyor capacity = 90 tph
- Sugar cane bulk density = 900 kg/m - (56 lb/ft)
v Conveyor speed = 5 m/min (0.083 m/s) (16.3 fpm)
- Driving sprocket diameter = 270 mm (10.6 in)
1 Driving pulley on driving shaft = 290 mm (11.4 in)
Pch -Total drag chain weight = 160 kg/m (both sides) (107.5 lb/ft)
L1 - Conveyor horizontal direct length = 2.5 m (8.2 ft)
L2 = Conveyor slope (inclined) direct length = 14.5 m (47,5 ft)
= Conveyor slope angle = 28
Solution:
1). CALCULATION ACCORDING TO MATERIAL FLOW:
kg/h = kg/m
m/h

or

lb/h = lb/ft
ft/h

Q - 90 tph = 90,000 kg/h (198,450 lb/h)

v 5 m/min = 5 x 60 = 300 m/h (984 ft/h)
Qt = 90,000 kg/h = 300 kg/m Qt = 198,450 lb/h = 202 lb/ft
300 m/h
984 ft/h
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L = L1 + L2 = 17.0 m (55.7 ft)

a) Fs = (Qt x L) + (Pch x L) x f =
Fs = (300 x 17.0) + (160 x 17.0) x 0.25 = 1955 kgf (4310 lbf)
b) Fi = Pch x L x f1 = 160 x 17.0 x 0.15 =
2
2
Fi = 2720 x 0.15 = 204 kgf (450 lbf)
2
c) Fk = (Qt + Pch) x L2 x sin 28 x f2 =
Fk = (300 + 160) x 14.5 x sin 28 x 0.35 = 1096 kgf (2416 lbf)
d) T = Fs + Fi + Fk = 1955 + 204 + 1096 =
T = 3255 kgf (7177 lb.ft)

N = T x v = 3255 x 0.083 = 3.6 ~ 5.0 CV

75
75
Or:
N = T x v = 7177 x 16.3 = 3.5 ~ 5.0 HP
33000
33000
2). CALCULATION ACCORDING TO TSUBAKI FORMULA:
T = [(Qt + 2.1.Pch) x f1 x L1] + [(Qt + Pch) x (f1 x L2 x cos + L2 x sin ) + [1.1.Pch (f1 x L2 x cos L2 x sin )]
= (kgf) (lbf)
Using the data above, calculate the tension using the Tsubaki formula:
T = [(300 + 2.1x 160) x 0.15 x 2,5] + [(300 +160) x (0.15 x 14.5 x cos 28 + 14.5 x sin 28)]+ [1.1 x 160 (0.15 x 14,5
x cos 28 - 14.5 x sin 28)] =
T = 4254 kgf (9380 lbf)

N = T x v = 4254 x 0.083 = 4.7 ~ 5.0 CV

75
75

N = T x v = 9380 x 16.3 = 4.6 ~ 5,0 HP

33000
33000

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3 CALCULA
3)
ATION ACC
CORDING TO
T THE WIN
NDLASS TO
ORQUE:
According to applied mecchanics the toorque calculaation to revollve the drivinng chain connveyor pulleyy just like thee
A
w
windlass
arm to
t pull the bu
ucket is:
F x R1 = P x R
W
Where:
P = Conveyorr chain force to
t pull the loaad, kgf;
R = Driving spprocket radiu
us, m;
F = Pulley perripheral forcee on driving shhaft, m
R = Driving pulley radiuss, m
R1
C
Calculate
the driving
d
chain
n conveyor power, using thhe data above.
F x R1 = P x R
a P is the forcce to carry up
a)
p the sugar cane plus the chhain weight, as
a we calculatted before:
P = Fs + Fi
F + Fk = 195
55 + 204 +1096 =
P = 3255 kgf (7177 lbff)
Or,
P = 4254 (9380 lbf) acccording to Tssubaki formulla.
b The conveyyor data above indicate thee sprockets diameters, = 270 mm, then: R = 0,135 (5.3 in).
b)
c The diameteer of the driviing pulley onn driving shaftt is, 1 = 2900 mm, then: R1
c)
R = 0,145 (5.7 in).
W need to finnd the force F to move the driving shaftt, so:
We
P = R1 = 32555 = 0,145 = F = 3030 kgf and, 7177 = 5.7 = 6673 lb
bf
F R
F
0, 135
5.3
F

N = F x v = 30030 x 0,083 = 3,35 ~ 5.0 CV

C
75
75

N = F x v = 6673
6
x 16.3 = 3.3 ~ 5.0 HP
P
33000 333000

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SUMMARY:
Chain Conveyors:
Chain conveyors are commonly used in siderurgy and mining industries to transport heavy minerals The
manufacturing industry also use widely chain conveyors to carry unit loads, pallets, grid boxes and general industrial
containers. These conveyors can be single or double chain strand or Catterpillar type chains. Single chain conveyors
are generally easy to install and have very minimun maintenance for users.
Many industry sectors use chain conveyor technology in their production lines.The automotive industry commonly
use chain conveyor systems to convey car parts through paint plants. Chain conveyors also have widespread use in the
white and brown goods, metal finishing and distribution industries.
Chain conveyors are also used in the painting and coating industry, ceramics, thermal treatment of metals, feed and
discharge systems of boilers. In automatic painting systems the products are attached to an above head chain
conveyor, keeping products off of the floor allows for higher productivity levels.
References:
Sugar Cane Handling and Process Equipment, Dedini, 1st Edition, 1975
Tsubaki Manufacturer, Chain Conveyor Calculations
Grinding Manual, Technical Publication, Fao/Allis-Chalmers, 4th Edition, 1985

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