Tea Beattie a1] Application iatEngineering Science And Application Design For BELT CONVEYORS By ISHWAR G. MULANI B.E. (Mechanical) (Formerly Head of Project Engg. Dept. Krupp-india) The compliment on book (manuscript); from world renown personality in the field of bulk material handling. G “We have seen this book and found to be interesting and useful for design engineers, application engineers and users of belt conveyors and bulk material handling plants. The book provides comprehensive information on design as well as application engineering for wide-ranging practical needs. We wish all the success for the book Engineeering Science And Application Design for Belt Conveyors ~ Dr, R.H.Wohibier Germany."Write / Communicate on following address to get this book : 1.G.Mulani C-1/204, Nikash Lawns, Sus Road, Pashan PUNE — 411021, India Telephone : 0091 — (0) 20 - 5882916 E-mail: parimul@pn2.vsnLnet.in Publisher : Mrs. Madhu.L.Mulani C-1/204, Nikash Lawns, Sus Road, Pashan PUNE ~ 411021, India © with Author and Publisher First Edition : October 2001 Printer : Saurabh Creation, Pune- 411030. India. Copying / photo-copying of book is immoral / illegal and spoils the book. i }ABOUT THE AUTHOR ‘The author is 1967- graduate in mechanical engineering from L.D. college of Engineering, Gujarat University, Ahmedabad, India, ‘The author has more than 31 years of experience in responsible and decision making position {cr application engineering, design and techno-commercial issues concerning belt conveyors, ther equipment and system engineering from simple to most modem plants for handling of bulk materials, in accordance with international practices. This experience has significant value as world-wide advancement inthe field of bulk material handling took place in the past three decades. The experience has been derived by working in reputed companies, who had / have work affiliation with prime German companies in this field. For the last 15 ¥ years, the author was heading Project Engineering department of M/s Krupp-India, which is a part of world: Tenowned Krupp-Germany group of companies. ‘The author has extensively travelled in the world (Germany, France, U.K., other European Countries, USA, Thailand, Malaysia, Korea, Singapore, Indonesia, Bangladesh etc.), as a part of official assignments. This has enriched the know-how and provided better understanding of the technical issues concerning designers and users of belt conveyors. The author's aforesaid back-ground hes enabled him to formulate this book to suit large scale needs, presentation of complex issues for easy understanding, in-built proofs, inclusion of Caleulation models to suit ‘design office set-up’ in business organisations; and to provide clear options for decisions by readers - who are often under time-pressure. The author has put his long term know-how in this book, which is time tested and has been extensively used during tenure of his service in realisation of many bulk material handling Plants; and obviously this know-how signifies the techno-commercial concurrence at various levelsPreface PREFACE This book deals with the fundamentals of belt conveyor design for handling of bulk materials. Any belt conveyor design mainly concerns with the calculation of capacity, belt width, belt speed, drive power and belt tensions. These parameters have profound effect on overall design, construction and ultimately the cost of conveyor as a whole. Therefore, the right design for these parameters is 01 paramount importance. Various methods and formulae are already in use for conveyor design. Much of the published information is seen all around; sometimes mismatching with each other and often without availability of Supporting derivation for designer. The designer can only make the right design if he has complete clarity on the theoretical background for the formula being used. |m view of above, this book aims at derivation / publication of various formulae and norms from first Principles of engineering-science for in-depth perception of the subject matter to the designer. This provides complete information to the designer and automatically clarifies the basic guidelines and limitation if any, for the particular design approach being followed. AAs the engineering analysis and derivations are based on basic rules; the book is likely to have long time ullity, The dynamics of belt conveyor mainly concems with motion and forces, and hence same are on the bas the subject matter by applying analytical engineering approach to various practices being followed for of very well known Newion’s law of motion. The author has tried to give new dimension to rationalization of data and thorough understanding for the readers at large. Although the book has necessary theoretical background, but itis written for the purpose of direct use for application-design for contractual requirements. This is a ‘decision making’ book for design and implementation purpose, Having done all the analysis of a particular topic, specific and clear-cut opinion {suggestions are incorporated to assist the designer / user for his quick / correct decision, to suit contract needs. . For such book to be of practical value, it needs to conform to commercially acceptable standard and ‘norms. The book design-approach primarily relies on ISO-5048, DIN-22101 and latest practices / norms being followed in this field all over the world. The readers, who are used to other standards in Europe or USA practice will also find this book very useful to get new insight into the subject and to comply to the respective standards in a more exact / easy manner. This is due to the fact that although calculation style could be different, the underlying considerations and principles are same.Preface ‘The book is written in S.1 units. However, clear notes are given at the end of certain chapters to use the ‘same in FPS units, which are presently prevailing in USA for belt conveyor technology. It is clarified that for FPS units, the force unit of poundal is used which is synonymous to Newton in S.l. units. This makes the transformation from S.1. system to FPS system quite simple, ie. it does not need any change in S. formula. Only FPS units are to be used in S.|. formula and the derived result is in poundals. This eliminates the vexing confusion whether to apply multiplier “g' in numerator or denominator during conversion between S.I. system and FPS system. Needless to mention 32.2 poundals are equal to 1 pound-force. Thus, all the S.J. formulae related to force-motion are valid when units are mass in Lb., dimension in Foot, time in second and force in poundal; instead of Kg, Metre, Second and Newton respectively. This is applicable to all the formulae, which are derived on the basis of general rules of science, and which are not unit specific empirical formulae. As stated earlier, main subject of the book is to find out belt conveyor important parameters such as capacity, belt width, belt speed, drive power and belt tensions. However, one cannot decide any one of these parameters without proper knowledge of complete conveyor. Therefore, the book contains design related necessary information about various components of conveyor. More information is given on conveyor specific components, compared to general mechanical components suct as gearbox ete. The belt conveyor rarely works in isolation. It is required to function in conjunction with directly associated other equipment and structures. Therefore the book provides conveyor related information about such equipment / structures. For example, the super structure for conveyors is a job for structural engineer, however its dimensioning and arrangement is practically fixed by conveyor designer. Hence, this book includes pertaining information about such items where certain decisions are expected from conveyor designer. The book is writen to facilitate its use by mechani familiar or not familiar to the subject. Therefore, various topics begin with this background of knowledge. engineer with usual qualification, who may be The book practically does not contain self-prociaimed assertions. It goes by engineering principles and Universally accepted practices; and creates Its own reliability by transparency. In this book, more stress is towards engineering approach and methods, which can be adopted for solution. There could be different view about the value of input data, i.e. whether to consider value of safety factor equal to 2.25 or 2.50 for particular case. The designer may adopt such values as per numerous considerations (contractual requirement / standards being followed / level of safely / reliably of available materials ete.) All the care has been taken in this book to provide impartial presentation on the subject matter. The book tries to make designer's work easy. However, bulk materials are highly varied in nature, and therefore, element of engineering judgement can not be eliminated altogether in solution to engineering problems. The designer should decide the right solution beflting to the specific need with open mind and 9Preface approach. As is the usual practice for such publications, the book and the author are not party to decision so made, ‘The author felt necessity to write this book considering the difficulty faced by engineers concerned with this subject, longer induction period, conficting stands in contract implementation and therefore the Need for rationalisation of published information. It appears that the engineering practices / tradition for this subject have multi-center evolution with too much time lag between cross-effect and wilingness to change towards common style, This is some what comparable to varied practices / standards in ‘metallurgy which was not even recognised for scientific consideration till very late stage of industrialisation, in spite of its very long time association with the human survivall The writing of this book; on not so streamlined application engineering subject, is a difficult / hazardous task due to mismatching data / practices. This makes the writing and recommendation process much more complex than anticipated; and one is likely to end the efforts before completion of work. This is particularly true for people in industrial profession. | am thankful to Dr. RH. Wéhibier of Germany for his encouragement to me in this matter, which has really helped for successful completion of this book during 2 years. {lam thankful to mechanical engineers Mr. G.M. Parmar, Mr. Jagdeep, Mr. Parikshit and Mr. Uday Singh for devoting their time and efforts in preparation of certain data and for conversion of the manuscript in t0 electronic form. | also express sincere thanks to all the fiends who have finally helped in publication of this book. The book is dedicated fo all the people who have contributed for the development in this field during ‘course of time; and to human beings’ eternal pursult for rationality and knowledge. Pune: 411 021, INDIA Ishwar G, Mulani Date: 8" November 2000 B.E, (Mechanical) Book AuthorContent Chaptor 4 1.0.0 11.0 144 412 Chapter 2 2.00 24.0 2.2.0 230 240 280 Chapter 3 3.00 34.0 320 330 3.4.0 350 366 3.70 Chapter 4 4.00 410 4.20 430 440 44a 442 443 45.0 454 452 453 454 485 489 46.4 46.2 483 484 485 CONTENT Bulk material handling plants and conveyors Need for bulk material handling plant with conveyors Introduction to buk material handling plant System description List of major equipment and structures forthe plant Introduction to belt conveyor Introduction to belt conveyor Main mechanical components in a conveyor Belt conveyor function Conveyor-profiles (conveying-paths) Method of feeding/loading belt conveyor Method of discharge from belt conveyor Bulk materials Bulk materials Bulk density Repose angle Surcharge angle Abrasiveness Material size Other characteristics Material characteristic data (table-1) Belts Belts Carcass functions and types Covers functions and types Belt types Textile fabric belts Textile fabric multi-ply conventional belts Reduced ply fabric belts (special ply fabric belts) Fabric belt data for conveyor design ‘Steel cord belts Stee! cord construction Steel cord belt construction ‘Steel cord belt characteristics and application Stoolcord belt range ‘Stee! cord belt data for conveyor design Design requirements in belt selection Stifinessiload support Impact strain Balt tension rating Troughabilty Bolt cover thickness Page number 1t09 1102 2009 4107 Ttoe 10016 10 101011 11012 12 131014 141016 17024 7 7 18 181019 19 19 19 20 to 24 251073 28 26 2610 28 28 28 to 36 301033 341035 351036 36 to 29 37 370.98 38 38 to 38 39 391061 30 39042 4210.43, 43 4310.46Content 466 Choice of carcass type 4610.47 46.7 Belt selection procedure 470.48 Examples-1, 2,3 &4 4910.59 468 Note on energy loss / carty forward factor for a lump 591061 Fabric belts’ table 2a, 2b, 20, 2d, 28, 2,29, 2h, 2f and 2) 61 to69 Steel cord belts’ table 3a, 3b, 3c and 3d 701073 Chapter5 Idlers 740134 5.0.0 Idlers 1” 5.1.0 Idlers function 74t075 520 Rolls (Rollers) 751080 624 Shell 761077 622 Housing 7 523 Sealing 7 524 Bearings T7078 525 Spindles 78 526 Greasing 78 527 Roll breathing 79 10 80 528 Roll Quality 80 53.0 Fixed frame idlers 811088 534 roughing idlers (Trough carrying idlers) 81 toaz 532 \V- trough carrying Idlers (2- roll rough carrying idlers) 83 533 Flat carying idlers 83 to 84 534 Impact idlers (Trough impact idlers) 84 635 V = type impact idlers (2 - roll impact iders) a 536 Flat impact idlers 85 537 Flat return idlers (Single roll return idlers) 85 538 V-type return idlers (2 - roll return idlers) 2510.88 539 Self aligning carrying idlors (S.A. carrying Idlers) 86 8.3.10 Soff aligning retum idlers (S.A. return idlers) 86 to 87 83.11 ‘Spacial purpose idlers 87 to88 54.0 Garland idlers 88 to95 S44 Gerland idler profile under load 1 B42 Garland 3 - roll canying idlers 81 tog2 543 Gariand 5 - roll carrying ilers 92 544 Garland 3 - rol impact ites 9210.93 545 Garland 5 - roll impact idles 4 546 Garland 2 - roll return idlers 94 t0 95 550 Main reason for belt misalignment 950.97 554 Misaligned Idlers centerline 96 552 Off conter loading of materiat 96 to. 97 583 Wind force or 554 Misaligned center line of pulleys 97 585 Faulty belt carcass o 56.0 Engineering analysis of selfaligning action by idlers 98 to 145 v oO QOContent 56.4 562 563 564 565 870 580 Chapter 6 600 61.0 620 630 640 Chapter 7 7.00 7.40 720 724 722 723 730 7.40 789 754 752 783 784 755 756 787 758 739 7.8.10 75.44 75.42 7.8.13 75.14 Pivoted setf-aligning idler (includes example-1) Inclined aligning force effect along conveyor width (includes example-2) ‘S.A. force due to trough shape and gravity (includes example-3) Forward tilt for idles (includes example-4) S.A. force due to bow - string effect (includes example-5) Rollers and idier- sets dimensions (includes table-4) Roller design (includes tablo-5 and exemple-6, 7 & 8) Table - 6 : Rotating mass of one roller Example-9 on breathing hole Capacity evaluation in system Capacity evaluation in system Guaranteed capacity Design capacity Examples-1, 2 & 3 for capacity calculation Notes on conveyor capacity (for load / forces) Bolt width, speed and capacity Design for belt width, speed and capacity Functional requirements for belt wicth Necessary belt width for lump size Belt width for material - X Bolt width for material -Y Other consideration to lump size ‘Table — 7: Permissible maxinium lump size (for belt wicth) ‘Selection of surcharge angle (includes table-8) Recommended belt speeds (guide values) Table ~ 9: Recommended maximum belt speed in m sec Necessary belt width for capacity Material cross - section on belt Cross - section on belt - 3 roll troughing idlers (for equal / unequat rol) - derivations. Cross - section on belt- 2 rll roughing idlers - derivations (Cross - section on flat bet - derivations (Cross - section on belt 5 rol roughing idles - derivations Effect on cross - section by gap between roles (includes table-10 & 11) Comparison of area, parabolic and circular are (includes table-i2) Reduction in cross section area due to belt bending radius Reduction in cross - section area due to conveyor inctination Reduction in cross - section area or conveying ability due to fil factor Conveyor potential (abilty) for capacity Principles for selection of belt width and speed Use of table - 13, 14, 15, 16, 17, 18 and 19 for cross ~ section area on belt Examples,283 Table - 13: Material cross ~ section area (parabolic arc) for 3 ~ rol idler ‘Table - 14: Material css - section area (citcular arc) for 3 rol idler Table - 15: Material cross - section area (parabotic arc) for 2 - roll idler vi 98 to 103, 103 to 408 106 to 108 108t0 141 1120 115 1150 119 119 to 123 12410 131 182 t0 134 138 to 144 138 135 135 to 136 136 to 140 140 t0 141 142 to 207 142 142 142 to 148 144 144 to 145 145 to 148 146 to 148 148 to 150 151 to 183 182 164 to 207 185 185 to 161 161 to 164 165 to 166 166 to 172 17310 174 174 175 175 t0 177 177 0178 17810 179 17810 181 181 to 182 182 to 188 169 to 193 194 to 198 199 to 200Content ‘Table - 16: Material cross - section area (circular arc) for 2— rol idler ‘Table - 17: Material cross - section area (parabolic arc) for fat rol idler ‘Table - 18: Material cross - section area (circular arc) for fat rol idler Table - 19: Material cross - section area (parabolic arc) for 5 - rol idler ‘Table - 20: Conveyor inclination factor Chapter8 Material behaviour on belt ‘Material behaviour on belt for transverse load Liquid side pressure I force Rankine theory Active pressure force Passive pressure / force Material side thrust on inclined face Rankine theory application to material on belt “Table - 21: Rankine factors 83.0 Coulomb - Rebhann wedge theory (coulomb theory) 83.4 ‘Active force Fa per meter 832 Passive force Fp per meter length of conveyor, 838 Etfectve force Fs on side roller, per meter length of conveyor 834 Derivation of wedge slope B ‘Table - 22: Coulomb factors 840 Method - 3 (Empirical method) 850 Method - 4 (i$0 formula) 880 Load on midle roller (includes table-23) 870 Concluding remark 88.0 Bett edge clearaice “Cat 90 % uit of material crs section on 3 - roller idler set (includes table-24 & 25) 89.0 Examples, 2,3,4,5,6,7&8 Chapter9 Bott cleaners 9.00 Belt cleaners 24.0 External belt cleaner et Single blade external belt scraper (cleaner) 942 Double blade external belt scraper (leaner) 913 ‘Skew mult - blade external belt scraper (leaner) 914 Cleaning free analysis 945 ‘Specialised extemal belt scraper (leaner) 8.16 ‘Comparison between conventional and specialised blade scraper ear Other extemal cleaners 920: Internal bet cleaner 930 Pulley cleaner 9.40 ‘Scraper design parameters Chapter 10 Bolt tractive pull and power 10.0.0 Belt tractive pull and power 10.1.0 Symbols for engineering quanties vil 201 to 202 203 204 208 to 206 207 208 to 261 208 0 210 an 21210 224 21210213, 21310216 216 10.217 217 to 221 218 224 t0 295 22310 224 228 22510 226 226 to 234 235 235 to 236 237 287 to 238 238 to 230, 239 to 240 240 to 261 262 to 280, 262 262 to 278 263 to 264 264 264 to 265 2650 271 27110274 27410 275 2750 278 27810 279 279 t0 280 280 281 to 364 281 to 282 282 to 285 oO 2 ) °Basic engineering rules on friction 285 10 287 ‘Method adopted for calculation of the tractive pull at steady state 287 Slope resistance, Fs 287 to 280 A Slope resistance carrying run, Fslc 287 to 288 Return run slope resistance, Fsir 288 to 289 Material acceleration resistance, Fa 289 to 200, Main resistance 290 to 315 Rotational resistance of idlers 280 to 203, i Balt flexure resistance 293 t0 294 Material flexure resistance 294 t0 295 Basis for artificial friction coefficient of conveying, 295 to 298 106.5 Calculation of # for conveyor with positive power 296 to 298, 10.6.6 Calculation of for conveyor with negative power 298 to 209 106.7 Division of into constituent coefficients (includes table-26, 26A, 27 & 27A) 299 0 303, 1068 Reasons for earlier said + increment in? (includes table-28, Ex. 1,2,3,4,5&6) 303 10 315 10.2.0 Idlers tit resistance 316 to 328 10.7.4 Tilt resistance by a roller 316 t0 317, 10.72 Tiltresistance for 2 - roll return idlers 317 to 318 10.73 Tilt resistance for 2 - roll carying idlers 318 to 320, 10.74 Tit resistance for 3 - roll roughing idlers (includes example-7 & 8) 320 to 322 10.75 Forward tt for garland idlers due to inclination (includes example-9) 328 t0 326 10.8.0 Skit board resistance, Fskt and Fsk2 328 to 339) 10.8.1 Acceleration zone length La within skirt - board (includes example-10, 14, 12 & 13) 927 to 336 108.2 Skit - board resistance, Fekt 336 to 337 1083 Skirt - board resistance, Fsk2 (includes example-14) 337 to 339 10.9.0 Belt scrapers (cleaners) resistance 339 10 341 10.9.4 External belt cleaner resistance, Foe 340 109.2 Internal belt cleaner resistance, Fei (Includes example-15) 340 10 341 10.10.0 Rotary nylon brush cleaner (external belt cleaner), Fes 341 10.110 Rotary rubber blades cleaner (external belt cleaner), Foe 341 10 342 10.12,0 Pulley cleaner resistance, Fp 342 10.13.0 Discharge plough resistance (includes exampie-16 & 17) 342 10347 10.14.0 Resistance due to related machine 347 t0 349) 10.14.41 Plough feader 37 10.14.2 Traveling trigper (includes example-18) 348 10.143 Recialmer machine 349 10.144 Fixed tripper 349 10.18.0 Pulley turning resistance, Ft 349 t0 350 10.18.0 ~ Belt wrap resistance around pulleys , Fw 350 to 352 4 10.17.0 Conveyor running resistance summary 352 10.18.0 Conveyor resistance summary table-29 353 t0 355, 10.19.0 This chapter and conveyor design 356 t Example-9 356 to 384 vilContent a Chapter 11) Take - up devices 365 to 385 a, 11.0.0 Take-up devices 365 3 144.0 Screw take-up 365 to 366 7 11.2.0 Vertical gravity take - up 366 to 367 9 11.3.0 Horizontal gravity take - up device 368 10 370 a: 11.4.0 Winch take - up device (fixed type) 37016 373 1144 ‘Stretching the belt for tension 372 a: 114.2 Winch take - up operation 372 At 14.3 Application 373 d 14.5.0 Principles for take up etfecton belt tensions 373 to 377 o 11.5.1 Floating take - up pulley (gravity force) 373 10 374 . 11.5.2 Non loating take - up pulley 37410 377 a} 11.6.0 Active winch take - up device 377 10 378 4 11.7.0 Accidental fal of gravity take - up mass (includes example-1), 378 to 381 ; 11.8.0 Tako up stroke (Includes table-80 & 31, example-2) 381 to 983 Oo 11.9.0 Rope and sheave system particulars for take up 384 1110.0 heave frictional resistance effect on take up force 384 10 385 : Chapter 12 Drive units 386 to 408 " 120.0 Drveunits 386 to 387 121.0 Electrie motor 387 : 1220 Gearboxes 388 0304 ° 12.2.1, Foot mounted worm gear box 386 0 389 42.2.2 Shaft mounted worm gear box 389 0 390 12.2.3 Horizontal foot mounted geared motor 390 to 391 ; 12.2.4 Parallel shaft helical goar box 31 } 12.2.6 Bevel helical gear box foot mounted 891 to 992 1226 Bevel - helical gear box shaft mounted 392 to 393, 423.0 Chain drive 393 0 394 124.0 V-belt drive 394 125.0 Mechanical power transmission efficiency of speed reduction mechanism (includes table-32) 394 to 395 . Flexible coupling 395 to 308 7 Pin & rubber bush coupling 307 | Geared type fiexible coupling 397 to 388 Grid type flexible coupling 398 to 309 Fluid coupling 309 to 404 f ‘Traction type fiuid coupling 399 | ‘Traction type fluid coupling with delay chamber 400 to 404 | Three chambers traction type special fui coupling 401 i Scoop type fluid coupling 402 to 403 Fill controlled turbo fuid coupling 403 to 404 Back stop (hold back) 404 to 406 } Pawi and ratchet type 405 - Differential band brake type 405Content 12.83 1284 1290 1210.0 12.14.0 Chapter 13 13.0.0 13, 13.102 13.110 13.120 13.124 13.122 13.130 13:13.4 13.132 13.133 13.134 13.14.0 13.150 Free wheel type (Roller hold back and sprag type hold back) Hold back (back stop) mounting Guards Base frame Notes on drive units Bolt tensions and conveyor design Belt tonsions and conveyor design Minimum tension in belt ‘Minimum tension for application of tractive pull to belt ‘Minimum tension in belt to limit sag Pulley belt fiction coefficient and wrap angle {includes table-33, 34, 35 & 96) Belt tension symbols Principles for calculating tensions in belt at various locations Ts during steady state operation Ts during starting / stopping of conveyor Calculation of tension Te Belt tension Tx at any point along conveyor Effect on belt tensions due to number of drives Drive listibution arrangement for conveyor Drive distribution based on reduction in tension alone ‘Commonly used drive distribution (for economy, etc.) Notes on drive distribution in conveyor ‘Take-up effect on tension calculation Floating take-up pulley (gravity take-up) Fixed take-up pulley (screw / winch take-up) Equivalent ineerly moving mass of belt conveyor Equivalent moving mass for idlers pulleys, Equivalent moving mass for drive unit Material loading on paral lengthis of conveyor Relationship among conveyor starting (braking) factors Starting factors relationship (for conveyors of + resistance during steady state) (includes example-1) Braking factors relationship (for conveyors of + resistance during steady state) Idier spacing (Includes tebte-37) ‘Adjustment in value of conveying resistance to suit calculation purpose Bolt conveyor of positive power Belt conveyor of negative power (regenerative conveyor) Belt carcass selection for longitudinal strength Safety factors for belt tensions Bolt unit strength at joint Joint efficiency Balt strength selection (includes example-2) How to proceed with design Conveyor length coefficient-C 405 to 408 408 407 407 407 to 408, 409 to 537 409 0 411 41110415 41110413, 41310415 41610418 418 41910 422 419 10 420 420 424 421 t0 422 42210 423, 423 10 427, 423 10 424 424 to 428 427 427 0 431 428 to 429 429 0 431 43110433, 432 432 t0 433, 433 43410439 435 10437 437 t0 499 440 10 444 441 10443, 442 44210443, 443 t0 447 443 10 445, 445; 445 10 448, 447 447 '0 448, 448 to 449Content 13.161 13.162 13.163 13.164 13.165 13.166 13.167 13.183 13.184 13.185 13.190 13.200 13.210 13.220 13.224 13.222 19.223 Chapter 14 140.0 (14.1.0 Maa 1442 1413 14.20 1424 1422 14.3.0 Design input basic quantity calculation Conveyor drawing / sketch with basic features ‘Material load per meter length on belt, Mm kg / m Carrying side Idlers rotating mass per meter length of conveying route. Me kg / m Retum idlers rotating mass per meter length of conveying route. Mr kg /m Volumetric conveying capacity design, Im® / sec ‘Astificial friction coefficient of conveying * Bolt mass per meter length, Mb ‘Table-38 Values of coefficient C" (average) Design procedure for belt conveyor tractive pull and belt tensions Original design input: 1P-1 Generation of design inputiP-2 Generation of design inputiP-3 Conveyor design stage! Conveyor design stage-t! Use of ft. f52, fot and fhe for conveyor design Drive type-1, without fluid coupling Drive type-2, with fluid coupling Example-3 & 4 Starting factors relationship (for conveyor of negative resistance steady state) Braking factors relationship (for conveyor of negative resistance steady state) Conventional values of belt line starting factor (includes table-39 & 40) Use of standards / codes in conveyor design Example-5 ‘The design capacity for load on conveyor Examples Material stabiliy on belt under acceleration / deceleration Example” Tension diagram Piotting/depiction of tension diagram ‘Type of tension diagrams ‘Some tension diagrams Drive unit functionat requirements. Drive unit functional requirements Electric motor Conveyor load torque - speed curves (without acceleration) deal torque - speed curve of a prime mover ‘Squirrel cage induction motor torque - speed curve Basic guide lines for drive / motor selection ‘Type - 1 drive (without fluid coupling) ‘Type 2 ative (with fuid coupling) Calculation for starting time 449 to 454 ‘449 to 450 450 450 to 454 451 t0 452 452 482 45210 454 454 484 10 405, 454 to 455 455 455 to 456, 458 0 484 464 to 465, 465 to 479 466 t0 468 468 to 470 47010475 47510 476 47810 477 ATT10 479 479 t0 480 480 to 499 499 to 501 501 to 518 518 10 520, 520 to 532 583 to 537 533 533 t0 534 534 to 537 538 to S47 538 598 to 540 539 539 1539 to 540 540 to 545, 54110 543, 543 to 545, 845 to 547 uContent Chapter 15 1500 154.0 15.4.4 15.4.2 15.13 18.1.4 18.2.0 153.0 183.4 18.3.2 183.3 15.4.0 155.0 155.1 155.2 1553 Chapter 16 16.0.0 16.1.0 16.1.4 16.1.2 16.13 16.1.4 1645 16.1.6 16.17 16.18 16.2.0 16.2.1 1622 16.23 1624 1625 16.26 1627 Chapter 17 17.00 17.4.0 1720 1730 17.46 1744 Pulleys Pulleys (includes table-41) Conventional pulleys (pulleys with plate diaphragms) Pulley construction Plummer blocks Rubber lagging (includes table-42) Pulley crowning Pulley behaviour under load (brief information) Pulley with turbo — diaphragms Pulley construction Taper lock elements ‘Other components of turbo diaphragms pulley External forces acting on pulley Pulley shaft design Basic information on forces, torque and bending moment acting on pulley shaft ‘Theories on shaft design based on stresses Shaft deflection Example: Conveyor frame Conveyor frame Frame fo stationary conveyor Head terminal Tail terminal Bend-pulleys support ‘Stingers ‘Stands Decking plate Wind guard Bott cover Conveyor frame for shittable conveyors Application Composition of shiftable conveyor fame Drive head station (OH) Retum station / Tal station (RS) Modules (Intermediate stations) Approach bridge Intermediate feed station ‘Supor structure ‘Super structure (Elevated structure) ‘Conveying system needs super structures lems of super structure Design norms end requirements ‘Super structure specification with respect to application Gantry (Open gantry) 548 to 568 548 to 549 549 to 554 550 to 551 551 to 552 552 to 583 553 to 854 554 to 585 955 10 558, 956 10 557 557 10 558 558 558 to 559 1559 to 568 559 to 564 561 to 565 566 567 to 568 569 to 587 569 569 1 576 570 svt 872 572 57210 574 874 10 875 57510576 576 878 10 587, 57710579 579 10 580 580 to 584 584 to 595 585 to 587 587 587 588 to 603 588 588 to $89 589 10 590 590 to 591 590 to 603, 591 to 592Content 1742 Gallery (Closed type gantry) 592 to 594 1743 Trestles, 594 t0 595 174.4 Houses for conveying system (Also includes some information on 1595 to 601 springs and viscous dampers vibration isolation) 174.5 Sheds 601 to 603 174.6 Cross over 603 Chapter 18 Conveyor profile in vertical plane 604 to 612 18.0.0 Conveyor profile in vertical plane 604 48.1.0 Curvature effect on tension distribution within belt 604 to 605 1820 Nomenclature 605 to 608 18.3.0 Concave curvature / radius 606 to 608 18.4.0 Convex curvature / radius 608 to 608 18.5.0 Transition length (Includes table-43) 609 10 611 Example 611 to 612 Chapter 19 Introductory information on equipment associated with belt conveyor 613 t0 625 19.0.0 Introductory information on equipment associated with belt conveyors 613 19.1.0 Feeders (belt feeders, vibrating feeders, apron feeders, and paddle feeders) 613 10615 1920 Bet weigher 61510616 19.3.0 ° Magnetic separators (suspension magnet, cross belt type and in ine belt type) «616 10 618 19.4.0 ‘Dust control equipment (dust extraction / collection type and dust suppression type) 618 to 619 19.5.0 ‘Sampling system 619 10 620, 196.0 Unloading equipment (wagon tipple, truck tippler and ship unloader) 620 to 624 19.7.0 Stockyard machines 621 10 625 Stackers 621 Reclaimers (side scraper rectaimer, portal scraper reclaimer, bridge type 621 10 623, scraper rectaimer, bucket- wheel on boom and bucket wheel on bridge) Blending / homogenization of bulk materials. 623 to 625 19.8.0 Horizontal curved conveyor 625 19.9.0 Cylindrical belt conveyor (pipe conveyor / tube conveyor) 625 Advertisement section 1. Krupp Industries india Ltd., Pune 44. Voith India Pvt. Ltd., Hyderabad 2. Mahindra (MECP Ltd. Engg. Division), Pun: 15. Rathi Transpower Pvt. Ltd., Pune 3. Concept Engineering Projects Pvt. Lid., Pune: 16. Saya ron & Engg. Co. Lid., Baroda 4. Magnetic Corporation Of India, Bangatore 47. Sinex Primemovers, Mumbai 5. Kaveri Ultra Polymers Ltd., Mumbai 18, Hosch Equipment (India) Put. Ltd, Kolkata 6. Jayashree Electrodevices Pvt. Lid., Pune 19, RIECO Industries Ltd,, Pune Jayashree Electron Pvt. Ltd,, Pune 20. Kali Material Handling Systems, Chennai 7. Eagle Agro Industries, Rajkot 21. North Land Rubber Mills, New Delhi 8. Oriente! Rubber Industries Ltd., Pune 22, Electromag Devices Pvt. Ltd., Mumbai 9. Fluidomat Ltd., Dowas, M.P. 40, Shaw Aimex India Pvt. Ltd. Faridabad, Haryana 24, GER Vibration Control Systems Pvt. Lid., Noida 11, Electro Zavod (India) Pvt. Ltd, Kolkata 25. Naveen Projects Ltd., New Delhi 12. Elmech Engineers, Mumbai 26. Siemens Ltd., Mumbai 18. Suniron Technique Put, Ld, Pune xii Nilos India Pvt. Lid., ChennaiBulk material handling plants and conveyors Chaptert: BULK MATERIAL HANDLING PLANTS AND CONVEYORS 1.0.0NEEDS FOR BULK MATERIAL HANDLING PLANTS WITH CONVEYORS Modern civilization requires handling of bulk materials in huge quantity. Our present civization aims at producing innumerable items for utlity and comfort of human race. All these items aie produced from raw materials from our unique planet with appropriate process / modification To cite some examples, we need huge-quantity of cement, which is made from mined materials. We need steel to make simple kitchen knife to steamers, which requires movement of huge quantity of iron ore at national 2s well as global level. Every man needs electric power at his disposal, which demands generation of electric power on mega scale. Hence requirement for movement of huge quantity of coal, from mine to thermal power station. The above examples need installation of special bulk material handling system at source of the raw material, and also at process (consumption) unit. The raw materials being mined has to be temporarily stored in gigantic piles, to be retrieved on need and to be loaded into railway-wagons / trucks. When such materials arrive at cement / steel / power plant, same are to be unloaded, stored, retrieved and finally to be consumed for making end product. Again, if the end product is @ new bulk material, it will require further handling for storage, reclamation and onward transport Not to forget food grains; often these are produced in one area, but surplus are to be transported to other area / country. This can demand bringing the food-grains to por, temporary storage, retrieval from storage and loading into ships (steamers). The reverse will happen at the port of receipt Le. unloading from ships, temporary storage at port, retrieval from such storage and dispatch by rail/ road. This needs buik material handling system of sophisticated nature, as quantity involved could be few tens of thousand tonnes in a day. Above are only few examples. The bulk material handling systems have innumerabie areas of application. tn the former time, the handling of bulk materials was manual when tonnage involved were very small. The effect of industrialization now reaching practically to every human being; the bulk materials turn over is now counted in millions of tonnes instead of hundred of tonnes in former times. ‘This demands bulk material handling systems for varied applications. ‘The bulk material handling system consists of numerous equipment, which work in @ coordinated preplanned manner to achieve ultimate functional need. The belt conveyors Bre very prominent and important equipment in such system, to ensure flow of material through various parts of the system. The 1Bulk material handling plants and conveyors designer's first choice is to use belt conveyors for this purpose due to its reliability and ruggednes: ‘except when system layout or nature of the material does not permit use of belt conveyors. 4.4.0 INTRODUCTION TO BULK MATERIAL HANDLING PLANT Bulk material handiing equipment, which also include conveyors, can rarely work in isolation. The bulk material handling equipment generally functions 2s an integral part of system / plant, Such system / plant are commonly known by any of the following names. = Bulk material handling system ~ ‘Material handling system = Bulk material handling plant - ‘Material handling plant The bulk material handling system consists Material inflow | - Boundary limit of “Bulk material handling system’ of many equipment and auxiliary services to achieve required functional needs. The belt conveyors are most populous equipment in such system to achieve material flow from | Materia stacking section starting to end point, in the whole set-up. + The material handling systems are generally ‘Material reclaiming section oe ~ tailor-made to fit into available land-area / + | Material outflow section | portarea / plant-area etc, Therefore, one rarely finds the two systems as an exact —__}—— i i Material outfiow replica of each other. However, all the I atansen tow desperet vehiies) eee eee eens | Bulk material handling system fiowogic | fundamental functions, and accordingly, * a OL Figure A most of the material handling system will have following basic features; as depicted in figure-A System has a section to receive incoming material. This can be ranging from simple manual unloading of truck, to highly sophisticated ship-unloader. System has a section creating some storage. This can be ranging from simple plow-discharge / tripper-discharge storage to complicated stacker to form large stockpiles with varied travel motions. under automatic command. ‘System has & Section for reclaiming the stored material. This can be achieved by simple means such as small hopper at ground level to be fed by bulldozer, or it can include expensive reciaimer machine as per fieeds ‘System will have material outflow section to feed material into consumption unit or into dispatch system / vehicles. : Aforesaid each section of the material handling system will have suitable equipment and conveyors. The equipment and conveyors of each section function in a preplanned coordinated manner for specific 2 oCBulk material handling plants and conveyors mode of operation. It is possible that all the mentioned section may not be present in a particular system. Also all sections are interlocked by common controls to function as a one “Bulk material handling system” from beginning to the end. The entire system works in preplanned coordinated modes to ensure smooth flow at optimum capacity without jamming / disruption in operation. The design stage Planning takes into consideration the operating time, maintenance time and use of various flow paths for best reliability in combination with economy. Figure-B shows a typical bulk material (coal) handling:plant in a thermal power station. Following clauses 1.1.1 and 1.1.2 describes the salient features of this typical plant. As mentioned before, most of the plants have certain basic similarities, and therefore, information on this plant will provide @ broad ‘outlook about the underiying principles in a bulk material handling system. L of | ‘seosescnc wou | TTPICAL COAL HANOUNG PLANT FOR A POWER STATION WINDL | | figueBulk material handling plants and conveyors 4.1.1 System description “The typical coal handling plant shown in igure-A functions as under. Material ‘The power station operates on Indian black bituminous coal arriving by railway Wagons from far-off mines. The coal characteristics are as below: Bulk density: {800 kg/m for volumetric computation and 1000 kg/m’ for loads Coalsize Incoming coal (-) 600 mm (unsized) Consumption coal of (-) 25 mm size 98%, as input to boilers system. Hardness 4510 65 HG! Repose angle : 36° average, minimum Moisture : Maximum upto 20% during monsoon ‘System desion principles ‘The coal handling plant is designed in double stream pattern i.e. main flow path have two line of conveying / crushing, wherein one line is working and the other line is standby. This ensures proper maintenance and cleaning of plant with uninterrupted flow of coal to boiler bunkers. In addition, cross connections have been provided between both the streams at number of points to ensure working of particular stream, even with non-operational status for some of its equipment. System capacity In general, each stream is guaranteed for 1000 mtph handling rate, and designed / sized for 1260 miph capacity. ‘This implies that the plant is to be sized for 1250 mi/hr. handling rate, which shall ensure guaranteed rate of 1000 miph even with lowest bulk density of 800 Kg/m®. However, this can result into load of 1250 mtph when bulk density happens to be 1000 kg/m®, and therefore this aspect is taken care by aforesaid difference in guaranteed capacity and design capacity. ‘System description The coal transportation to power station is by 1676mm broad gauge Indian railway system. The coai is received mainly in open box type 8 wheeler wagons of 80/90 tonnes gross weight. The coat handling plant includes 2 Nos. of “Side discharge type” wagon tipplers. Each tippler is provided with “Side arm charger (SAC)" to bring-in loaded wagon and to eject out empty wagon from tippler platform. The tippler ‘and SAC operate as a single unit in interlocking mode to ensure safe and quick unloading of coal. The ‘each set of tippler and SAC is designed for 20 tips/hr. of 8 wheeler single wagon at a time, or 2 Nos. of 4-wheeler wagon in pair. Ezch wagon tippler is provided with water spray type high efficiency dust suppression system, which operates automatically during tipping operation to contain dust emission. Each tippler is also having water pre-spraying unil to spray water on waiting wagon to augment dust suppression effect during dry 4Bulk material handling plants and conveyors seasons. This plant include such dust suppression system at some of the locations, as same does not degrade material being handled. Coal unloaded by wagon tippler falls into the adjoining hopper. Steel pan apron feeder is provided under ‘each tippler hopper to draw coal at controlled rate to feed out-going belt conveyor. The apron feeder is equipped with DC motor drive to vary speed and thereby facilitate the setting of discharge rate in accordance with operational requirement. These feeders are at starting point of the coal handling piant ard hence they decide the pace of working for most of the system. The apron feeder has been used due to lumpy nature of material and high fall of material from wagons. The (-) 600 mm size coal being unloaded at wagon tipplers, is conveyed to primary crusher house or to uncrushed coal storage by conveyor Nos. C-1A, C-1B, C-2A/2B, C-3A/3B, C-4A/4B and C-14. The uncrushed coal storage is formed by discharge through telescopic chute and further spreading by bulldozers. The coal from the storage is reciaimed by pushing on to adjoining track hopper by bulldozers. The coal handling plant include 55 m long track hopper for manually unloading of coal from unexpected type of rail wagons and also as an additional facility to receive coal. 2 Nos. of plow feeders are provided under track hopper to extract coal at controlled rate and to feed out-going conveyor No C-15. The plow feeders are rail mounted on conveyor frame to reciaim the coal during to-and-ro travel. The plow feeder has variable speed drive to adjust the discharge rate. Conveyor No C-15 convey this uncrushed coal to conveyor Nos. C-4A/4B leading to primary crusher house. The aforesaid uncrushed coal storage system is provided as a standby additional facility. ‘The primary crusher house includes 2 Nos. of rotary breaker type crushers, which have cylindrical drum of 4.26 m dia, x 8.54 m length rotating at approximately 11 rpm. The coal being fed into drum is lifted up by integral shelve for gravity drop into drum. This results into breaking of coal, which pass through apertures on cylindrical face, for conveying by underneath system. The primary crushers reduce coal of (1600 mm size to (-) 180 mm size, Conveyor No. C-5A/5B convey this primary crushed coal of (-) 160 mm size, to secondary crusher house, where it is first fed to vibrating screen to screen out (-) 25 mm size coal. The coal of (+) 25 mm to () 150 mm size flows into respective secondary crusher for reduction to 98% (-) 25 mm size. The secondary crushers are of ring granulator type. The crusher rotor is fitted with series of ring hammers. The crushing action is mainly by impact and compression with minimum attrition, The rotor pushes crushed coal through bottom screen plate as output product, The secondary crusher house includes spring and viscous damper mounting system for crushers to provide vibration isolation to main structure. The primary crushers are mounted on independent RCC foundation-cum-structure to prevent transmission of vibration to main structure. The primary crushers 5Bulk material handling plants and conveyors being very slow in speed (11 rpm), the spring and viscous damper arrangement is not very effective. Conveyor Nos. C-6A/6B, C-7, C-8A and C-8B convey secondary crushed coal to main storage yard. ‘The coal handling plant includes 2 Nos. of stacker-curn-reclaimer machine, having bucket wheel on slewing and luffing boom. The machines are rail mounted for linear travel. One stacker-cum-reciaimer machine is working in conjunction with yard conveyor No C-8A, and the other machine is working in conjunction with yard conveyor No C-8B. During stacking mode; the stacker-cum-reclaimer machine is fed by yard conveyor to form stockpile of (-) 25 mm size coal, along rails on both sides. During rectaiming mode, the stacker-cum-reclaimer reclaims this coal from stockpiles, and feeds on to respective yard conveyor, to convey towards boiler-bunkers. ‘The machine stacking capacity is 1000 mtph guaranteed and 1250 miph designed i.e. same as for 9 rate ‘conveying stream, The machine peak reclaiming rate is also same as above, but rectal fluctuates continuously from minimum to maximum in cyclic patter, in each slewing pass and therefore, the guaranteed reclaiming capacity on 4 hour average basis is nearly 70% of above. The plant include stacker-cum-rectaimer machines of foregoing specifications, as same are suitable for this application, This dual purpose machine silently performs stacking o reclaiming operation in neat / clean manner with {east pollution of dust. The belt conveyors in the plant have 1200 mm wide textile fabric belts running at 3.0 mps speed end designed as per iSO / IS standards, The carrying idlers are of 3 rollers 35° trough type and return idlers are of single / double roller type. The plant includes additional emergency reclaim system having 2 Nos. of hoppers, 2 Nos. of vibrating feeders and conveyor No. C-16, The emergency reciaim system is located at the end of storage yard, and is rated for 50% capacity of mainline system. Electromagnetic type suspension magnet and over-band in-line magnetic separator have been positioned at critical points in the system to remove tramp iron from coal. These are sized for 1000 gauss strength and force index of 100,000 in working zone during stabilised operation (hot condition). ‘The plant has inline belt weighers at numerous locations to measure conveying rate and the quantity being conveyed for correctly setting the plant operation, and for other necessities. The weighing accuracy is 0.5% in stationary installation and 2.5% for installation on stacker-cum-reclaimer machines {rmobile machines). ‘The coal handling plant is complete with ancillary equipment such as cyclone / bag filter type dust collection system, dust suppression system, ventilation system, sump pumps, maintenance hoists, chutes, gates, water line and compressed air line for plant cleaning, fire fighting system, etc.; for efficient and reliable operation of the plant, round the clock. 6Bulk material handling plants and conveyors The super structure includes stee! fabricated galleries and trestles for elevated conveyors, steel fabricated transfer houses at junction of conveyors and crusher houses. The elevated conveyors are housed inside galleries having corrugated sheet cladding, and chequered plate / grating walkways on both side of each conveyor for ease of maintenance. The houses have been amply dimensioned for minimum 1.2 m free space around equipment for ease of maintenance. The transfer houses have corrugated sheet steel cladding and crusher houses have brickwork cladding. The houses have RCC floors, and are complete with staircases, access doors, maintenance doors, windows, etc. The super- structures have been designed in accordance with statutory rules and standards. The super-structure design takes into consideration the various stresses arising due to dead loads, wind loads, seismic loads, live loads, material incrustation, etc. The coal handling plant is provided with all necessary electrical and instrumentation for safe and dependable working of the equipment and the system. The plant operation is fully automatic from central control desk with provision for choosing various flow path as per the operational needs. work for underground structures, tunnels, RCC hoppers, stockyard base, The plant needs suitable ci storm water drainage, cable trenches, foundation for equipment, foundation for structures, etc. 4.4.2 List of major equipment and structures for the plant Main equipment and structures for this typical coal handling plant are as below, which provides a feel about items involved in such plants. Mechanical: 4) Side discharge wagon tippler with integral weigh-bridge. 2Nos. 2) Side arm charger with i's railtrack. 2.Nos, 3) Apron feeder with i's dribble conveyor. 2.Nos. 4) Belt conveyor including belt, pulleys, Idlers, scrapers, drive unit and take-up mechanical. For ‘conveyor Nos. C-1A, C-18, C-2A/2B, C-3A/38, C-4A/4B, C-5A/SB, C-6A/68, C-7, 0-84 C-8B, C-9, C-10A/10B, C-11A/11B, C-12A/12B, C-13A/13B, C-14, 0-15 and 0-16 27 Nos. 5) Rotary plow feeder in conjunction with conveyor C-18. 2.Nos. 6) Primary crusher of rotary breaker type, with drive. 2Nos. 7) “Secondary crusher of ring granulator type, with drive, 2Nos. 8) Vibrating screen. 2 nos.Bulk material handling plants and conveyors 9) Stacker-cum-reciaimer with all accessories and drives. 2.Nos 40) Belt weigher for conveyors for conveyor Nos. C-1A, C-18, boom conveyors , C-12A/12B, C-14 and C-16. 8 Nos. 44) Inline magnetic separator for conveyor Nos. C-1A, C-1B, C-18, C-SAV/5B, C-11A/11B. 7 Nos. 12) Metal detector for conveyor Nos. C-12A/128. 2.Nos. 13) Travelling tripper on conveyor Nos. C-13A/13B. 2 Nos. 14) Bunker slot sealing system in conjunction with trippers. 2.Nos. 15) Telescopic chute at discharge end of conveyor No. C-14. 1No, 16) Rack and pinion gate below emergency reclaim hoppers. 2.Nos. 17) Vibrating feeders below emergency reclaim hoppers. 2.Nos. 18) Motor actuator operated flap gate. 52 Nos. 19) Bunker level indicator (high and tow). 24 Nos. 20) Ventilation system for tunnels of C-1A, C-1B, C-2A/2B, C-34/3B, C-15 and C-16. 6 Nos. 21) Ventilation system for switch gear rooms. 4.Nos 22) Air conditioning unit for controt rooms. 5 Nos. 23) Water spray type dust suppression system for WT-A, WT-B,TH-1,TH-2,TH-4,TH-6, stockpiles, TH-7 and TH-8, 14 Nos. 24) Dry cyctone-cum-bag filter type dust extraction system for TH-3, PCH, SCH, TH-9, TH-10 and TH-14 6 Nos. 25) Dry cyclone-cum-bag filter ype dust extraction system for reducing level of coal dust in bunkers’ air. 4 Nos. 1No. 26) Water supply system to dust suppression units. 8Bulk material handling plants and conveyors 27) Water line for plant cleaning. 28) Compressed airline for plant cleaning. 28) Sump pumps for removal of seepage water in underground structures. 30) Electric hoist and manual hoist (in houses), \eluding monorail, for maintenance of equipment 31) Springs and viscous dampers vibration isolation mounting for secondary crushers. 32) Coal sampling system Electricals and controls: All electricals and controls, which are integral to equipment ‘and from main control room to equipment. Structurals: 1) Conveyor frame, 2) Galleries and trestles for elevated length of conveyors. 3) Transfer houses and crusher houses. 4) Chute-work at junction of equipment. §) Steel grid on wagon tippler hoppers, manual unloading hoppers, emergency reclaim hoppers and bunker siots. 6) Rail-track for mobile machines, 7) Cross-over on conveyors. Civil work: For mechanicals, electricals and structurals, ‘Spare parts: For mechanicals and electricals. 1No. 1No. 42.Nos. 65 Nos. 2Nos. 1No, 1 ot 4 ot lot 1 ot 1 ot 1 ot 4 lot tot 4 tot totIntroduction to belt conveyor Chapter2: INTRODUCTION TO BELT CONVEYOR 2.0.0 INTRODUCTION TO BELT CONVEYOR This chapter describes the belt conveyor for conveying (handling) buik material, It is necessary to have design related basic information about various component of belt conveyor before attempting to design belt conveyor. Like most of the design problem of compiex equipment, the design of belt conveyor is also plagued by the contradiction whether egg first or hen first. The design of belt conveyor as a whole depends upon design / construction of individual component, but the design of many individual components depends upon ultimate design construction of belt conveyor. This issue is ‘taken care appropriately in design procedure, and also by arranging the chapters in sequence such that designer / reader has relevant information on components prior to each stage of designing, 2.1.0 MAIN MECHANICAL COMPONENTS IN A CONVEYOR ‘The following figure-1 schematically shows the mechanical components of a typical belt conveyor, This book includes necessary chapters, as listed in index, to provide relevant information of these ‘components to the designer. , \ | (1) ca I | | ‘ oe oe ® oo oe 1: Tall pulley (in special case this can also be drive pulley with drive-unit coupled to it) 2: Snub pulley (at head-end and tall-end) 3: Internal belt cleaner (internal belt scraper) 4: Impact idlers (impact rollers) 40Introduction to belt conveyor tee ‘8: Return idlers (return rollers) et (continuous loop of carrying run & return run) end pulleys 4 8: Take-up pulley ° 9: Take-up unit 40: Carrying idles (carrying rollers) ) 41; Pulley cleaner (pulley scraper) . 42: Extemal belt cleaner (external best scraper) 413: Head pulley (normally this is discharge pulley and also drive pulley. Drive unit is coupled to > this pulley when being drive pulley) } 2.2.0 BELT CONVEYOR FUNCTION The belt conveyor rear end is known as tail-end, The material is fed onto belt conveyor near tall-end, ‘The material so fed onto belt conveyor rests on upper run of belt and travels forward with the belt. The material on reaching head pulley drops down automatically due to gravity and discharge velocity, while turning round the head pulley. The belt conveyor forward end is known as head-end. Thus material is conveyed from tail end to head-end in continuous manner. The point where material is put on belt is known as feed-point loading-poiint. The conveyor can also have more than one feed point or moving feed point. In such situation, the location of rear most feed point would be obviously close to tall-end, ‘The point where material is getting discharged from bell is known as discharge-point. Generally this is head-end of conveyor, but it can also be created at intermediate point by specialized means as would be explained latter. Itis to be specifically noted that belt conveyor simply conveys / transports whatever quantity of material is put on belt at feed point, without any control on quantity to be conveyed. If the incoming material quantity is less, it operates at partial load. If the incoming material quantity is excessive, it will lead to spillage and even breakdown. Therefore, it is very important that the quantity being fed to conveyor > ‘should not exceed the design capacity. , The equipment which puts correct / regulated quantity of material on belt are known as feeders. If the ' conveyors are in series, say conveyor-A feeds to conveyor-B; conveyor-B feeds to conveyor-C; conveyor-C feeds to conveyor-D ete., then first conveyor-A should reosive material from feeder or some | other machine with controlled output. If this is ensured for first conveyor-A, then all other subsequent 7 connected conveyors B, C, D etc. will receive same feed without any need of feeders for conveyors B, i ©, D etc.. Use of feeder or appropriate machine at the starting point of belt conveyor system is very " |Introduction to belt conveyor important and should never be overlooked. Any compromise in feeding system shell result into inadequate utilisation and matfunctions, with wasteful capital expenditure for the system as a whole. Sometime, small belt conveyors starting from outlet of hopper and conveying fine granular material, i have regulating-gate at feed point (skirt-board). This ensures reasonably controlled conveying, but this should be treated as an exception rather than rule Belt feeder is_one type of feeder. It is similar to belt conveyor but its application and working is remarkably different from belt conveyor; and hence it should not be confused with belt conveyor. The design procedure of belt conveyor is also applicable to belt feeder with appropriate difference. i 2.3.0 CONVEYOR-PROFILES : (CONVEYING-PATHS) i 2 Horizontal This book deals with the standard — | conveyor lying in single vertical plane Le. curvatures if any, are only = > appearing in vertical plane. | Traditionally, the word conveyor implies above meaning, Incline-horizontal (Asconding-horizontal) | The conveyor, which has curvatures. |} in vertical plane as well as in horizontal plane is called ‘Horizontal o_O i Curved Conveyor’. The horizontal \ Horzontal-dectne curved conveyor is similar to | Dectine aforesaid standard conveyor with additional design check and manipuiations for belt stability in horizontal plane. The horizontal curve radius is very large, and therefore, its application is limited to long distance cross-country conveyor or where such large radius is i feasible, This book deals with the | Fixed tipper: Itis an integral part of conveyor profile i ° a and can be incorporated in any of above \ ere eta Profle for intermediate discharge. i referred as ‘conveyor’. The conveyor es —_ i can have basic profiles (conveying- Conveyor profiles Figure-2 paths) as shown in figure-2. 12Introduction to belt conveyor 2.4.0 METHODS OF FEEDING / LOADING BELT CONVEYOR Generally @ conveyor receives the feed by any of the following methods: 2.4.1 By feederls from hoppers / storage ‘The hopper can be over ground or at ground level storage. The feeder extracts material from such storage at controlled rate and feeds to the conveyor. The feeder can be of various types such as vibrating-feeder, belt- feeder, apron feeder etc. A typical arrangement is shown in figure-3, The feeding arrangement will be of fixed location type, placed at a starting point of a particular section of the belt conveying system. 2.4.2 By preceding conveyorls The discharge of becomes direct feed for the next conveyor. Generally, this is at a fixed location. A typical ‘arrangement is shown in figure-4 preceding conveyor 2.4.3 By process equipment ‘The equipment like crusher, screen etc discharges at a controlled rate, which become feed for the outgoing conveyor. ‘These will be generally at fixed location. Figure-5 shows crusher feeding to belt conveyor. 2.4.4 By travelling machine The travelling machines such as bucket wheel-reclaimer, paddle-feeders, travelling hopper equipped with discharge-feeder ete ‘operate in conjunction with the stationary ‘conveyor, Keeping mechanically continuous 13 aera) Feeder _-— Discharging conveyor ae D) | ) — Fees | Receiving conveyor a Figure- 4 (schematic) Crusher Figure- 5 (schematicn to belt conveyor Connection. The traveling machine feeds the material at controlled rate onto conveyor. The feeding Point on conveyor will be shifting to and fro steadily or in steps. The feeding arrangoment will be at starting point of the particular section of the belt conveying system. 2.5.0 METHODS OF DISCHARGE FROM BELT CONVEYOR Materiat discharge from belt conveyor can be by following methods: 2.5.1 Head pulley discharge ‘This is the most widely used natural method | for material discharge from belt, as shown in figure-6. The discharge can flow to next conveyor / equipment or on ground to form: stockpile, 2.8.2 Both end ae discharge ow Figure - 7 (schematic) The reversible conveyor discharges at both the ends ie at head end while running in forward direction, and alternatively at tall end while running in reverse direction. This figure-7 shows such arrangement of discharge. The discharge flows to next conveyor / equipment or on ground to form stockpiles. | Figure. 8 (schematic) 2.5.3 Tripper Po discharge This is a very common method of material discharge before the head pulley of conveyor (intermediate discharge). The tripper arrangement is created by forming belt loop in carrying run by means of pulleys ‘as shown in figure-8. The discharge from tripper pulley can be diverted for the required purpose. The tipper discharge can be on one / both sides of conveyor or it can be fed back onto conveyor for discharge at head end. Full quantity of material flows to any one of above paths. The flow division by 14Introduction to belt conveyor chute cannot ensure consistent proportion in division, particularly for lumpy materials. Therefore, itis not used for specific division. The tripper arrangement has two versions viz. fixed tipper and travelling tripper. Fixed Tripper The tipper arrangement is an integral part of conveyor at fixed location. The discharge can be diverted to one-side / both sides of conveyor or back onto belt for discharge at head end, as explained before. Traveling Tripper — The tripper is a self-contained machine with wheels running on rails, which are installed along conveyor length. The tripper moves over conveyor length (horizontal), while maintaining continuous ‘mechanical connection with the centrally positioned belt conveyor all the time. The tripper discharge can be diverted to one side / both sides of conveyor or back onto belt for discharge at head end. The ‘ripper discharge can have following applications: _— Tripper discharge can move to and fro steadily or in steps. The discharge can fil series of bunkers cr form a large linear stockpile on ground as shown in figure-9 & figure-9A respectively. Tripper travel + ON \ A € Figure - 9 (schematic) Figure - 9a (schematic) 15Introduction to belt conveyor — Linear travel stacker and stacker-cum-reciaimer have traveling tripper as a part of whole machine, ‘The discharge from tripper is diverted to stacking boom conveyor to form large linear stockpile on ground, as shown in figure-10. The stockpile formation can be for simple storage or for blending Purpose. The stacker forms the stockpile by travel in steps or by continuous motion. The stockpile formation can be of free style, or in accordance with automatic logic programme for specifi pattem in composition. The widely used stockpile patterns are chevron, windrow, strata, cone-shell, etc, Stacker Yard conveyor Linear travel stacker — Yard conveyor 4 = Figure- 10 (schematic) 4 Plow discharge is an economical mean to create intermediate discharge for small capacity slow speed flat belt conveyor 2s shown in figure-11. The plow diverts the materia! to fall from the side of the belt. Plow can ‘be positioned in / out to get discharge at different points. Plow can be travelling type also. Plow creates faster wear of belt, and therefore, it is used for less abrasive materials in combination with slower speed of belt. Plow discharge can be used for required uility orto form stockpile on ground. Pian Figure - 11 (schematic) 16Bulk materials Chapter3: = BULK MATERIALS 3.0.0 BULK MATERIALS ‘The belt conveyor is required to convey bulk material. The bulk material comes in contact with various element of conveyor during this conveying process. The bulk materials have wide ranging characteristics such as some are smooth where as some are rough, some are heavy and some are light, and so on. The bulk materials external physical nature ie. characteristics have great influence on design of belt conveyor. ‘Therefore, firstly itis necessary to know and understand the nature of bulk material to be conveyed. This enables to make the right design for overall economy and optimum performance with minimum ‘operational problems. In most of the cases, the belt conveyor is concemed with the extemal physical nature of material, and therefore, this chapter deals with the same, Generally, conveyors handle naturally occurring materials, which are chemically inert. However, if particular material is chemically active, same’ should be taken into consideration in accordance with specific chemical characteristics. ‘The various parameters of bulk material, effecting the conveyor design, are explained below. 3.1.0 BULK DENSITY Belt conveyor is required to convey certain quantity of materials in tonnes per hour. The material is accommodated on belt forming certain cross-section of material on belt as explained in chapter-7. This cross-section multiplied by belt velocity provides volume of material being transported in unit time, Thus belt conveyor abilty to transport material is volumetric in nature, The aforesaid transported volume is converted into tonnes by multiplying it with the ‘Bulk Density’ of ‘material, in the condition as itis on belt. The bulk density is defined as mass per unit volume. The unit volume for expression could be m3 or ft3 as Per units being adopted for calculation. However test volume needs to be large enough to represent correct status of material, particularly for lumpy material, The bulk density of material varies according to status of material such as- ~ Bulk density of material in natural deposits will be very high and this should never be used for conveyor design. — Bulk density of material will increase somewhat on storage and compaction. = Individuat tump or grain density is quite high compared to bulk density because seme does not account for cavity between particles. Lump or grain density should never be used for conveyor design. — Bulk density marginally increases due fo material settlement on vibration. The bulk density referred in conveying as well as in this chapter is the bulk density of material as on belt (or in the similar condition). The material data should have correct value of bulk density for contractual needs between user and designer. 17