MECHANICAL ENGINEERING

DESIGN PROJECT

DESIGN OF
BELT CONVEYOR

PRESENTED BY-:

KUMAR ANJANEYA DAS

KRUSHNA CHANDRA KAR

GUIDED BY -:

MR. DEBASISH TRIPATHY

ASSISTANT PROFESSOR,

DEPT. OF MECHANICAL ENGINEERING,

VSSUT,BURLA

 ACKNOWLEDGEMENT

We have taken efforts in this project .

However, had not it been the kind support
and help of many individuals and
organizations , we would have had an
unfinished project. We would like to extend
our sincere gratitude to all of them. We are
highly indebted to Mr. Debasish Tripathy,
Assistant Professor, Mechanical
Engineering, VSSUT, Burla for his
guidance and constant supervision as well as
providing necessary information regarding
the project and also for his support to
complete the project. Also special
appreciation goes to our fellow colleagues
Debjyot Dash , Debadyuti Nayak etal who
have willingly helped us out with their
abilities.

 ABSTRACT
 Belt conveyor is the integral part of
any industry relying on mining operations and
carrying operations. But the issue of the
longevity, capacity, speed and strength while
minimizing power and improving cost
efficiencies is very paramount in every
industry. Hence in this project we have focused
on the techniques to design a effective and
efficient belt conveyor for a Ferrochrome plant
to carry the materials through a given distance
and height. Also moving deep into the project
we have selected the suitable belt material for
avoiding the wear and tear of the same due to
the abrasion caused by the flowing materials.
Moreover, optimum diameter for the pulley,
belt thickness, belt material density and idler
 spacings are devised for the smooth and noise
free operations of the whole system.
 CONTENTS
 INTRODUCTION…………………………………
………………………
 MAIN ELEMENTS AND DIFFERENT
PARTS……………………………
 SCHEMATIC
DIAGRAM………………………………………
………..
 FUNDAMENTAL
TERMS……………………………………………
……
 PROBLEM
STATEMENT………………………………………
………….
 DESIGN
CONSIDERATIONS………………………………
……………
 DESIGN
PARAMETERS……………………………………
…………….
 DESIGNING A CONVEYOR
BELT………………………………..........
 BELT POWER
CALCULATIONS…………………………………
……....
 BELT TENSIONS AND
FRICTIONS……………………………………….
 BELT MATERIAL SELECTION
…………………………………………....
 BELT CARCASS
SELECTION………………………………………
…....
 COVER GAUGES AND
QUALITY………………………………………
 CALCULATION OF BELT
MASS………………………………..............
 PULLEY
DIAMETER…………………………………………
…………….
 GRADUATED IDLER
SPACINGS………………………………………..

 INTRODUCTION
A Belt Conveyor system is a
common piece of mechanical
handling equipment that moves
materials from one location to
another.
 Belt Conveyor system allow quick
and efficient transportation for a
wide variety of materials which
 make them very popular in material
handling and packaging industries.

MAIN ELEMENTS OF BELT
CONVEYOR
 BELT
 IDLERS
 PULLEYS
 DRIVE UNIT
 SUPPORTING STRUCTURE
 Diagram of a belt
conveyor system
 FUNDAMENTAL TERMS
 THE CARCASS
 THE COVER
 NUMBER OF PILES
 BELT WIDTH
 BELT THICKNESS
 COVER THICKNESS
 SURCHARGE ANGLE
 INCLINATION ANGLE
 TROUGHING ANGLE
 The carcass
 The carcass is arguably the most important
part of a conveyor belt because not only
does it have to absorb tremendous tensile
stresses and strains it also has to convey
the material placed on it. At the same
time, it has to cope with a many different
mechanical and thermal demands.
Typically, a carcass contains layers of
specially woven fabrics with rubber inner
plies or other materials such as steel cords
embedded in the rubber. It is the carcass
that provides the inherent characteristics
of a conveyor belt such as its tensile
strength and elongation (elasticity or
‘stretch’ under tension).
 The cover
 In most cases, the carcass is protected on
both sides by a rubber outer layer. This is
commonly referred to as the ‘cover’. The
purpose of the rubber cover is to actually
protect the carcass from damage. There
are several types or ‘qualities’ of cover,
each of which is designed to contain
specific properties. The quality
characteristics of the cover grade largely
determine the ability of the belt to
withstand damaging effects such as wear
 caused by abrasion, ripping, tearing, heat,
cold and the many other potentially
harmful effects caused by fire, moisture, oil
and other chemical reactions. The actual
specification and quality of the cover
largely depends on the materials the belt
is required to carry and the surrounding
operating conditions. A more detailed
explanation of the different types of cover
qualities and their strategic importance is
provided later in this manual.
 Number of plies
 A typical multi-ply carcass can consist of
between two to six plies in the required
tensile strength. For elevator belting, three
to six plies can be necessary due to the risk
of tearing at the bucket holding bolts. The
technological advances made by Dunlop
in recent years has led to a reduction in
the number of plies for some constructions
but at the same time achieving higher
tensile strength and better mechanical
properties.
 Belt width

Belt widths are usually stated in millimeters

(mm) but sometimes in meters. Preferred
widths are internationally standardized
although other belt widths are available on
request. Standard widths in mm:
300, 400, 500, 600, 650, 800, 1000, 1200, 1400,
1600, 1800, 2000 and 2200
The permitted tolerances on standard belt
widths according to international standards
are:
Belt width 300-500 mm ± 5 mm
Belt width 600 or wider ± 1 %
 Belt thickness
 The total belt thickness of the belt is the
sum of both the top and bottom covers
and the thickness of the carcass. For
actual values please refer to the section of
this manual regarding relevant individual
belt types. The permitted tolerances of the
total belt thickness according to
international standards are:
 Belt thickness up to and including 10 mm:
± 1 mm
 Belt thickness over 10 mm: ± 10 %
 Cover thickness
 The actual thickness of the cover is an
important consideration in actual belt
selection. Generally speaking, the more
abrasive the material being carried and
 the shorter the conveyor, the thicker the
cover should be. However, covers that are
too thick can potentially cause other
problems. In principle, the difference in
thickness between the top cover and the
bottom cover should not exceed a ratio of
more than 3 to 1. The thickness of top and
bottom cover is stated in millimeters (mm).
The permitted tolerances of the cover
thickness according to international
standards for fabric belting are:
 Cover thickness up to and including 4 mm:
- 0.2 mm
 Cover thickness over 4 mm: - 5 %
 Surcharge angle
Due to undulations of the belt passing over the
conveyor idlers, the natural angle of repose of
the material is decreased. This decreased
angle known as ANGLE OF SURCHARGE.

Inclination angle
The angle of inclination of a conveyor changes
the carrying capacity. The load cross-section
area of an inclined load is reduced when
viewed in a vertical plane as the surcharge
angle is reduced perpendicular to the belt. An
approximation of the reduced capacity can
be determined by multiplying the horizontal
capacity by the Cosine of the inclination
 angle.

Troughing angle
For standard 3 roll idlers, the most common
trough angle is 35° although trough angles from
20° to 45° are not uncommon. Steeper trough
angles give increased capacity but can have
consequences for convex and concave curves
and transition zone.
 PROBLEM STATEMENT
 TO DESIGN A CONVEYOR
BELT FOR A FEROCHROME
PLANT TO LIFT IRON ORES TO
AN ELEVATION OF 20 METER
HEIGHT WITH A VELOCITY OF
BELT 3 METERS PER SECOND
AND OF A CARRYING
CAPACITY OF 20 TONNES PER
HOUR THROUGH A
HORIZONTAL DISTANCE OF 100
METERS.
 DESIGNCONSIDERATIONS
 DESIGNING THE SYSTEM FOR CONTINUOUS
FLOW OF MATERIALS.
  GOING IN FOR STANDARD EQUIPMENTS
WHICH ENSURES LOW INVESTMENTS AND
FLEXIBILITY.
 INCORPORATING GRAVITY FLOW IN THE
MATERIAL FLOW SYSTEM.
 ENSURING THAT THE RATIO OF THE DEAD
WEIGHT TO THE PAYLOAD OF MATERIAL
HANDLING EQUIPMENT IS MINIMUM.
 DESIGN PARAMETERS
 BELT MATERIAL SELECTION
 BELT DIMENSIONS
 BELT POWER AND TENSION
 IDLER SPACING
 PULLEY DIAMETER
 DESIGNING A CONVEYOR BELT

TO DESIGN AN ELEVATED INCLINED

CONVEYOR BELT TO CARRY IRON ORES IN A
FEROCHROME PLANT WE ASSUME THE
FOLLOWING DATAS-
 BELT WIDTH(B) = 0.6 m
 ANGLE OF REPOSE = 35˚
 ANGLE OF SURCHARGE = 25˚
 ANGLE OF TROUGH = 35˚
 IDLER DIAMETER = 152 mm
 BELT MATERIAL DENSITY =2200 Kg/𝑚3
 MASS OF MOVING PARTS OF BELT
CONVEYOR(Q) =41 Kg/m
  VELOCITY OF BELT = 3 m/s
[All Datas are taken from Fenner Dunlop
Design Data Handbook Ch-3, Page-3]
 BELT POWER CALCULATIONS


Putting following values in the

above equation,

FC = 0.0225
L=100 m
tf =60 m
C=20 tonnes/hr
H = 20m
Q =41 Kg/m
S= 3 m/s

We get, Power = 3.45 KW

 CALCULATION OF
FRICTIONS AND TENSIONS
 Putting the following values in the above
equations,
 Fe = 0.020
Fc = 0.0225
Q = 41 Kg/m
L = 100 m
tf = 60m
C = 20 tonnes/hr
H = 20 m
B = 0.6 m
K = 0.58 (for 240˚ angle of contact)
We get,
1.Return side friction = 0.3217 kN
2.Total empgty friction = 1.287 kN
3. Load friction = 0.072 kN
4. Load slope tension = 0.363 Kn
5. belt slope tension = 0.1177 kN
6. Effective tension = 1.722 kN
7.Slack side tension = 0.998 kN
8.Tight side tension = 2.844 kN

For Inclined Belts,

1. Maximum tension for drive at head

pulley,
Tmax = Te+ Belt slope tension – Return
 side friction + Tsag
=1.722 + 0.1177 – 0.3217 + 1.09
=2.608 kN

2. Maximum tension for drive at tail pulley,

Tmax = Te+T2 + Belt slope tension –
Return side friction
=1.722 + 0.998 + 0.1177 – 0.3217
=2.516 kN

 BELT MATERIAL SELECTION

 THE CARCASS MATERIAL IS SELECTED IN
ACCORDANCE TO THE REQUIREMENTS OF
A FEROCHROME PLANT SUCH AS VERY
GOOD IMPACT RESISTANCE AND HIGH RIP
RESISTANCE.
 SO THE SELECTED MATERIALS FOR WARP
AND WEFT ARE -
CARCASS TYPE – PN(315-375) [CROW’S
FOOT WEAVE]
WARP- POLYESTER
WEFT- NYLON
 NITRILE RUBBER (NBR) OF GRADE HIGH
TEMPERATURE NITRILE (Z-NITRILE) IS
SELECTED AS COVER MATERIAL DUE TO
 OPERATION RANGE OF HIGH
TEMPERATURE.
 BELT CARCASS SELECTION
 Required working tension =Tmax (kN)/Belt
width (B) in m
 =2.55/0.6
 =3.86 kN/m
 Belt width(taken)= 600 mm

From table 5,page 2.6,

Lump size for belt width 0.6 m is 125 mm.
Lump size = 0.125 m
As the selected Belt Material is PN(315-
375),with 2 piles ,i.e, PN 750/2 has an
allowable working tension = 56 kN/m
As here allowable working tension is greater
than the required working tension , so the
material selection is safe.
Also the maximum width associated with
PN(315-375)/2 piles is between 1000 mm to
1300 mm, so our belt width is in safe range.
[from table 2A and 2B ,page 4.4]
The maximum width associated with 35 ˚
trough angle from table 3
,is B=600 mm
So the belt width is safe from the viewpoint of
troughability.
 COVER GAUGES AND QUALITY
 Time cycle of conveyor = 2* L/S = 2 *100/3
= 66.66 s
 From table 1,page 5.2 of Fenner Dunlop
Design Data Handbook,Belt cover
thickness corresponding to the time cycle
of 66.66 s and lump size 125 mm is (5-8)
mm.
 It is taken as 6 mm.
 Pulley side cover > (¼) * carrying side
cover =1.5 mm
 Let the pulley side cover thickness = 3 mm
 CALCULATION OF BELT MASS
 From Fenner Dunlop Design Data
Handbook,page 8.4 table 1 for PN(315-
375) and PN(750/2), the belt carcass mass
is 6.0 Kg /𝑚2
 and belt thickness = [4.7+2*cover
thickness]
 From table 3 for heat resistance grade Hi
Temp Nitrile
 Carcass mass factor = 1.05
 Cover mass factor = 1.16
 So mass of carcass = 1.05*6.0 = 6.3 Kg/𝑚2
 Mass of belt cover = (top cover thickness+
bottom cover thickness)*belt cover mass
factor
 Belt thickness = 4.7+ 2*6 = 16.7 mm
 Mass of belt cover = 1.16* 12 = 13.92 Kg/𝑚2
 Mass of belt = 13.92 + 6.3 = 20.22 Kg/𝑚2
 Mass of belt per meter run = 20.22 *0.6
=12.132 Kg
 PULLEY DIAMETER
 We have to design both tight side pulley
and slack side pulley.
 High tension /Tight side pulley – type A
pulley
 Low tension /Slack side pulley – type B
pulley
 The parallel face pulleys should be used as
the belt material is high strength fabric.
 Pulley face width =(600+100)mm = 700 mm
(for belts upto 650 mm wide)
 From page (6.5) Fenner Dunlop Design
Data Handbook,using table 2A for PN
(315-375) and PN 750/2 Carcass, the
diameter of pulleys is 360 mm ,i.e, the tight
side pulley and the slack side pulley have
the same diameter,i.e, 360 mm for belts
operating at less than 30% of allowable
working tension.
 No crowning is needed as it will overstress
the carcass and damage the belt at the
centre and moreover, here we used idlers,
so there is no need of using crowned
pulleys.
 GRADUATED IDLER SPACING
 Live load = C/3.6S (Kg/m) = 20/3.6*3 =1.85
Kg/m
 ML = Mass of belt + live load
 =12.132 + 1.85 =13.982 Kg/m
 From Fenner Dunlop Design Data
Handbook, equation 3.26 –
 carrying idler spacing =(8*T*sag) /(ML
*9.81 *10−3 ) = 2.02 m
 sag is taken as 0.02 ,i.e, 2% here.
 So the corresponding belt tension required
to restrict the sag to 2% of idler spacing is
less than 4.51 KN
 Return idler spacing is taken as 3.0 m
approximately everytime
rd
 Impact idler spacing is 1/3 0f carrying
idler spacing ,i.e, 0.673 m.
 A TYPICAL 3D MODEL OF
BELT CONVEYOR
  REFERENCE
 Fenner Dunlop Design Data Handbook For
Belt Conveyor.
 R.S Khurmi Design Book.
 Wikipedia and various web resources.

 THE
END
THANK YOU FOR
WATCHING……