Design of Belt Conveyor system for material handling

- SoNAM M. GUJRATHI
ASSISTANT PROFESSOR,
SANJIVANI COLLEGE OF ENGINEERING,
KOPARGAON
Processes in material handling system
1.Picking Up the load
2.Transporting the Load
3.Setting the load down
It is said that “The best handling is the least
handling”
 Types of loads handled by MHS
1.Bulk Loads
It consists of large no. of homogenous particles or
lumps of any material.
E.g. Coal, Mineral Ore, sand, stone
2.Unit Load
It is rigid single mass, handled and transported as
a one piece
E.g. Machines, box, containers
 Containerization
The process of converting bulk loads into a unit
load by using containers, is known as
containerization.
Material Handling Equipments
 Guide lines in selections of material
handling equipments
1.Direction of load travel
2.Length of load travel
3.Type and properties of loads to be handled
4.Required load moving capacity
5.Characteristics of production process
6.Methods of stacking loads
7.Local conditions
8.Initial and operation cost
 Objectives of MHS
1.Accuracy In transporting loads to destinations
2.Precision in Pick up of loads
3.Transporting loads in scheduled time
4.Transporting loads in required time
5.Transporting loads without damage
6.Automation with minimum manpower
7.Low initial and operational cost
8.Simplicity and easy maintenance
9.Operational Safety
Classification of MHE
 HOISTING EQUIPMENT
• Group of devices with lifting gears
• Mainly used for unit loads
• Vertical as well as horizontal direction material
moving
• Types – 1. Hoisting machines
• 2. cranes
• 3. Elevators
• Example of hoisting machines – jacks, chain
pulleys, rope pulleys, portable hand hoists etc.
• Example of cranes – wall jib cranes, stationary
jib cranes with rotary pillars, travelling
cantilever wall cranes, electrically operated
overhead travelling cranes etc.
• Example of elevators – cage elevators, vertical
skip elevators, manually propelled stackers
etc.
 Types of Conveyors
1.Flat belt conveyors
2.Troughed belt conveyors
3.Blanket Belt conveyors
4.Woven wire belt conveyors
5.Chain Conveyors
6.Apron Conveyors
7Screw Conveyors
1Flat Belt and troughed belt
conveyors
ADVANTAGES OF FLAT BELT CONVEYOR
• Operated over long distances
• High material handling capacity
• Low frictional characteristic
• Light in weight and simple construction
• Min maintenance
 Troughed belt conveyor
• The width of flat belt conveyor limit vol
carrying capacity, by giving trough shape to
the belt by means of idlers, the vol carrying
capacity can be increased
• Nylon and polyester belts are used for
troughed belt
• Generally 3 idler type or 5 idler type
Troughed belt
3.Blanket belt conveyors(used for high
inclination)
• Previous 2 types can't be used for inclination
more than 35 degrees
• If inclination is more then material will slide
down in such case blanket belt conveyor is
used.
• It consists of main belt conveyor and auxiliary
conveyor
• Belt slope varies between 45 – 60 degrees.
 4.Woven Wire Belt Conveyors
Used in wovens, quenching baths, washing plants, drying
paint(stainless steel and mild steel wire)
5.Chain Conveyors
6.Screw conveyors
• The screw conveyors can carry hot as well as
wet materials. They can transport the material
from fine powder to animal feeds, coal to
slurries etc.
7. Apron Conveyor
• These type of conveyors are used constructed
of a series of parallel endless roller chains
running on tracks supported by frame.
• Usually handles heavy, large lumped, abrasive
and hot material.
 Requirement of good belt
1.Adequate strength
2.Good longitudinal and lateral flexibility
3.High Wear Resistance
4.Freedom from ply separation
5.Low elastic and permanent elongation
6.Low water absorption
7.Least affected by moisture
Components of conveyor belt
1.carcase :It is body of belt and take care of all
the forces acting on it.
Ex: Textile fabric carcase and steel cord carcase
2.Rubber covers:
Types of conveyor belt
1.Fabric Ply belts
Carcase of cotton, polyester, rayon polyamide etc.
belts: Thickness ranges from 5mm to 10 mm on higher side.
On lower side from 2 to 5 mm with no of plies 3 to 12
Can be operated by small pulleys
2.Steel Cord: Thickness varies from 5 to 10 m on higher side
and lower side from 2 to 5mm
 Conveyor pulleys
A conveyor arrangement uses following type of pulleys
1. Driving pulleys (head and tail pulleys)
2. Snub pulleys
3. Idlers
 Types of Drive and tail pulleys
1.Crown Face Type Pulley: 2. Wing Type Pulley:
Lagging increases the
friction coefficient.
 Snub pulleys
• To change the direction of the belt for various
reasons like:
• Increase in the angle of lap on drive and tail
pulleys
• Facilitating the loading and unloading
operations etc.
 Idlers
• Uses of idlers
1.To support conveyor belt along with load on
upper run
2.To support belt on lower run
3.To support the belt at loading point with
minimum wear
4.To align belt on pulleys
5.To give trough profile to belt
6.To change the shape of run from trough to flat
 Types of idlers
1.Roller type idlers with ball bearings:
-Used for light duty application
 Types of idlers continued……
2.Roller type Idlers with roller bearing:
Used for Heavy duty
 Types of idlers continued……
3.Rubber covered idlers
It has thin rubber sleeve is provided to avoid
the abrasive in case down side of drive where
dirt is present.
 Types of idlers continued……
4.Impact idlers:
5.Disc type idlers:
6.Spring type idlers:
 Belt take up Devices
1.Screw type take up:
Used to maintain
sufficient tension in
Belt.
 Belt take up Devices continued….
2.Vertical Gravity type Take up:
3.Horizontal type take up devices:
4.Winch operated:
 Capacity of conveyors
• The rate at which material is being carried out by the
conveyor is called as capacity of conveyor(volume
rate(m3 /s) and mass flow rate in kg/s)
• Effective belt width(b):It is the width of material
storage on belt
Let,
B=belt width(m)
b=(0.9B-0.05)m
v=belt speed (m/s)
Q=capacity of conveyor(m3 /s)
M=capacity of conveyor in kg/s
ρ= mass density of bulk material(kg/m3 )
 Capacity of horizontal belt conveyors
Q=Cb2 v(m3 /s) b=(0.9B-0.05)m
Mass capacity= ρQ
where C=surcharge factor
Capacity of Inclined belt conveyors
Q=kb2 v(m3 /s) b=(0.9B-0.05)m
Mass capacity= ρQ
where k=flowability factor
Conveyor belt speed
Factors affecting selection of conveyor
belt speed
1.Material to be conveyed
2.Inclination of convener
3.Type of belt
4.Conveyer length
5.Cost of set up
6.Maintanance cost
 Standard belt width and angle of
surcharge
• Belt
widths:400,500,450,600,650,750,800,900,1000,1200
,1400,1600,1800,2000,2200,2400 mm
• Factors affecting angle of Surcharge:
1.Material Type 2.Speed of conveyor belt 3.Type of
conveyor belt
 Head and tail pulley
Dmin =K1 K2 Zp
Where,
Dmin= Minimum Diameter of drive pulley,K1 =Material factor for
plies,K2=Belt tension and arc contact factor,Zp=No. of plies
 Continued for Head and tail pulley
Where

The pulleys are standardized on the basis of belt width.

For required belt width, the standard diameter is selected such that
it is greater than the minimum pulley diameter given by equation
Dmin =K1 K2 Zp
Length of pulley is given by,
Lp=length of pulley mm
B=width of pulley mm
S=side margin(60 to 75mm)
1.Follwing Data refers to a flat belt conveyor for
transporting crushed rock:
Mass density=2 ton/m3
Belt speed=1.75 m/s
Belt width=0.8m
K for surcharge angle 25 degree=2.35 x 10-4
Determine capacity of conveyor in ton/hr.
2.A horizontal belt conveyor is used for transporting
the bulk material having mass density
1200kg/m3.The surcharge factor C for the belt
width is 650mm.If Belt speed is
1.75m/s,determinr capacity of conveyor.
3.The horizontal flat conveyor is used for
transporting 500 metric ton of iron ore/Hr at belt
speed of 1.5m/s.The mass density of ore is
1800kg/m3 .if surcharge angle is 20
degree,determine the required belt width.
Thank you