Industrial

Process
            

(CONVEYORS AND CONVEYING SYSTEM)

Activity 2

Prepared by:
Mendina, Darelle James M.

Instructor:
Engr. Augusto A. Avanceña
INTRODUCTION
A conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another. Conveyors are especially useful in applications involving
the transport of heavy or bulky materials. Conveyor systems allow quick and efficient transport
for a wide variety of materials, which make them very popular in the material
handling and packaging industries. They also have popular consumer applications, as they are
often found in supermarkets and airports, constituting the final leg of item/ bag delivery to
customers. Many kinds of conveying systems are available and are used according to the
various needs of different industries. There are chain conveyors (floor and overhead) as well.
Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand
pushed trolleys.

PROCESS INVOLVE IN HANDLING

Dry, granular solids can be conveyed in a number of ways. Two common devices
for transporting granular solids are the angular-pitch vibrating conveyor and the
horizontal differential-motion conveyor. The variability in the design and
performance between the two types stems from the differences in the kind of
motion required to move the mass in one direction. The most significant
difference between the two solids-conveying systems is the presence, or absence,
of motion in the plane normal (perpendicular) to the plane of the conveying
surface. Angular-pitch vibrating conveyor In its simplest form, the angular-pitch
vibrating conveyor consists of a trough with a mechanism to oscillate it. This type
of conveyor can typically be either a “brute-force” type or the natural-frequency
type. The majority of angular-pitch vibrating conveyors require vibration isolation
to prevent imparting unwanted vibrations to the surrounding support structure.
The typical operational frequencies of these conveyors are from 5 to 60 Hz, with
common pitch angles from 10 to 45 deg. Typical pitch displacements can range
from 0.03125 to 1.5 in. A brute-force type vibrating conveyor is one that relies
strictly on imparting a force to a mass to achieve.
These important factors are crucial to the selection process because the right
conveyor will:
• Improve operations by maximizing process efficiency
• Balance material flow through various systems
• Increase processing rates
• Reduce labor requirements
• Avoid back-ups and spillovers
• Offer a constant, controlled material flow
• Avoid unnecessary equipment maintenance or downtime
• Operate compatibly with other process equipment and systems
• Maintain high product quality The right conveyor should be able to supply
material at a rate that effectively matches the system’s processing capacity.
The conveyor’s size should also meet or exceed the capacity of the processing
machine center or equipment it is servicing. Listed below are common conveyors
used in powder handling and what to expect from each: Flexible screw conveyors
are the most common conveyor because of their low cost and size variety.
Flexible screw conveyors operate using a continuous shaftless helicoid screw that
moves almost any type of solid material through it. They typically operate on an
incline and can transport up to 80 feet. Standard sizes range from 2 in. to 8 in.
diameter and can convey up to 1,800 cfh. Flexible screw conveyors, however, are
typically used for smaller capacities. Flexible screw conveyors are cost-effective,
able to fit into tight spaces, easy to clean, low maintenance because of few
moving parts, smaller capacity, and offer flexible installations. But be aware that
flexible screw conveyors generally are impractical for long distances, and are not
self-cleaning. These conveyors also must run fully charged. Pneumatic/Vacuum. In
this type of conveying, the solid is carried by a gaseous stream, which imposes a
pressure gradient along the conveyor line. Pneumatic/vacuum conveyors can
move almost any type of dry material and offers moderate degradation,
depending on the product and the number and degree of conveyor bends.
Pneumatic/vacuum conveyors are best suited for high capacity applications over
distances of up to about 400 feet. Pneumatic conveying is also appropriate for
multiple sources and destinations. Vacuum or low pressure is used for generating
air velocities from 35 to 120 ft/s. Pneumatic/vacuum conveyors are dust-tight, can
operate at varying volume levels, are compact, sanitary, and offer self-contained
filtration. The disadvantages are higher power consumption and higher
installation costs.

A tubular drag chain conveyor consists of a tubular steel casing that carries a
“flighted” chain that catches material and pulls it along the conveyor. Tubular
drag chain conveyors operate best at low to medium volume, work well with wet,
dry or fragile material, and offer low degradation. Tubular drag conveyors are
completely enclosed and suited to convey up to 150 ft. Sizes range from 3 in. to
12 in. diameter. Travel velocities can range from 30 feet to 100 feet per minute
with conveying capacities up to 70 cfm. Tubular drag chain conveyors are quiet
and require minimal maintenance. Other advantages include gentle handling, low
degradation, high capacity, heavy duty 24/7 operation, are dust free, and can
convey at different planes – allowing for great flexibility in system layout. The
disadvantage: the higher capital costs associated with it, especially where long
distances are involved. Also, power requirements are slightly higher than other
types. On the other hand, the versatility and ability to handle diverse materials
under various temperatures and pressure conditions far outweigh the
disadvantages.

Aeromechanical conveying utilizes the features of both pneumatic and

mechanical conveying. The aeromechanical tubular design uses a wire rope
assembly with evenly spaced polyurethane discs that move at high speed. The
rope assembly runs in specially designed sprockets at each end of the conveyor.
The action of the rope assembly traveling at high speed creates an air stream
running at the same velocity. As the material is fed into the air stream, it is
fluidized and conveyed to the outlet where it is centrifugally ejected.
Aeromechanical conveyors can convey almost any type of material. The conveyor
has the capability of bending at 90° angles. This allows many system layout
options, which optimizes available factory space.
The disadvantages: aeromechanical conveyors cannot start or stop under a full
load, suffers from rope fatigue, and requires a metered feed.

Vibrating conveyors consist of a flat-bottomed metal trough that transports

material through controlled vibrations. But what vibratory conveyor is right for
your application? There are many factors involved in the selection. The No. 1
most important factor: the material being processed. What is the size? Is it fine?
Mid-sized? Coarse? Also, what is the moisture content? Product moisture content
may cause severe feeding problems because moisture increases surface tension
and material tends to build up on the surface. Another factor to consider is
product weight and density. Lighter materials do not have as much mass and feed
more slowly than heavier products. Thirdly, how flexible is the product? Rigid or
solid products feed more successfully than other less-flexible product. A vibrating
conveyor can handle multiple processing tasks and convey dry, hot or cold
materials over long distances but may require high maintenance due to the
vibrations. As you can see, there are many factors and considerations that go into
choosing the right conveyor for your operation and application. But with careful
thought, research and planning, the right conveyor will give you the best results,
improve operations, reduce labor, operate compatibly with other equipment and
systems, and much more.

Belt

Belt Conveyors are material handling systems that use continuous belts to convey
products or material. The belt is extended in an endless loop between two end-
pulleys.  Usually, one or both ends have a roll underneath. The conveyor belting is
supported by either a metal slider pan for light loads where no friction would be
applied to the belt to cause drag or on rollers. Power is provided by motors that
use either variable or constant speed reduction gears.The belts themselves can be
made from numerous materials, which should correspond to the conditions under
which the belt will be operating. Common conveyor belting materials include
rubber, plastic, leather, fabric, and metal. Transporting a heavier load means a
thicker and stronger construction of conveyor belting material is required. Belt
conveyors are typically powered and can be operated at various speeds
depending on the throughput required. The conveyors can be operated
horizontally or can be inclined as well. Belt conveyors can be troughed for bulk or
large materials.

Roller Conveyor Systems

Roller Conveyors use parallel rollers mounted in frames to convey product either

by gravity or manually. Key specifications include the roller diameter and axle
center dimensions. Roller conveyors are used primarily in material handling
applications such as on loading docks, for baggage handling, or on assembly
lines among many others. The rollers are not powered and use gravity, if inclined,
to move the product, or manually if mounted horizontally. The conveyors can be
straight or curved depending on the application and available floor space.

Powered Roller

Powered Roller Conveyors use powered rollers mounted in frames to convey

products. Key specifications include the drive type, roller diameter and material,
and the axle center dimension. Powered roller conveyors are used primarily in
material handling applications that require the powered conveyance of the
product. Various drive types include belts, chains/sprockets, and motorized
rollers. Some of the uses of powered roller conveyors are food handling,
steelmaking and, packaging.

Slat Belt Conveyor/Apron

Apron/Slat Conveyors use slats or plates made of steel, wood, or other materials

typically mounted on roller chains to convey product. The slats are not
interlocked or overlapping. Apron/slat conveyors are used primarily in material
handling applications for moving large, heavy objects including crates, drums, or
pallets in heavy-industry settings such as foundries and steel mills. The use of slats
in heavy duty use cases prolongs the service life of the conveyor over other
conveyor types that employ belts, which would wear out quicker under the
exposure to heavy loads. These conveyor systems are usually powered and come
in many sizes and load capacities.

Ball Transfer Conveyor

Ball Transfer tables or conveyors use a series of mounted ball casters to allow for
unpowered, multi-directional conveyance of the product. Key specifications
include the ball material and size. Ball transfer conveyors are used in material
handling applications such as assembly lines and packaging lines, among others.
When positioned where multiple conveyor lines meet, they are used to transfer
products from one line to another and are often used in sorting systems. Many
sizes and load carrying capacities are available. Ball transfer conveyors are not
powered and rely on external forces to move the product along the conveyor.

Magnetic

Magnetic Conveyors use moving magnets mounted beneath stationary plates,

tables, or other kinds of non-magnetic slider beds, to move magnetic (ferrous)
materials, often in the form of machining scrap. Magnetic conveyors are
commonly used as chip conveyors to remove ferrous chips from machining
centers. Systems can be configured to use horizontal motion, vertical motion, or
combinations. They can be beltless or may use a conveying belt instead of a slider
bed. Underneath the conveying belt, a rail containing an electromagnet is used to
attract ferrous materials to the belt. Because of the magnetic attraction of the
product to the conveyor, these systems can also be used upside down.

Bucket

Bucket Conveyors or bucket elevators use multi-sided containers attached to

cables, belts, or chains to convey products or materials. The containers remain
upright along the system and are tipped to release material. Bucket conveyors are
used in applications such as parts, bulk material, or food processing and handling.
The conveyed material can be in liquid form or dry such as sludge, sand, manure,
sugar, and grain. The systems can be used horizontally or can be inclined or
vertical to change levels of the delivered products. Many sizes and load carrying
capacities are available depending on the application.

Chute

Chute or Trough Conveyors are material handling systems that use gravity to

convey product along smooth surfaces from one level to another. Key
specifications include the chute material and the physical dimensions such as
length and chute width. Chute conveyors are used for scrap handling, packaging,
postal service package or mail handling, etc.  Chutes are designed to have a low
coefficient of dynamic friction, allowing the product or material to slide easily,
and can be straight or curved depending on the needs of the application.

Chain/Tow/Drag Line Conveyor

Drag/Chain/Tow Conveyors use mechanical devices attached to moving members,

usually chains or cables, to drag or tow products. Drag conveyors are used for
moving bulk materials in bins, flights, or other attachments and can have multiple
discharge or loading points. Tubular drag conveyors use a fully enclosed system of
chains to convey product in any direction. Chain conveyors use a chain, or
multiple chains to move pallets or other hard-to-convey products. Tow
conveyors use a towline such as cables or chains, usually in the floor or just above
it, to tow product directly or to tow wheeled carts or dollies.

Overhead

Overhead Conveyors are mounted from ceilings that use trolleys or carriers
moved by chains, cables, or similar connections. Overhead conveyors are
primarily used in material handling applications where the product needs to be
hung, such as dry-cleaning garment lines, paint lines, or parts handling systems, or
for cooling and curing. Various types of overhead conveyor
systems configurations are available including electric track, monorail, trolley, as
well as inclined or ramped. Depending on the application, the load-carrying
capacity may be critical. Most overhead conveyors systems are powered and
controlled, while others are hand-operated conveyor belts.

Pneumatic/Vacuum

Pneumatic/Vacuum Conveyors use air pressure or vacuum to transport materials

or items in or through closed tubes or ducts or along surfaces. Pneumatic/vacuum
conveyors are used primarily in materials handling applications such as dust
collection, paper handling, ticket delivery, etc. and in processes such as chemical,
mineral, scrap, and food. Materials for the conveyors can be metallic or non-
metallic depending on the media being conveyed. Various sizes are available
depending on the load and throughput requirements. 

EQUIPMENT INVOLVED IN HANDLING SOLIDS:

Conveyor belting
• The belt is an endless moving rubber covered conveyor for transporting
materials.
• The belt conveyor is made of special wear and impact resisting rubber
compound with cord breaker strip impeded in tough rubber. 
 Belt idlers
• The idlers are used to carry and train the belt.
• Idlers must be selected to properly protect and support the belt and load
to be carried.
• The types of belt idlers with in the series include 20 degree and 45 degree
toughing cushion, belt training, flat belt and return idlers.
 Drives
• The drive equipment used for transmitting power from the motor to the
driving pulley or pulleys.
• Practically all belt conveyors are driven by an electric motor directly
connected to a speed reducer unit through a flexible coupling.

Take – ups
• The take – ups used to maintain the slack side tension
• Every belt conveyors must be equipped with a take – ups to: – Allow for
stretch and shrinkage of the belt due to variation of temperature and
atmospheric pressure. – Insure that the maximum tension in the belt is
sufficient to prevent undue sag between idlers. – Insure that the tension in
the belt in the back of the drive pulley is sufficient to permit such pulley to
transmit the load.
The basic types of take – up used for belt conveyors are automatic counter
weighted types(a and b) and manually adjusted screw types (c) for vertical
or horizontal travel.
 Pulleys, shafts and bearings
• The pulleys with their shafts and bearing used to drive the belt and
change its direction of travel. 6. Supporting structure
• The structure is which supports and maintain alignment of idlers, pulleys
and the drive.
• The adhesion ( wheel grip) between the belt and the driving pulley can be
increased by i. Changing the pulley ii. Increasing the arc of contact iii.
Using stretchers(take – ups)
Types of Belt conveyors (a) Flat Belt Conveyor :
• In this conveyor, the active side of belt remains flat supported by
cylindrical rollers or flat slider bed. • The conveyor is generally short in
length and suitable for conveying unit loads like crates, boxes, packages,
etc. in manufacturing, shipping, warehousing and assembly operations. 
Troughed Belt Conveyor :
• In this conveyor, comparatively wide flat belt is supported on troughed
carrying rollers or shaped supporting surface so that the two edges of the
active side of the belt are elevated from the middle part to form a trough.
• This provides a greater carrying capacity than a flat belt of equal width for
conveying bulk materials or those materials which would slide off flat belts.
• These conveyors are used in handling bulk materials of different classes.
Closed Belt Conveyor:
• In a closed belt conveyor, the specially fabricated belt, after being loaded
with the material, can be wrapped completely around the load.
• It essentially forms a closed tube moving along with the material. The
advantages of a closed belt conveyor are: i. it can handle fragile materials
safely and without breaking by reducing inter particle collision, ii. it can
handle fine bulk materials without being swept by air (however, it is not
really air tight at loading and unloading points), iii. ability to handle
corrosive and reactive materials without contamination and iv. the tubed
belt can travel around bends in more than one plane.
APPLICATION:
Conveyor selection depends on product type, throughput or speed, elevation
change, and in some cases, industry focus. Belt conveyors, for instance, come in a
variety of sizes and can range from foot-long units used on packaging lines to
mile-long systems used for mining operations. Conveyors can be hand powered—
where products are moved along manually over rollers or wheels—or
engine/motor powered, or gravity powered. In general, though, they are driven
by AC and DC motors, either directly or through reduction gears, chains, and
sprockets, etc. Products generally ride on the top surfaces of conveyors, though
exceptions exist.

SAFETY PROTOCOLS
There are many hazards associated with working at or near a conveyor, including:

 Rotating parts or pinch points can drag in, crush or entangle

 Confinement or assembly areas (the area between a fixed object and a
moving one) can shear or crush
 Parts that slide or reciprocate (press down) can crush or shear
 Items can break or be ejected (thrown from) the conveyor system
 Items can fall off the conveyor
 Electrical, fire or explosion hazards

When working near any conveyor:

Do

 Wear hard hat and safety shoes.

 Tie back (and tuck in) long hair.
 Know the location of the emergency "shut-off" devices and how to use
them.
 Make sure all safeguards and guards including cages, barriers,
guardrails, warning signals, and other safety devices that are required
are in place and operational.
 Know how to work near machinery safely.

Do Not

 Do not wear loose clothing or jewellery.

 Do not climb, step, sit or ride on the conveyors.
 Do not alter or remove guards or safety devices.
 Do not try to remove stuck items or debris until the conveyor is locked
out.
 Do not service the conveyor without following lock-out procedures.

What are some safety tips for working near a gravity conveyor?
Gravity conveyors include those that have rollers, wheels or chutes where objects
move by gravity or momentum only.
Do

 Guard pinch points on rollers and wheels and between the conveyor and
receiving table.
 Provide adequate guardrails along sides to prevent all objects from
falling off.
 Provide retarders (friction areas) if heavy objects are conveyed.
 Ensure there are warning devices near the receiving areas if you cannot
see the packages moving on the conveyor.
 Ensure draft checks (fire doors) are installed where conveyors pass
through fire walls or floors.
What are some tips when working at a "powered" conveyor?
"Powered" or "power" conveyors include the use of belts, live rollers, slats, or
buckets.
Do

 Position yourself so that you are not hit by objects moving down the
conveyor.
 Ensure that you can see the conveyor system when you are at the
operating controls.
 Ensure that guards are in place for all moving parts of the drive system
and in all zones where hazards such as in-running nip, drawing-in,
trapping and crushing, friction burns or abrasion are present (includes
above, sides, and below the conveyor).
 Guard all pinch points between the conveyor system and fixed objects.
 Locate guardrails around low level conveyors and areas where
conveyors pass through the floor/ceiling.
 Locate emergency stop cut-off switches near the operator and along the
length of the conveyor at approximately 30 meters (100 feet) apart (or
closer).
 Ground belts on belt conveyors to prevent static buildup.

What are additional tips when working with other types of conveyors?
When working with aerial conveyors:

 Make sure that guards and protection plates are in place to protect
people working below from falling objects.

When working with bucket conveyors:

 Make sure that both vertical and horizontal bucket conveyors are totally
enclosed.

When working with pneumatic conveyors:

  Familiarize yourself with control devices and release valves to cut off air
flow in the event of blockage.
 Shield joints and access points to prevent material from being thrown in
the event of gasket failure.
 Ensure that screening is in place at the suction end to prevent large
objects from being sucked in.

When working with portable conveyors:

 Use only weatherproof electrical components.

 Make sure power cables are located where they will not be walked on or
run over.
 Make sure that sideboards are high enough to prevent large items from
falling and smaller items from being thrown by the wind.
 Chock the wheels on trucks and rail cars that are being loaded or
emptied by portable conveyors.
 Do not exceed the rated load capacity of the conveyor.

When working with movable conveyors:

 Install barrier guards, guardrails and/or mark the ground to indicate

operating area of the conveyor.

REFERENCES:
https://www.thomasnet.com/articles/materials-handling/understanding-
conveyor-systems/
https://www.chemicalprocessing.com/assets/wp_downloads/pdf/CP09_Hapman
ReportV2.pdf
https://www.chemengonline.com/solids-conveying/
https://en.wikipedia.org/wiki/Conveyor_system
https://www.slideshare.net/AmanuelDiriba/lecture-4-material-handling-
equipment