2020 09/10/20

design data
Design Intent
15t/h to convey ssp and tsp

General Data Convayed Product Data

Material Characteristics Density
Phosphate, Pulverized
Phosphate, Broken 1200
Phosphate, Fertilizer 960
Phosphate, Sand, Cement 1360
Phosphate Rock 1200-1360
Phosphate Sand 1440-1600
Triple Super Phosphate (Calcium Phosphate (V)) 800-880

taken from initial calcuations

Value

From Mix Exit to Cutter Tip (Meters) 15

From Mix Exit to Cutter Tip (Feet) 49.2
Belt Width (Meters) 2.2
Inside Width (Meters) 1.83333333333333
Inside Width (Feet) 6.01333333333333
Block HT (Meters) 0.7
Block HT (Feet) 2.296
XSA Block SQM IF Square 1.28333333333333
Factor For Shape 0.4
XSA Block M2 Max 0.513333333333333
XSA Block SQFT Max 5.52264533333333
Vol Block CUFT 271.7141504
Vol Block CU/M (Meters) 7.69401530227948
Density SSP LB/CU FT (Feet) 80
Density SSP KG/M (Cubic Meters) 1281.44
WT Den Full Tons 9.7040768
Belt Speed M/Min (Meters/Min) 0.8
Belt Speed FT/Min (Feet/Min) 2.624
Res Time Min 18.75
TPH 31.05304576
Meters 3/H 24.1825593856

Drive Centres (Meters) 15

Drive Centres (Feet) 0.049212598425197
Length 2 Strands 0.098425196850394
Length Inc 8.2" For Drums 8.29842519685039
Total Length Belt (Feet) 16.5968503937008
KW Belt 11
 KW Mixer 7.5
KW Cutter 2.2
Total KW 20.7
KW/T 0.666601278341078
Design parameters
input data Value
Conveyor Capacity 1500
Belt Speed 0.3
Conveyor Height 0
Conveyor Length 15
Mass of a set of idlers 20
Idler Spacing 1.2
Load Due to belt 25
Inclination Angle of conveyor 0
Coefficient of Friction 0.02
Start-up factor 1.5
Drive Efficiency 0.9
Friction Factor 15
Breaking Strength loss factor 0.75
Grivtational Acceleration 9.81
Calculations
load due to the convayed materials 416.666666666667
load due to idlers 16.6666666666667
Belt Tension in steady state 2015.955
Belt Tension whilst starting the system 3023.9325
power at drive pulley 0.6047865
size of motor 0.671985
Acceleration 0.134397
belt breaking strength 40319.1
idler design
input data Value
capacity of conveyor 1500
Belt speed 0.3
belt tension near idler T1 50000
Ilder Length 1.2
Belt Sag 0.01
Weight of belt 15
Idler Speed 50
Grivtational Acceleration 9.81
Pi 3.14
Calculations (Flat idler)
weight of the conveyed mterial 1388.88888888889
Spacing of idlers 27.9509299564701
Diameter of idler 0.114649681528662
Total load acting on each idler 380831.42066
Maximum Bending Stress on Idlers 1128389.39453898
Belt Dimension, Capacity And speed
input data Value
 Belt Width 1200
Belt Speed 1.25
Roller Diameter 1800
Pi 3.14
belt capacity 2250000
belt sectional area 500
Material Density 1000
Mass of Material 52.5
Conveyor capacity 236.25

Capacity of Troughed Belts for 3 Roll equal length Ideler 175

Capacity Factor 1.08
Volumetric Belt Load
Load Capacity of belt conveyor
Specific Weight of the convayed material
no of revolutions per minute 13.2696390658174
The Conveyor length 1
inclination angle 100
Conveyor length 100
Conveyor height 10
Belt basic length 28
Roll Diameter for belt
core diameter
belt length
belt thickness
Number of wraps of the belt
Outside diameter of the roll
Diameter of roll centre
Belt power and tension
input data Value
Power @ drive pulley drum 3.624250422375
Total Tangential force at the periphery of the drive pulley

Power required for conveyor 3.7

Lift
Belt tension at steady state 2863.12786286905
Coefficient of Friction 0.02
Conveyor Length 14
Grivtational Acceleration 9.81
load due to idlers 170
Load Due to belt 177.5
load due to the convayed materials 18.88
inclination angle of conveyor 100
Vertical Height of conveyor 2
Belt Tension while starting 3.09217809189857
 Start-up factor 1.08
Incline belt the drive at head pulley is
Value
Drive @ head pulley
Drive @ Tail pulley
Effictive Tension 0.054524852
Total empty friction 0.00028032075
load friction 0.00996328125
Return side tension 7.848981E-05
Load slope Tention 0.04428125
Equipment friction factor 0.0225
Belt conveyor Capacity 6.5
Terminal Friction Constant 6
Weight of material and Belt 0.0635
Maximum Tension 1.5
Drive Factor
Tension @ a particular Point
Unitary Maximum Tension 0.0125
Belt power 0.068156065
Idler spacing
Value
Total Live Load 7.888
Live Load 78.88
Conveyor Length 100
Idler spacing @ any point 0
mass of belt @ live load 656.38
Percentage of the idler spacing 0.01
Pulley Diameter
Value
Pulley Wrap Length @ Terminals 5.024
Pulley Diameter 800
Effictive Pull 2899.4003379
Coefficient of Friction with support rollers 0.033
Coefficient of Friction with skid plate 0.33
Total load of convayed materials 78.88
mass of belt 577.7
mass of roll idlers 570
Acceleration 3.00604287066852
Belt Breaking Strength 15.1010434265625
Friction Factor 0.25
Breaking Strength Loss Factor 0.75
Motor
Value
Minimum Motor Power 4.02694491375
Efficiency of the reduction gear 0.9
Motor Horse Power
Horse power required
Horse Power Required to drive the conveyor empty
Horse Power Required to move material horizontally
Horse Power Required to elevate material
Torsional Moment
Force
Coefficient of Friction
no of revolutions per minute of motor
Power 1.43
Cycle Time of conveyor 44.8
Torque 0.521240458015267
Pulley Rpm 26.2
 Conversions
meter to feet 3.28
Pound/Cubic Foot to kilogram/ meters cubic 16.018
Cubic Foot to Cubic Meters 35.315

Material Characteristics
Surcharge Angle Units Symbol

15 kilogram per meter ^3

- kilogram per meter ^3
- kilogram per meter ^3
kilogram per meter ^3 ρ
kilogram per meter ^3 ρ
kilogram per meter ^3

Units Symbol Formular

meters
feet 15*3.28
meters B
meters B*(5/6)
feet 1.833*3.28
meters
feet 0.7*3.28
meters squared 1.833*0.7
unit less
meters squared 1.2833*0.4
square feet 0.5133*3.28^2
cubic feet 49.2*5.5226
cubic meters 271.714/35.315

tons per hour

 Units Symbol Formular
tons per hour CC
meters per second V
meters H
meters L
kg m'i
meters l'
kilo grams per meter mb
degrees δ
unitless f
unitless Ks
unitless Kd
unitless Cr
unitless Cv
meters per second ^2 g constant

kg/m mm (CC/3600)*1000
kg/m Mi m'i/l'
newtons Tb1.37*f*L*g*[2*mi+(2*mb+mm)*cos(δ)]+(H*g*mm)
newtons Tbs Tb*Ks
kilowatts Pp (Tb*V)/1000
kilowatts Pm Pp/Kd
meters/sec ^2 A (Tbs-Tb)/[L*(2*mi+2*mb+mm)]
newtons Bs (Cr*(Pp*1000))/Cv*V

Units Symbol Formular

tons per hour W
meters per second V
T1
meters L
meters H
kilo gram per meter Mb
rpm N
meters per second ^2 g constant
constant π constant

kilo gram per meter ML (10*W)/(36*V)

Meters S (8*T1*H)/(Mb+ML)*g
Meters D (60*V)/(π*N)
Newtons F (10*W*S*g)/(36*V)
Newton meter ^2 b (8*F*L)/(3*π*D3)

Units Symbol Formular

 mm
meters per second V
mm d
constant π constant
kg/sec B.C 3.6*A*ρ*V
M^2 A
kilogram per meter ^3 ρ
kilo grams Mm C/3.6*V
tons per hour C CT*ρ*Cf*V/1000

CT

unitless Cf
M3/H VL LC/C
tons per hour Lc
tons per Meter^3 W
rpm n V*1000*60/D*π
m horizontal distance / inclination angle
degrees ϴ
m
m
m 2*length along conveying route
D √d^2+(0.001273*L*G)
m d
m L (d+(D-d/2)*π*N)
mm G
N
m D'
m d'

Units Symbol Formular

kw Pp Fu*V/1000

N Fu Pp*1000/V

kw P
m L
N Ts1.37*f*L*g*[2*Mi+(2*Mb+mm)*cos(δ)]+(H*g*mm)
unitless f
meters L
meters per second ^2 g constant
kg Mi
kg Mb
kg Mm
degrees ϴ
meters H
N Tss Ts*Ks
 unitless Ks

Units Symbol Formular

Tmax
Tmax
kn Te
total empty friction + load friction + load slope tension
n Fe*(L+tf)*W*0.00981
n Fe*(L+tf)*c/3.6*V*0.00981
n Fe*W*L*0.4*0.00981
n C*H/3.6*V*0.00981
Fe
tons per hour C
m tf constant
kg/m W
kn Tmax (1+K)*T
K
T
kn Tumax Tmax*10/b
KW Pb Te*V

Units Symbol Formular

kn TL LL*Lc
kg LL
m LC
Is 8*T*Sg/Mρ*0.00991
kg/m Mρ
Sg

Units Symbol Formular

m 2*π*D/1000
mm D
N Fu μT*g(Mm+MB/2)+μR*g(Mi+MB/2)
μT
μR
kg Mm
kg MB
kg Mi
meters/sec ^2 A (Tss-Ts)/[L*(2*Mi+2*Mb+Mm)]
n Bbs Cr*Pp/Cv*V
unitless Cr
Cv

Units Symbol Formular

Kw Pmin PP/η
η
hPmin Hpreq/η
Hpreq Hpe+HPm+HPj
HPe
 HPm
HPj
Mt 1/2*D*(F+μWg)
N F
μ
n n=9500*1000*P/Mt
kw P
Ct 2L/V
KNm T 9.55*P/pully rpm
rpm
Material Characteristics
Abrasive Index Notes

2 https://www.renold.com/upload/renoldswitzerland/conve
3 TO BE USEED FOR ALL CALCS! https://www.renold.com/upload/renoldswitzerland/conve
2 Highly corrosive, gives off toxic fumes

Notes

conveying length
conveying length

inside width of belt

need to check Cake Lump height

lump size Cake Lump

cake shape factor taken from tables
cake block
cake block
cake volume
cake volume
 Notes
Working Capacity

Lift 0 as flat belt design

0 as flat belt design

m)*cos(δ)]+(H*g*mm)

2*mb+mm)]
value to be used to select the belt type from the manufactures catalouge

Notes

?
?
?

Notes
clination angle

eying route

Notes

m)*cos(δ)]+(H*g*mm)

Lift
 Notes

on + load slope tension

Notes

Notes

*g(Mi+MB/2)

*Mb+Mm)]

Notes
ext standard motor greater than Pmin will be sufficient
d/renoldswitzerland/conveyor_chain_-_designer_guide.pdf
d/renoldswitzerland/conveyor_chain_-_designer_guide.pdf

xsa cross sectional area

S.No Paramater Units Values
1 Belt Width mm 1200
2 Length of Conveyor m 14
3 Basic Belt Length m 28
4 Belt Speed m/sec 1.25
5 Angle of Inclination degree 100
6 Conveyor Capacity tons/hr 4
7 Belt Tension while Starting KN 1.15
8 Belt Tension at Steady State KN 1.5
9 Power at drive pulley kW 1.75
10 Minimum Motor power kW 1.25
11 Idler Spacing m 0.2
12 Diameter of pulley mm 2200
13 Belt power kW 1.43
14 Power required by conveyor kW 1.43
15 Belt thickness mm 1000
16 Torque KNm 1
17 Breaking Strength - 0.5
Belt Den Calcuations

Design Data

Convayed Material Properties Symbol Value Unit

Troughing Type
Working Capacity 750 TPH
Design Capacity Q 1000 TPH
Conveyed Material Name Phosphate, Rock, Pulverized
Density ρ 0.961 kg/m^3
Angle of Repose β 20 degrees
Temprature
Lump Size mm
Convayor Data & Geometry

Belt Width B 500 mm

Belt Speed
Conveying Length
Conveying Height (Lift)
Maximum Inclination Angle
Troughing Angle
Carrying Idlers Type
Roller Diameter
Return Idlers Type
Roller Length
Angle Of Wrap 1 At Pulley Drive 1
Angle Of Wrap At Snub Pulley 1
Angle Of Wrap 2 At Pulley Drive 2
Angle Of Wrap At Snub Pulley 2
v m/s
L m
H m
δ Degrees
λ Degrees
mm
mm
α1 Degrees
α12
Formular Notes
 Belt Den Calcuations

Design Data
Input Data
Installation Symbol
Troughing Type
Design Capacity Q
* Conveying Length / Belt Length L
* Conveying Height (Lift) H
* Belt Width B
Belt Speed v
Length of Middle Carrying Roll I
Troughing Angle λ
Inclination Angle / graident of flight δ
Cross Sectional Area of bulk solid on the Belt S
* Coefficient Factor (or Correction) CF

Material Symbol
Material Name
Density ρ
Maxiumum Particle Size A,max
Minimum Particle Size A,Min
Lump Size
Temprature 80-90
Angle of Repose βST
check Surcharge angle βDYN
Bulk weight
Moisture Content

Conveyor Belt Symbol

Friction Coefficient Of Pulleys μ
Friction Coefficient Of Pulleys at Start-Up μA
Angle Of Wrap 1 At Pulley Drive 1 α1
Angle Of Wrap At Snub Pulley 1 α12
Angle Of Wrap 2 At Pulley Drive 2 α2
Angle Of Wrap At Snub Pulley 2 α21
Drive Factor c1
Drive Factor at Start-Up c1A
Drive Factor At Pulley Drive 2 c2
Drive Factor At Pulley Drive 2 at Start-Up c2A

Factors Symbol
Graviational Acceleration g
Effective degree of filling

Design
Capacity Symbol

Power Requirements Symbol

Power for empty & load over the horizontal P1
Power for lift of fall P2
Power for trippers, skirtboard friction, ploughs P3
Power at Drive Pulley PT
Required Motor Pulley PM
Selected Motor PN
 Value Unit Formular
3 roll
15000 TPH
1500 m
0 m
2200 mm
1.38 m/s
800 mm Idler length if 3 or 5 roll
35 Degrees
Degrees
1630.09721236441 M2 0.1084*B^2.1473
1.05004343026075 (-0.0002*λ+0.0219)*βDYN+0.0408*λ^0.7903

Value Unit Formular

Phosphate, Rock, Pulverized
0.961
mm
mm
0 mm
Degrees C
25 Degrees
25

% by weight

Value Unit Formular

-
-
Degrees
Degrees
Degrees
Degrees

Value Unit Formular

9.81 m/s^2
Value Unit Formular

Value Unit Formular

kw
kw
kw
0 kw PT = P1+P2+P3
kw
kw
Notes

Use for analysis

Standard Table 1

Standard Table 3

if three rolls ?

Notes

Notes

Notes
Notes

Notes
common calulations for proper design

description
*head pully and tail same size
*if one pulley is lager than the other

*measured in feet per min (FPM)

at one time when the load is known per sqare foot

at one time when the load is known by pounds per hour

Horsepower

See Table

pull needed to move belt and load horrizontally

Additional tension required to prevent slippage on drive pulley
Total tension to move belt and load horizontally
Determines the working strength of the belt to handle the job on per inch of width basis
See Table
input data symbol Value units
Belt Length L 1021.9905 mm
Belt Length L 1198.76719529664 mm
Drive pulley Diameter D 8 mm
Tail pulley diameter d 6 mm
Pi π 3.1415 unitless
Center to center distance C 500 mm

Conveyor Speed S FPM

Revolutions Per Minute RPM

Belt Load P 0 lbs

Belt Load P lbs
Load per Square ft. (lbs.) G1
load per Hour (lbs.) G2
Belt Weight W inches

Level Conveyors HP
Inclined Conveyors HP
Coefficient of Friction F
Overall Belt Weight M

Effective Tension E lbs

Slack side tension E1 lbs
Tight side Tension E2 lbs
Operating Tension T lbs
Drive Factor K
formular http://www.sparksbelting.com/blog/understanding-conve
L = (D+d)/2 *π+ 2C
L = (D+d)/2 *π+ 2*C+(D-d)^2/4*C

S=D*RPM*.2618*1.021

P= G1 * C(in feet) * W(in feet)

P= G2/(S*60) * C (in feet)

HP=(F * S * (P+M))/33,000
HP=((P x B)+(P+M)* F * S)/33,000
See Tables http://www.sparksbelting.com/blog/understanding-conveyor-belt-calculations

E= F * (P+M)
E1=E * K
E2= E+E1
T= E2/W
See Tables
og/understanding-conveyor-belt-calculations

veyor-belt-calculations
Material Material Density (kg/m^3) Angle of Repose (Deg)
Aggregate 1442 20 Yes
Alumina 961 11 No
Betonite, 100 mesh 881 21
Cement, Clinker 1362 18
Cement, Portland 1362 19
Coal, Antracite sized 961 14
Coal, Bituminous ROM 881 19
Coal, Clean 801 18
Coal, Lignite 721 19
Coal, Powder river Basin 801 19
Coke, Petroleum 721 19
Copper Ore 2002 22
Corn 769 10
Cullet, Fines 1602 19
Earth, ROM Dry 1201 17
Earth, Wet with Clay 1682 22
Granite 1442 15
Gravel, Bank Run 1602 19
Gravel, Pebbles 1522 15
Gypsum 1201 15
Iron Ore 2403 18
Iron Ore Pellets 2002 22
Kaolin, Clay -3 1009 18
Kaolin, Clay, <3in. 1009 17
LIme, Hydrated 641 20
Limestone, Crushed 1442 19
Molybdenum Ore 1602 20
Overburden 1602 21
Phosphate, Rock 1362 15
Phosphate, Rock, Pulverized 961 20
Rice, Hulled 753 10
Sand, Dry Bank 1762 18
Sand, Foundry 1201 20
Taconite, Pellets 1922 20
Trona 2114 20
Wood Chips 400 22
Zinc Ore 2563 19
Material Material Bulk Density (kg/m^ Angle of Repose (Deg)
Angle of Repose (Deg)
 TABLE 1 TABLE 2
STANDARD IDLER DIA. (mm)
STANDARD WIDTH (mm)
Carrying Idlers Impact Idlers Return Idlers Support Idlers

300 51
400 63.5 120
500 88.9 138
650 108 156 150
800 133 180 180
1000 159 215 215
1200 193.7 250 250
1400 219.1 290 290
1600
1800
2000
2200

CALCULATION FOR START-UP kA

Motor/coupling type
Rigid Couplings
Flexible Coupling
Hydraulic Coupling

Location of Take-up
Installed at the Head
Installed at the Tail

Take-up Type
Fixed Take-up
Moveable Take-up
 TABLE 3 TABLE 4
STANDARD IDLER LENGTH (mm) STANDARD
ELECTRIC
Belt Width Troughing Type MOTOR (KW)
B (mm)
Flat 2 roll 3 roll Deeptrough 5 roll 1.5
300 380 200 - - - 2.2
400 500 250 160 - - 3
500 600 315 200 - - 4
600 700 340 250 - - 5.5
650 750 380 250 - - 7.5
800 950 465 315 200 165 11
1000 1150 600 380 250 205 15
1200 1400 700 465 315 250 18.5
1400 1600 800 530 380 290 22
1600 1800 900 600 465 340 30
1800 2000 1000 670 530 380 37
2000 2200 1100 750 600 420 45
2200 2500 1250 800 640 460 55
75
90
110
Garland (5 roll) 132
160
200
250
315
400
500
630
Additio
 TABLE 5 TABLE 6
MATERIAL CARCASE NOMINAL
BREAKING
SYMBOL PLY MATERIALS STRENGTH (N/mm)
B Cotton (Natural fibre) 125
P Polyamide (Synthetic fibre) 160
E Plyester (Synthetic fibre) 200
EP Plyester - Polyamide (Synthetic fibre) 250
D Aramid (Synthetic fibre) 315
F Steel Weave (Ferroflex) 400
ST Steel Cord (ST belt) 500
630
800
1000
1250
1600
2000
2500
Additional material properties affecting material flowability and conveyor belt capacity
 TABLE 7
COVER THICKNESS GAUGES (mm)
COVEYOR LOAD/DUTY CARRYING SIDE PULLEY SIDE

Light packayge conveying 2 2

Gravel, Earth, Potash etc. 2-4 2-3
Ore, Ballast, Coal 4-8 2-3
Slag 4-8 2-3
Coarse ballast, coarse Ore 8 - 12 3-5
Large lump Coal 8 - 12 3-5
nd conveyor belt capacity
 TABLE 8 TABLE 9 TABLE 10
COVER GRADE - DIN 22102 (April 1991) Pulley
Standard Pulley Diameter
COVER GRADE W X Y Z Diameter DTr (mm)
Tensile strength N/mm2 min. 18 25 20 15 100 100

Breaking elongation % 400 450 400 350 125 125

Abrasion loss mm3 max. 90 120 150 250 160 160

200 200

250 250

315 315

400 400

500 500

630 630

800 800

1000 1000

1250 1250

1400 1400

1600 1600

1800 1800

2000 2000
 TABLE 10 TABLE 11
Diameter Of Pulley Groups (mm) Drive location
A B C

100 - - Single Pulley Head Drive

125 100 - Tail Drive
160 125 100 Head and Tail Drive
200 160 125 Dual Pulley Head Drive
250 200 160

315 250 200

400 315 250 Tail Drive (Braking)

500 400 315

630 500 400

800 630 500

1000 800 630

1250 1000 800

1400 1250 1000

1600 1250 1000

1800 1400 1250

2000 1600 1250

100 3
c -