Design of belt conveyor 1. Introduction to material handling equipments In any industrial process, the product being manufactured passes through various phases and it needs to be transported from place to place. This could involve processes such as transporting of raw material to the machines and then shifting the machines from one station to another station and finally to the store or warehouse, This involves the use of material handling equipment. Simplest form of material handling is to take material from one place to another place manually or with the help of worker. In large production setups, where the production rates are high and the product to be handled is such that manual transportation is not possible, sophisticated material handling systems would be required Material handling system does not contribute directly to the product value, but it adds to the cost of the product and is therefore sometimes is referred to as a necessary evil. In fact, least handling is the best handling. 4.4 Bas objectives These basic objectives that a material handling system should fulfill are: 1. Quick and precise pick-up of loads Quick and efficient transfer of load with planned time interval. Transport of loads in planned quantity. Safe transport without any damage. Accuracy in delivering at the destination. Automation with minimum human element. Low initial and operational costs. Simple and easy to maintain, PP nNEARen Safe operationDesign of belt conveyor 4.2. classifications The material handling system, based on design and operational characteristics can be broadly classified in to three groups as shown below: Material handling equipment Hoisting equipment a) Pure hoisting equipment: jacks, winches, pulley blocks etc. b) Cranes: EOT cranes, jib cranes etc. ©) Elevators: lift elevator, bucket elevator etc. Il. Conveying equipment: Belt conveyors, Chain conveyors, Screw conveyors, Apron conveyors. Ill, Surface and overhead equipment: Fork lifts, Trucks, Railway cars, Overhead mono- rails. 1.3 Basic principles of selecting material handling system 1. Direction of load travel Length of load travel. Properties and characteristics of the material being handled. The rate of flow of material Kind of the production process. Method of loading and unloading. Existing layout and conditions of the work space. SNEAReND Initial and operational costs.Design of belt conveyor 1.4. Some important material handling system 1.4.1 Conveyor + Belt Conveyor + Apron Feeder + Screw Conveyor + Deep Pan Conveyor + Drag Chain Conveyor + Flexowell Conveyor + Rope way Trolley + Skip Charging System 1.4.2. Stacker Reclaimer + Linear stacker Reclaimer + Bridge type reclaimer + Circular stacker cum reclaimer + Bucket wheel stacker cum reclaimer 1.4.3, Wagon tippler + Side discharge + Central discharge 1.4.4 Vibro Screen + Linear movement + Circular movementDesign of belt conveyor 2. Belt conveyors A belt conveyor consists of an endless belt of a resilient material connected between two pulleys and moved by rotating one of the pulleys through a drive unit gearbox, which is connected to an electric motor. The driving pulley end is called as head end, and the pulley is called as head pulley. Conversely, the other pulley is at the tail end and is referred to as the tail pulley as shown in figure 2 Material is conveyed by placing it on the belt, through a feeder. As the belt rotates, the material is carried with it on the other end, where it is then dropped in the discharge chute. It should be noted that discharge can be arranged at any point along the run by means of special discharge devices. As the belt rotates, due to the weight of the belt and the conveyed material, the belt will sag. To support this sag, rollers called as idlers or idler pulleys are placed on both sides (carrying side and the return side). Closely spaced idlers are placed at the loading point, as there is some impact due to the falling material and overcrowding of the material in this region. The belt is subjected to tension an it being from a resilient material is prone to elongation. This reduces the tension in the belts. Reduction in tension causes slackness of the belt on the pulleys resulting in slippage and loss in power. To compensate for this, a tensioning device called as take-up arrangement is used. TRANSITION IDLERS. TROUGHED IDLERS RETURN IDLERS. Figure 2. Belt conveyorDesign of belt conveyor 2.1 Types of belt conveyors VIL Channel Stringer Belt Conveyors |. Truss Frame Conveyors Slider Bed Belt Conveyors U-Trough Belt Conveyors Flat Slide Belt Conveyors Totally Enclosed Belt Conveyors Custom engineering conveyors 2.2 Advantages of belt conveyor over other system Ren Can be operated over long distances over any kind of terrain Having high load carrying capacity and carry all kinds of loads. Noiseless as compared to chain conveyors. Much simpler to maintain and don't require any major lubrication system like chain conveyors. Their reliability has been proved over a long period by its use in the industry. Environmentally more acceptable Low labor and low energy requirements. Unlike screw conveyors, belt conveyors can be easily used for performing processes functions in a production lineDesign of belt conveyor 2.3 Types of conveyor layout (A) Horizontal (B) Inclined upwards (C) Inclined upwards — Horizontal (D) Horizontal- Inclined upwards (E) Horizontal Inclined Horizontal (F) Inclined Horizontal InclinedDesign of belt conveyor 2.4 Methods of loading and discharging Consideration of assumption: 1) The material should be placed centrally on the belt. 2) The material should be fed in the direction of belt travel and at a speed as near as possible to that of the belt. ‘A) Hopper based loading B) Processing unit based loading C) Loading from a preceding conveyor i) Head and discharge il) Both end discharge ii) Plow discharge D) Tripper discharge 2.5 Major equipments of belt conveyor i. Conveyor Belt ji, Pulleys ili, Idlers iv. Coupling v. Bearing vi. Drive unit vii. Electric motor viii, Cleaning deviceDesign of belt conveyor 2.6 Requirement of belt which is to be used in belt conveyor 2.6.1 High strength: The belt is subjected to tensile loads. It is also subjected to other loads due to scrapers, plows. The material fed also creates an impact load on the belt, All these conditions require the belt to have high strength 2.6.2 Low self weight: The belt is continuously driven on the pulleys, The power requirement to drive this belt is dependent on its weight. 2.6.3. High wear resistance: The belts are subjected to rough working conditions over a long period of time. Besides this, scrapers, plows, and other cleaners further create wear as they rub over the belt surface. The belt should thus have a high wear resistance to survive in tough conditions. 2.6.4 Low elastic and permanent elongation: Any elongation in the belt reduces the tension created in the belt. This would reduce the power transmitting capacity of the belt should have a low elastic and permanent elongation. 2.6.5. Flexibility: They should have a good flexibility in the longitudinal and lateral planes. In many cases, belts are made to run over many pulleys. The belt material should have the necessary flexibility to mould over the idlers. 2.6.6 High resistance to ply separation: Belts are made from plies, which are bonded with a rubber element. The bonding of the plies should be such that it doesn't separate out due to the repeated bending of the belt over the pulleys. 2.6.7 Low water absorption capability: Water if it gets absorbed by the belt increases the weight of the belt. This would result in increased power consumption and reduced conveying capability. It also gives more dimensional stability of the beltDesign of belt conveyor 2.6.8 Suitable working environmental conditions: Humidity, extreme heat or cold. The belt material should be good enough to ensure that it works with optimum results under such working environmental conditions. 27 Introduction to Troughed Belt Conveyor: There are many possible variations in the design of a troughed belt conveyor depending on the purpose and duty for which the conveyor is being designed. Similarly the choice of individual components, features and accessories found on a conveyor should be selected on the basis of the functions which have to be performed by the conveyor. Troughed belt conveyors offer an efficient means of transporting materials in large quantities (bulk), over distances ranging from a few meters to several kilometers, continuously As will be seen below, troughed belt conveyors are only one of the types of belt conveyors available in the market today however, the troughed belt conveyor takes numerous forms and is used in many different applications with tremendous success. It is important to draw a distinction between bulk handling of materials and unit handling. The former refers to the transportation of particulate product(s) on a continuous basis for example, the conveying of lumpy ore from a mine to a processing plant or for transporting coal from a stockyard to a bunker above a crusher. "Unit handling’ on the other hand is generally described as discontinuous as this involves the transportation of for example, packed boxes, filled bags of cement and so forth ‘A troughed belt conveyor as described in this refers to conveyors which are used to convey product in bulkDesign of belt conveyor 2.7.4 Types of Troughed Belt Conveyors The term ‘'troughed’ belt conveyor originates from the form of the carrying belt within the supporting idler sets and differentiates this conveyor from alternative bulk handling belt conveyor types which include ‘Pipe’, 'Sicon’, ‘Sandwich’, 'Pocket or Sidewall’, 'Cablebelt’ “Square’, 'U-con' conveyors, etc Examples of these different types of conveyors can be seen below. Th) ih) pare |@| The type of conveyor to be used in any particular application depends on a number of factors including the conveying route, properties of the material to be transported, environmental considerations ete.Design of belt conveyor 3. Conveyor belt Conveyor belt is made up of compounds comprised of natural rubbers, styrene-butadiene rubber blends of natural and other synthetics, nitriles, butyl, ethylene propylene-based polymer, polychloroprene, polybutadiene, polyvinyl chloride, urethanes and silicones, etc., Each of those elastomers has specific usefulness for various ranges of properties and operating conditions from which manufacturers and end-users can choose. Nylon or EP Belt Steel cord Conveyor belting and its corresponding cover composition can be designated as either (1) General Purpose Belting, or (2) Special Purpose Belting. Each of these two broadly classified groups should be further defined depending upon the specific end use. 3.1 Constructional details Conveyor belts generally are composed of three main components: 1) Carcass 2) Skims 3) CoversDesign of belt conveyor 3.1.1. Carcass: The reinforcement usually found on the inside of a conveyor belt is referred to as the carcass. The functions of a carcass include the following Provide the tensile strength necessary to move the loaded belt. ‘+ Absorbs the impact of the impinging material being loaded on to the conveyor belt. * Provide the bulk and lateral stiffness required for the load support. ‘+ Belts are connected at the ends by splicing them with belt fasteners. The carcass should provide the necessary strength to hold fasteners. The carcass is normally rated by the manufacturer in terms of maximum permissible operating tension. The carcass can of two major types: 1. Fabric ply type 2. Steel cord type 3.1.2 Skims: The rubber, PVC or urethane between the plies is called as skim. Skims are important contributors to intemal belt adhesions, impact resistance and play a significant role in determining the belt load support and trough ability. Improper skims can give reverse effect too. It can lead to ply separation failureDesign of belt conveyor 3.1.3 Covers: They are used in conveyor belt construction to protect the conveyor belt carcass and also to extend its service life. Its desirable properties such as: Textures. Clean ability A specific co-efficient of friction Cut resistance, Enhanced impact resistance. Hardness. ) ) ) 4) Aspecific color ) ) ) }) Fire, oil and chemical resistance.Design of belt conveyor 4. Conveyor pulley The most commonly used conveyor pulley is the standard steel pulley. They are manufactured in a wide range of sizes and consist of a continuous rim and two end discs fitted with compression type hubs. In most wide faced conveyors pulleys, intermediated stiffening discs are welded inside the rim. Outer pulleys available are self cleaning wing types, which are used at the tail, take up or snub locations where materials tends to built up on the pulley face, and magnetic types which are used to remove tramp iron from the material being conveyed. 4.1, Conveyor Pulley Assemblies Conveyor pulley construction has progressed from fabricated wood, through cast iron, to present welded steel fabrication. Increased use of belt conveyor has led industry away from custom-made pulleys to the development of standard steel pulleys with universally accepted size range, construction similarities, and substantially uniform load carrying capacity for use with belts having a carcass composed of plies or layers of fabric. “Standard” drum and wing pulleys are suitable for these applications. The present trend, however, is to use higher tonnage conveyor system with wider, stronger belts that incorporate a carcass of either steel cables or high strength tensile members. In these applications, where high tensions are encountered, the use of custom made “engineered” welded steel pulleys is dictated. 4.2. Type of pulley based on fabrication 1, Typical welded steel pulley. Fabricated curve crown pulley. ‘Spun end curve crown pulley. Lagged welded steel pulley. Welded steel pulley with grooved lagging Slide-lagged pulley. Lagged wing pulley. PNOARON Fabricated wing type pulley.Design of belt conveyor 4.3. Type of pulley based on Function 1) 2) Snub pulleys 3) Idlers a) Carrying idlers. b) Retum idlers. ing pulleys (Head and Tail pulleys) 4.3.1 Head pulley Normally the discharge end of the conveyor where the material is transferred to another conveyor is called as the Head end and the pulley in this end is called the head pulley. Most of the cases the drive is attached to the Head end of the pulley and so head pulley will designed stronger and bigger when compared to others. Head pullley is rubber lagged to increase the grip or friction between belt and Pulley. Figure: Head PulleyDesign of belt conveyor 432 Tail pulley The pulley which is situated in the receiving end of the conveyor is called as tail pulley. Some times Screw take-up will be situated in this pulley. This pulley is movable when take up is kept in this. When belt takes a turn for take-up arrangement or for any other drive arrangement this term comes. This acts as a support when belt takes a turn. 4.3.3. Snub pulley ‘Snub pulleys are incorporated into the design of a conveyor in order to increase the angle of wrap of the belt on the drive pulley. The greater wrap angle on the pulley allows more power to be introduced into the belt as is passes around the drive pulley without slip ‘occurring, In this way, fewer drives are needed on longer conveyors or conveyors with high conveying loadsDesign of belt conveyor 5. Idlers The needs for Idlers are to give proper support to conveyor and also to the Material to conveyor. An endless conveyor belt in a conveyor structure is dragged from the tail pulley where material is loaded onto the conveyor, to the head pulley or drive pulley where the material is discharged. Between a conveyors’ tail and head pulleys, whether the distance is a number of kilometers or merely a few meters, the carrying and retum strand belting is supported on idler sets. The rolls are fitted with antifriction bearings with seals and with adequate lubrication packed into it. The friction between the roller surface and the belt makes the rollers to rotate and thus material is transferred from one point to another through belt conveyor. TRANSITION IDLERS TROUGHED IDLERS IMPACT IDLERS RETURN IDLERS Figure 5 The arrangement of Idlers in a Belt ConveyorDesign of belt conveyor 5.1 Idlers serve following functions 1) Support the belt and the conveyed material on the upper run and the belt in the lower run with minimum frictional resistance, 2) Spacing of the idlers is reduced near the loading point, so as to support the belt due to impact of material in that region. This would prevent the belt from wearing quickly 3) Idlers help in centering the belt and guiding it to the drive and snub pulleys, 5.2 Type of Idlers 5.2.1 Carrying idler sets These idler sets support the carrying-side (top) conveyor belt onto which the material is loaded and transported. In the loaded zone we have Impact carrying Idler which is covered by rubber material to absorb the loads as the loading or transferring points. Also we have Self-aligning carrying idlers to avoid the belt off tracking Figure 5.2.1 carrying idlersDesign of belt conveyor Carrying or troughing idler sets usually comprise between two and five individual idler rolls mounted into a common base, which is attached to the conveyor structure. Each idler roll in a ‘set’ comprises its own set of bearings, seals, shaft and outer shell 5.2.2 Return idler sets These idler sets support the retum-side (bottom) conveyor belt which returns to the tail pulley after having discharged product over the head pulley. The diagram shown above is flat return type of Idler where only one flat roller is used. The retum idler may also have more than one idler arrangement which is called as Garland type idlers. Figure 5.2.2 return idlersDesign of belt conveyor ‘Once the material has been discharged from the carrying belt, the return belt is guided back to the tail pulley on return idlers. The impact, carrying and return idlers are spaced at different intervals. On the carrying: ide, the mass of the belt plus the load conveyed is greater than the mass to be supported on the return-side and thus, for the tension in the conveyor belt (by the take-up and induced by the drive unit), the idler spacing is selected accordingly. This 'sag' in the belt between the carrying and retum idler sets must therefore be designed on the basis of the heaviest load that the conveyor is to transportDesign of belt conveyor 6. Coupling 6.1 Function As the name indicates Couplings are the device used to couple or connect two shafts, this is one of the most important component of any drive system. Since it is impossible to maintain co linearity between two shafts couplings are designed to provide better flexibility to allow initial or running shaft misalignment. Following are the type of flexible couplings. + Fluid Coupling + Chain Coupling + Geared Coupling + Grid coupling + Universal coupling 6.1.1 Fluid Coupling There are three essential parts to a fluid coupling: the driving (input) section known as the impeller the driven (output) section known as the runner and the casing which bolts to the impeller enclosing the runner providing an oil tight reservoir. Both impeller and runner each represent half of a hollow torus with flat radial vanes. At the inner circumference a conical baffle is attached to the impeller and a flat baffle is attached to the daar anneDesign of belt conveyor Running These components comprise the working circuit. The operation of the fluid coupling requires mechanical input energy, normally provided by a standard NEMA B electric motor which is connected to the impeller and casing. The runner, which has no mechanical connection with the impeller, is directly connected to the driven load. A variety of mechanical connections; couplings, sheaves, and hollow shaft mountings, are available to provide the mounting configuration best suited to the application. Finally the fluid coupling must be initially charged by removing the fill (fusible) plug and adding the recommended amount of oil based on the required torque. Starting Standard NEMA B motors are recommended when using fluid couplings and will start virtually unloaded. Since the motor is mechanically connected to the impeller and casing, the low inertia of these components and the oil are the only loads imposed. As the electric motor accelerates to running speed, the impeller begins to centrifugally pump oil to the stationary runner. Transmission of oil is diffused by the conical impeller baffle, producing a gradual increase in torque, allowing the motor to accelerate rapidly to full running speed. When all the oil is pumped into the working circuit, continuous circulation of il will occur between the impeller and runner forming a flow path like a helical spring formed.Design of belt conveyor As soon as the transmitted torque reaches the value of the resisting torque, the runner starts rotating and accelerates the driven load. The time required to reach full speed is dependent on the inertia of the driven load, the resistive torque, and the torque being transmitted by the fluid coupling. Running The operation of a fluid coupling is based on the hydrokinetic principles and requires that the output speed be less than the input. This difference in speed is called slip. Further this principle provides that the output torque is equivalent to the input torque, since windage and oil circulation losses are negligible. Therefore, efficiency equals 100% minus the percent of slip. At full running speed fluid couplings will normally slip between 1% and 4%, The oil circulation between the impeller and runner has formed a vortex at the outside circumference of the working circuit and is no longer deflected by the conical baffle, Overload — Stall Should the load torque increase, the slip will increase, which causes the runner to drop in speed. The vortex of oil circulating between the impeller and runner will expand to provide additional torque. The extent to which this vortex can expand is limited by the flat baffle on the runner. Consequently fluid couplings provide inherent overload protection. If the increase in torque causes the oil in the working circuit to expand to the point of contacting the baffle, the coupling will stall and slip will be 100%. This continuous high slip generates heat and the oil temperature will rise unless the overload is removed. When the temperature rises to the temperature limit of the fusible plug, the core of the plug will melt, release oil from the coupling and effectively disconnect power to the output shaftDesign of belt conveyor To prevent the loss of oil the use of a proximity cutout switch or thermal trip plug and limit switch is recommended. Coupling guards must be designed to permit air circulation for cooling and to protect when oil is released from fusible plug due to overload 6.1.2 Chi Couplings Chain couplings operate similarly to gear couplings. Sprockets on each shaft end are connected by a roller chain Figure 6.1.2 chain coupling The clearance between its components as well as the clearance in mating the chain to the sprockets compensate for the misalignment. Loading is similar to that of geared couplings. Packed Grease Lubricants is primarily used with this types of construction, necessitating a sealed sprocket cover. A detachable pin or master link allows removal of the chain.Design of belt conveyor 6.1.3 Gear Coupling Gear couplings compensate for misalignment via the clearance between gear teeth. Figure 6.1.3 Gear Couplings Shaft-mounted external gear teeth on both shafts mate with internal gear teeth on a housing that contains a lubricant. Other designs mount external teeth on only ‘one shaft, mating with internal teeth mounted to the other shaft. Acceleration or deceleration can result in impacts between gear teeth due to backlash from the clearance being taken up on opposite sides of gear teeth. Misalignment will result in sliding relative motion across mating teeth as they pass through each revolution.Design of belt conveyor 6.1.4 Grid couplings External grid cou 19S use a corrugated steel grid that bends to compensate for loading induced by misalignment. Figure 6.1.4. Grid Coupling Grooved discs attached to the ends of each shaft house the grid, which transmits torque between them. Low amplitude sliding motion develops between the grid and grooves as the grid deforms under load, widening in some locations and narrowing in others over each revolution.Design of belt conveyor 6.1.5 Universal Coupling Universal joints are used for may 1um allowable misalignment up to 20 to 30 degrees, depending upon the specific design. They are used extensively for the drive shafts of vehicles to allow the wheels to move with the suspension system. Universal joints use a four-spindled component called the spider to connect two shafts terminating in yokes or knuckles at right angles. = 5029 tng stato auch Trensmission Ln Figure 6.1.5 Universal Joint : shat Each of the four spider journals is supported by a bearing or bushing contained in one of the knuckles, which allow articulation. In some cases, greater articulation can decrease wear rates by allowing more complete development of a lubricating film.Design of belt conveyor 7. Bearing ‘As we all know, Bearings are used to give support the shaft of the roller or idle pulley at both ends. They give also rotational motion of shaft by giving it support with very less friction. Though some friction is taken place due to the metal to metal contact inside the bearing between metal balls and metal casings, it is very negligible as compare with the direct contact of rotating shaft and main frame of the conveyor. Types of Bearings: There are many types of bearings, each used for different purposes. These include ball bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered roller thrust bearings. 7.1 Ball Bearings Ball bearings, as shown below, are probably the most common type of bearing. They are found in everything from inline skates to hard drives. These bearings can handle both radial and thrust loads, and are usually found in applications where the load is relatively small Figure 7.1. Exploded viewDesign of belt conveyor In a ball bearing, the load is transmitted from the outer race to the ball, and from the ball to the inner race. Since the ball is a sphere, it only contacts the inner and outer race at a very ‘small point, which helps it spin very smoothly. But it also means that there is not very much contact area holding that load, so if the bearing is overloaded, the balls can deform ‘or squish, ruining the bearing. 7.2. Roller Bearings Roller bearings like the one illustrated below are used in applications like conveyer belt rollers, where they must hold heavy radial loads. In these bearings, the roller is a cylinder, 0 the contact between the inner and outer race is not a point but a line. This spreads the load out over a larger area, allowing the bearing to handle much greater loads than a ball bearing. However, this type of bearing is not designed to handle much thrust loading. A variation of this type of bearing, called a needle bearing, uses cylinders with a very small diameter. This allows the bearing to fit into tight places. Figure 7.2. Cutaway view of a roller bearingDesign of belt conveyor 7.3. Ball Thrust Bearing Ball thrust bearings like the one shown below are mostly used for low-speed applications and cannot handle much radial load, Barstools and Lazy Susan turntables. use this type of bearing 8. Drive unit for belt conveyor A) Direct gear motor drive B) Drive through parallel shaft gear box C) Drive through primary reduction by v belt and secondary by gear box D) Drive through spiral bevel or worm gear box 9. Motor Motor is a prime source of the energy to run the whole belt conveyor system. By taking current, it produces the mechanical work and this mechanical work is given to head pulley or tail pulley of the conveyor by means of gear box drive as discussed above. We can also use an induction motor with variable speed drive by changing its frequency 10. Cleaning device ‘An important property of the rubber covered conveyor belts is the high coefficient of friction of rubber. This reduces the tendency of material to slip on inclines. However it also increases the difficulty of cleaning the belt ‘Some of the devices for belt cleaning are discussed below: a) Belt scraper b) Rotating belt cleaners ©) Water spray and wiperDesign of belt conveyor 1. Problem Design a belt conveyor to transfer 200 tthour of foundry sand through a horizontal distance of 20 meter. Foundry sand has density of 1.25-1.3 Uhour. Assume all the related data for belt speed and angles. Co-efficient of friction between belt drive roller and belt is 0.3. What happens when the transfer of same material at some angle for the same condition? Conclude from results. n data Material is to be conveyed = foundry sand Length of the conveyor = 20 m Capacity of the conveyor = 200 tonnes Type of the conveyor = horizontalDesign of belt conveyor Solution: 11.1 Design of belt Important factors are to be considered: ) Angle of repose and angle of surcharge ) Flow ability ) Effective belt width for material ) Volume capacity of belt, Q ) Mass capacity of belt ) Belt speed 11.1.1 Selection of belt width ‘* angle of repose of the material to be conveyed = 45 degree ‘+ therefore surcharge angle = 30 degreeDesign of belt conveyor 11.1.2. Density of the material which is to be conveyed * density = 1.25 — 1.3 tonnes/m’ (from following table) Density and angle of repose of commonly conveyed materials Material Recommended max. angle of belt to horizontal, deg Density tonesim3_| Angle of repose, deg ‘Anthracite, fine, dry 06-0.95 45 Gypsum, smail lump 1244 40 Clay, dry, lamp 1045 50 Gravel 12 T5419 45 Earth, dry 12 45 Foundry sand 24-26 T2513 45 Ash, dry 23 0406 50 Time stone, Lump 20 T2415 45 Coke 7 0,36-0.53 50 Wheat flour 23 0.45-0.66 55 Oat 18 04-05 3 Saw dust 2 016-032 39 Dry sand 18 T4165 45 Wheat 18 0.65-0.83 35 Tron ore 18-25 2125 50 Peat 18 033-047 45 Coal(from mine) 8 065-078 50 Dry cement 20 1013 50 Slag, anthracite 22 0609 45Design of belt conveyor 11.1.3 Angle of throughing belt Angle of throughing, B = 36 degree The cross section of the lump on throughed belt of width ‘w' is shown in figure Area of c/s of lump, A=1/2(.6W +.6W+2x 2W cosd)x.2W sind +1/2(.6W +..4W cos0)1/2(.6W +.4W cosO)cotp Where, @ = throughed angle ¢ = angle of reposeDesign of belt conveyor Volume/meter length of the belt = A x | This must be equal to volume of material to be conveyed/meter length of belt, Mass/meter length of the belt Ax L= = mdi density of the material . Me/p = 1/2(.6w +.6w+2 x .2w cos0) x .2w sind +1/2(.6w+.4w cos 0)1/2(.6w+.4w cosd)cot¢ ~ Where, m, massimeter length of belt P = density of material If we know the values of mc, P, 8 and @ then we can find width of the belt from standard belt size data. Finding belt size width, Assume, travel speed initially = 2.5 meter/s, Mass rate = 200 tonnes/hour @ = 36 degree © = 45 degreeDesign of belt conveyor Therefore, m,= mass rate to be conveyed / speed of travel ~ = (200 x 1000) / (3600 x 2.5) = 22.22 kg And the density of the foundry sand = 1.3 tonnes/m? = 1300 kg/m? Now putting this value in equation 1, Therefore 22.22/1300 = 1/2 (.6w+.6w+2 x.2W cos36) x .2w sin36 +1/2(.6w+.4w cos36)1/2(.6w+.4w cos36) colds (.7618w)(.1175w) + (.4618w)(.4618w) 3027w* Therefore, 22.22 / 1300 = 0.3027w* W min = 0.2376 m or 237.6 mm. This is minimum width required of belt, to avoid spillover select 400 mm width of belt which isa standard one. Now, let recalculate the equation 1, because according to belt width in mm belt speed may vary. So, for 400 mm belt width, maximum recommended speed, v = 2 m/s (from the table)Design of belt conveyor ‘Allowable belt conveyor speed in mis Type of material conveyed Belt width, mm 400 500 | 650 | 800 | 1000 Gravel, stone, coal, ash, ores [1.5 15 2 275 | 275 Coke, friable materials 1.25 1S Ts | 175 | 20 Dry and wet sand, grains and 2 3 35 a 4 light materials ‘Abrasive materials, fine coke, [| 1.25 2 2 25 25 slag, crushed ore ‘Abrasive materials: = 175 | 175 2 In large lumps, slaggy rock, ores Now put this value in the equation 2, mg = (200 x 1000) / (3600 x 2) = 27.8 kg Now put this value of me in equation 1, 27.811300 = 1/2 (.6w+.6w+2 x.2w cos36) x .2w sin36 +1/2(,6w+.4w cos36)1/2(.6w+.4w cos36) col4S Therefore, 27.8/1300 = 0.3027? And 80, W min= 0.265 m = 265 mmDesign of belt conveyor Here, we conclude that belt must require minimum 0.265 m width to avoid spill over select 400 mm belt width. 11.1.4. Mass of the belt/meter length of the belt my = 5 kgf /meter (from table) Weight of conveyor belts, kgfimeter Belt width, mm ‘400 500 650 800 1000 ‘Average weight 5 65 9 2 16 per meter run, kof 11.1.5 Length of belt for one passes, Here conveyor is having horizontal layout and so the angle of elevation = 0 degree ‘Angle of elevation 4 = tan“ 0/20 = 0 So, length of belt | = 20/cos 0 = 20 mDesign of belt conveyor 11.1.6 Total length of belt passes, (We can calculate this after the calculation of pulley diameter and the thickness of belt,) We are getting, Diameter of the pulley D = 500 mm =0.5 m Thickness of the belt t = 8 mm = 0.008 m So, Total length of the belt = D + 2 (t/2) + 20(2) = 0.500 + 2(0.008/2) + 40 = 0.504 +40 = 40.504 mDesign of belt conveyor 11.1.7 To check the no. of plies of belt, Here, our belt width = 400 mm And the density of conveyed material = 1300 kg/m* So, from table Table to check the number of plies of belt Density of material conveyed, m3 Belt | _ over O48 085 125 178 width, [Up to 0.85 125 178 25 mm Designation of belt fabric, oz No.of [28 | 32 | 28 | 32] 36 | 42 [32] 36 | 42 | 48 | 32]36| 42 | 48 plies, i 400 Min 3 3 |3}f3;/-/-|4l-]-|-|-|-|-]- Max | 5 4 fs s4{-/-l4/-|-|-|-]-|-|- 500 | Min 3 3 |4/4f3}-f4{4]-|-l-|-]-/- Max | 6 5 ;essfsl/-fs{s|i-|-l-|-|-|- 650 | Min a 4 [5 /4]4fs]s{s]4]-fsls|4f- Max | 7 6 |7 sels/sléels|/s|- els|s|- 800 | Min a 4 [s[sl/4/4]s|sl4]slelela|a Max | 8 7 [el7lelel7{seléls|7lse| és a