Eng.

Abdel-Rahman Sorour
E i
Environment
t Manager
M – MBCC.TM
MBCC TM
Mechanical Conveyors
1.Belt
Belt Conveyors

2
 Introduction
Belt conveyors
y are extensively y used in
almost all industries

Because it is characterized by:

• economic i operation
ti
• reliability
y and adaptability
p y
• possibility to transport a wide range

of material lump sizes,

sizes moisture
content, chemical characteristics and
temperatures. 3
 Description of Belt Conveyors
Belt conveyor is composed of four main
stations::
stations
tail station
discharge or head station
longitudinal frame
take--up
take p station
station..
N.B.:
The drive unit may be attached to head or
tail p
pulley
y
4
Description of Belt Conveyors

5
The Main Mechanical Components
p

6
The Main Mechanical Components
p

7
 Cross Section of the Channel
Frame

Cross-Section of a troughed Belt Cross-Section of a Flat

Con e or tripartite and 30o
Conveyor Belt Con
Conveyor
e or
inclination of the outer idler

8
Function of Belt Conveyor

Weigh feeder

Direction of flow

The material if fed onto the belt conveyor near

tail station to rest on upper run on belt and
travels forward with the belt

9
Belt conveyors Profiles

Horizontal Inclined

Horizontal - Inclined Inclined - Horizontal

Declined Horizontal - Declined

Declined - Horizontal Compound path

10
Horizontal with mobile tripper
 Feeding Belt Conveyors
By feeder/s from
hoppers storage:
storage:
„ Feeders
F d extract
t t
material from such
storage at controlled
rate.
„ There are various

types of feeders such

as vibrating feeders,
belt feeders, apron
feeders etc.

11
 Feeding Belt Conveyors
By preceding
conveyor/s::
conveyor/s

The discharge of
preceding conveyor
becomes direct feed for
the next conveyor.
conveyor

12
 Feeding Belt Conveyors
By process
equipment::
equipment

Equipment like
crusher, screen etc.
discharge at
controlled rate.

13
 Feeding Belt Conveyors
By traveling
B t li
machine:
The traveling
machines such as
reclaimed, traveling
hopper equipped
with discharge
feeder etc.

14
 Discharging from Belt Conveyors
„ Head pulley discharge:
discharge:
This is the most widely y used method for
material discharge from belt, as material
is directly
y discharged
g from head pulley.
p y
„ Both end discharge:

The reversible conveyor discharges at both

ends.

15
 Auxiliary Equipment
„ Two way gate (Diverter):
(Diverter):
A device that controls the
direction of material in chutes.

„Belt weigher
g
(Belt scale):
The belt weigher enables
to know both flow rate
t/h
/ and qquantity
y being
g
conveyed, tones. 16
 Auxiliary Equipment
„ Magnetic separator:
A permanent or an electrical
magnet, which removes
iron/steel items that is not
required (tramp irons) from
material while moving with
b lt or att discharge
belt, di h point.
i t

„ Metal detector:
A device installed at the
belt that senses the
presence of metals among
conveyed material. 17
 Design of Belt Conveyor
D i
Design off belt
b l conveyor is
i a wide
id topic.
i

The steps
Th t off belt
b lt conveyor design
d i start
t t
from defining constrains, deciding
suitable design parameters and finally
carrying
y g out design g procedures.
p

There are two approaches:

Precise approach
Rough Preliminary approach 18
 Precise approach
Input data:
• Material to be transported
• Transport rate or capacity
• Conveyor overall dimensions
• Operating conditions

Calculated parameters:
• Belt width, belt speed and Idlers shape
• Idler spacing
A3 A1 • Wrap angle

Design procedures:
• Resistances and power calculation
• Tensions
• Sizing of components
Note: Calculations must follow one of the standards like ISO 5048, 19
CEMA (Conveyors Equipment Manufacturers Association) , etc.
Slide 19

A1 180 - 240
A.SOROUR, 22/10/2009

A3 drive torque===transfearto==belt width*belt leng

th in the wrap zone
A.SOROUR, 22/10/2009
 Rough Preliminary Approach
1- Obtain material properties from table-1

2- Calculate the corrected capacity

p y
= capacity (m3/hr)*Belt speed (m/s)

3- Decide the suitable belt width to support

the required capacity using table-2

4- Use the charts in figure-6 to obtain power

5- The required motor power = shaft power * 1.10

Note: Output may be used for estimation purposes only, and shall 20

never be used for final procurement.

Mechanical Conveyors

„ 2.Screw
Screw Conveyors

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 Main components
Component Description

A Conveyor Screw

B Shaft Drive End

C Hangers and Bearings

D Trough Ends

E Conveyor Trough

F End Flange

G Feed & Discharge Spouts

Supporting Feet &

H
Saddles

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 Direction of conveying
• Left-hand
f h d and d Right-hand
i h h d helix
h li on common shaft.
h f
• Clockwise rotation conveying towards center of trough.

A4

• Left-hand and Right-hand helix on common shaft.

• Anti-clockwise rotation conveying towards both ends of shaft.

A5

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Slide 23

A4 push--c.w
A.SOROUR, 22/10/2009

A5 pull - ccw
A.SOROUR, 22/10/2009
 The handling capacity
It is determined by:
• Diameter
Di t off the
th helix
h li
• Pitch of the helix
• Rotational speed
• Loading (filling degree)
• Nature of the material to be handled
Material
Filling Degree ϕ
Description Examples

Light
Li h non-abrasive
b i and d ffree fl
flowing
i Flour grain,
Fl i dry
d
0.45
materials pulverised coal, cereals

Fine- grained
Fi i d or small-
ll sized
i d materials
t i l Coal,
C l coarse salt,
lt sand,
d 0.25 - 0.3
which are not quite free flowing Cement

Heavily abrasive, tough materials

containing hard lumps with poor flow Ash, gravel, clinker 0.15
ability 24
 Capacity Equation
Where: Im=60 ϕ ρ (π/
(π/4)) D S n 2

- Im: Conveyed material flow rate (t/h)

- ρ: Conveyed material density (t/m3)
- D: Screw diameter (m)
- S: Screw pitch (m) – S=D for easily movable materials
S=0.8D for poorly movable materials
- n: rotational speed
p ((rpm)
p )

Since the tangential speed “V” is normally (1 – 1. 5

m/s),
),
the rotational speed can be estimated from: n = 60 (V/S)

Material distribution for different filling degrees ϕ

25
 Screw handling capacity
Screw Conveyor at Filling 0.25
0 25

120.0
D=250

100.0
D=315

80.0
D=400
D 400
S peed rpm

60.0 D=500

D=630
D 710
D=710 D=800
40.0 D=900
D=1000 D=1120
D=1250
20.0

0.0
0.0 50.0 100.0 150.0 200.0 250.0 300.0
3
C
Capacity
i m /hr
/h
26
 Power Equation

P= Im (λ L + H) /367 + 0.05 D L

Where:
• P: Consumed power (kW)
• Im: Conveyed material flow rate (t/h)
• L: Conveying length (m)
• H: Lifting height (m) . ( = Zero if horizontal )
A6 • λ: Progress resistance coefficient ( for: cement λ=1.9 ; coke & sand λ=3.0 )

27
Slide 27

A6 due to frection between material and spiral

A.SOROUR, 22/10/2009