Lecture 3 - Belt Conveying - Static Design Procedure

Belt Conveying of Bulk Solids
O
Overview
i off Static
St ti Design
D i Procedure
P d
Dr Craig Wheeler
Senior Lecturer, School of Engineering
Associate Director, TUNRA Bulk Solids Research Associates
The University of Newcastle, Australia.
Overview
2
This module provides the fundamental design

principles
p p for static belt conveyor
y design.
g
Topics covered include:
• Belt Carrying Capacity • Power Requirements
• Belt Velocity • Steady State Belt Tension
• Belt Width Distribution
• D i Tension
Drive T i Relationships
R l ti hi • Counterweight Design
• Conveyor Idler Rolls • Belt Selection
• Other Considerations
CBSPT University of Newcastle 1

Belt Conveyor Static Analysis 3
Static analysis methods include:

• ISO5048 – International Standard
• DIN22101 – German Standard
• CEMA – Conveyor Equipment Manufacturers
Association Handbook
y Handbook
• Goodyear
Conveyor Belt
• Yokohama Handbook Manufacturers
• APEX Handbook
Belt Conveyor Carrying Capacity 4
The carrying capacity or throughput for a belt conveyor is given

by:
Qm =  A v k
Where:  = Bulk density of material being carried

A = Cross sectional area of material on the belt
v = Belt velocity
k = Slope (reduction) factor

Cross-sectional area depends on the belt width and idler

configuration.
The cross sectional area is a function of the contact or 'wetted'

perimeter 'b' of the material on the belt and may be expressed as
A = U b2
where b = Contact perimeter

U = Non-dimensional cross sectional area shape
factor which depends on the idler configuration.
Shape Factor for a Flat Belt - Single Idler System

A
b = 0.9 B - 0.05 (m)

B
Defining  as the surcharge angle and assuming the surface

of the material on the belt is parabolic in form,
form it can be
shown that: 
b tan 
A =
6
tan 
Hence; U1 =
6

7
Surcharge angle is best measured.
Shape Factor for a Three Idler System
Again assuming symmetrical loading and that the surcharge

is parabolic in shape it can be shown that:
1  tan 
U3 = {sin +  sin 2 + [1+4cos + 2 (1+cos 2)]}
(1+2)  2 6
where;  = y / x

Shape Factors - Three Idler System

eg:  = 0.75 and 1.0
Optimisation of Carrying Capacity

Optimisation with input to 
For given values of  and  the carrying capacity may be
maximised by:
dU
Setting  = 0 leads to
d
* * 2 * *
cos  +  cos 2  - tan  (sin  +  sin 2 ) = 0
3
Assigning particular values of  and  this equation may be
solved to determine the value of * to maximize U3.

Optimum * for Maximum U3 as a Function of  and 
where;  = y / x
450
 200
Optimum * for Maximum U3 as a Function of  and 
vs U
 = 25 Deg
0.190
0.185
0.180
0.175
U
= 0.75 &  = 35o

0.170
U3 = 0.173
0.165
0.160
0.0 0.5 1.0 1.5 2.0
 = y/x

Consider load distribution on idler rolls.

The carrying capacity for a belt conveyor is given by:
Qm =  A v k =  U b2 v k
Therefore knowing the slope factor k and the belt speed v, the
contact perimeter b, is given by:
Qm
b
Uvk
Slope Factor, k (ISO and DIN)

The slope factor, k, is determined by taking into account the
decrease of the surchargeg (top
( p parabolic)
p ) section,, S1, when
material is fed onto an inclined part of a belt.
tan 
S1  x  b  x  cos  
2
S1
6
S2
 bx   b  x  
S2   x    cos     sin  
  2    2  
A  S1  S 2

Slope Factor, k (ISO and DIN)

The slope factor, k, is given by:
S
k  1  1 1  k1 
S2
Where k1 is the reduction factor of the surcharge portion. For
uniformly loaded, properly aligned conveyors handling middle
lump size material, k1 is approximated by:
cos 2   cos 2 
k1 
1 cos 2 
slope angle of conveyor
When  the surcharge section S1 becomes non-existent and
only the lower section S2 can be used for handling purposes.
Belt Velocity 16
Determining Factors
Belt velocityy depends
p on:
• Characteristics of the bulk material to be conveyed
• Maximum lump size
• Powders may generate dust
• Carry capacity
• Belt tension
• Conveyor slope
• Standard drive reduction ratios

Belt Velocity 17
Advantages and Disadvantages

Advantages of high speed conveying:
• Higher carrying capacity
• Typically more efficient operation
Potential Disadvantages:
• Dust generation
• High fracture in the case of fragile materials
• Belt tracking becomes critical
• Reduced conveying slope due to material lift-off at idlers
• High belt wear if feed and transfer chutes not suitably designed
• High lining material wear in feed and transfer chutes
• Noise issues
Recommended Max. Belt Speeds

18
Apex - Table A2
Belt Width Grain or Run-of-Mine Coal Hard Ores
Free Flowing Crushed Coal and and
mm (inch) Materials Earth Stone
300 (12) 2.0 - -

350 (14) 2.0 1.5 -
400 (16) 2.0 1.5 -
450 (18) 2.5 2.25 1.75
500 (20) 3.0 2.25 1.75
600 (24) 3.0 2.5 2.25
650 (26) 3.25 2.75 2.5
750 (30) 3.5 3.0 - 3.5 2.75
800 (32) 3.75 3.0 - 3.5 2.75
900 (36) 4.0 3.0 - 3.5 3.0
1000 (40) 4.0 3.0 - 3.5 3.0
1050 (42) 4.0 3.0 - 3.5 3.0
1200 (48) 40
4.0 3 25 - 4.0
3.25 40 30
3.0
1350 (54) - 3.25 - 4.0 3.0
1400 (56) - 3.25 - 4.0 3.0
1500 (60) - 3.25 - 4.0 3.0
1600 (64) - - 3.0
1800 (72) - - 3.0
2000 (80) - - 3.0

Recommended Max. Belt Speeds – CEMA (2005) 19
(5m/s)
Conveyor Belt Width 20
Determining Belt Width

Given:
• an idler configuration
• shape factor U,
U and
• a belt speed
Qm
The contact perimeter b, is then calculated → b 
 Uvk
The minimum belt width is then be determined from ISO/DIN.
b = 0.9Bmin – 0.05 (m) for Bmin 2 m
b = Bmin – 0.25 (m) for Bmin> 2 m
Th f
Therefore th minimum
the i i b lt width
belt idth is:
i
Bmin  1.11b + 0.05 (m) for Bmin 2 m
Bmin = b + 0.25 (m) for Bmin> 2 m
Other Considerations - Material migration through horizontal curves
- Spillage at discharge as belt flattens
- Lump size

Conveyor Belt Width 21
Recommended Lump Size Relative to Belt Width (CEMA)

0.6
05
0.5
e
a rg
rch
. Su
eg
0.4
d
LUMP SIZE (m)
20
ge
s,
ar Fines size is no
e
Fin
ch
ge S ur
0.3 r g. greater than 1/10 the
%
ha de
90
rc
Su 30
s,
g. es
,
maximum lump size.
mp
de Fin
Lu 0% 20
ps
%
0.2 , 9
10
um mps e
lL Lu arg
Al rch
% .Su
10 0 deg
3
ps
0.1 Lum
All
0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
BELT WIDTH B (m)
Belt Width and Velocity - Throughput 22
o o
 = 0.75,  = 35  = 0.75,  = 35
3500 3500
3000 3000
2500  2500


Belt Width [mm]
Belt Width [mm]
2000  2000

1m/s
1500 1500 2m/s
3m/s
4m/s
1000 1000
5m/s
6m/s
500 500 7m/s
8m/s
0 0
0 1000 2000 3000 4000 5000 6000 0 2000 4000 6000 8000 10000
Throughput @ vb = 1m/s [m 3/h] Throughput [m 3/h]

Belt Width and Velocity Considerations 23
Annual Equivalent Cost per Unit Length as Function

of Belt Width and Velocity (Roberts and Harrison)
L = 5 km,  = 0.85 t/m, fs = 7:1
Cost versus Belt Width Cost versus Belt Velocity
24
Overview
• Belt Carrying Capacity • Power Requirements

• Belt Velocity • Steady State Belt Tension
• Belt Width Distribution
• Drive Tension Relationships • Counterweight Design
• Conveyor Idler Rolls • Belt Selection
• Other Considerations

Drive Tension Relationship 25
The force required to drive a belt must be transmitted from the

drive pulley/s to the belt by means of friction between the belt
and ppulley.
y
The power transmitted results from a difference in tension
between the side the belt approaches and leaves the drive
pulley.
Where Power is transmitted
F1 from the pulley to the belt.
F1>F2
Where Power is transmitted

F2
from the belt to the pulley.
F2>F1
26
Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

Consider an element of the belt whose position is defined by angle .

F1
F = Tension at section defined by  (N)
F1 = Tight side tension, (N)
 F2 = Slack side tension,
tension (N)
d Fe = Net driving tension, (N)
 Fc = Centrifugal tension, (N)
F2
N = Normal force
 = Effective friction factor between the belt
F + dF and pulley for wrap angle 
Typical values are:
d
2  = 0.25 for steel pulley
dFc  = 0.35 for lagged pulley
dN
d
 = Angle of wrap or contact, (radians)
ec v = Belt velocity (m/s)
F  dN qb = Mass of belt (kg/m length)
ec = Distance of line of action of tension from
d
2 drum surface
Assumptions:
The well known drive tension relationship is based on several
simplifying
p y g assumptions
p which are often not stated. These
assumptions are:
• Centrifugal tension is low compared with the drive
tensions and therefore may be neglected.
• The friction is fully developed around the total arc of
contact and the friction coefficient is constant around the
arc This can only occur if the belt is slipping or on the
arc.
verge of slipping at every contact point.
• The distance ec is assumed to be zero.

Considering the equilibrium of the element shown and setting

dFc = 0 it can be shown that:
dF
+ F = 0
d
he solution of this first order, linear homogeneous
differential equation is:
F = F2 e 
Now, the maximum value of F1 occurs when  = , hence:
F1
F1
 = e 
d F2

F2
The effective driving force Fe, is the difference between F1

and F2. That is :
Fe = F1 - F2
Let:
F2 1
Fe = Cw = (e  - 1)
Where: Cw = Wrap Factor (which determines how much tension Fe

can be transmitted from the drive pulley to the belt for a
specific value of F2, friction factor  and wrap angle 
Therefore: F1
= Cw + 1
Fe
The driving or transmitted power is : P = Fe v

Friction Factor Determination
W
Steel
F Belt
32

Effect of Variation in Friction for Active Creep

F1
F
1 Assume the friction
coefficient
ffi i t is
i given
i by:
b
F2  ac  ac 

 = o ( 1 -
ac )
F
1

o o F2

for: 00    ac

  ac
Substituting into the differential equation and solving yields :

F1  
F2 = e o ac/2
It is apparent that o = 2. Or the equivalent 'uniform' friction 
= o /2. Thus, for the assumed value of  = 0.35 the 'real'
friction coefficient is 0.70.
Recommended Coefficients of Friction between Conveyor Belts with Rubber Covers

and Pulley Surfaces of Differing Finishes in Steady State (DIN22101 and ISO5048)
Pulley Surface
Operating Condition Bare Steel Pulley Polyurethane Rubber Lagging Ceramic Lagging
(smooth) Lagging (herringbone (herringbone
(herringbone grooves) grooves)
grooves)
Dry 0.35 to 0.4 0.35 to 0.4 0.4 to 0.45 0.4 to 0.45
Wet 0.1 0.35 0.35 0.35 to 0.4

(pure water)
Wet 0.05 to 0.1 0.2 0.25 to 0.3 0.35
(contaminated, clay)

Types of Conveyor Drives
• The effectiveness of the conveyory drive is dependent

p on the
belt tension, the belt/pulley friction and the angle of wrap.
• For design purposes the tight side tension F1 dictates the type
and size of the belt, while the slack side tension F2 is the
minimum value required for driving the belt successfully.
• The belt tensions are influenced by the angle of wrap and

this is dependent on the type of drive used.
Conveyor Drive Arrangements

Drive Drive
Drive 1
Snub Snub
Drive 2
(a) Plain Drive (b) Snubbed Drive
(c) Dual Drive on Head Pulley

Bend
Pulley
Drive 1
Drive 1
Drive 2
Drive 2
(e) Dual Drive on Return

(d) Dual Drive

Dual Drive Analysis

F1 F1

 eμ1 θ1
Fi
Fi

Fe1 = F1 - Fi
Fi
Fi
  eμ2 θ 2
F2 F2

Fe2 = Fi - F2
Dual Drive Analysis

Combining individual pulley relationships:
F1
 eμ1 θ1 μ2 θ2 
F2
Since: Fe1 = F1 - Fi and Fe2 = Fi - F2
Fe1  eμ1 θ1 1 
 eμ2 θ2  μ θ 
Fe 2 e
2 2
1 
Let: Fe1 P
r  1 Since same belt velocity
Fe 2 P2
Where: P1 and P2 are the nominal powers for drives 1 and 2.

Dual Drive Analysis

Assuming  = 1 = 2 , then the relationship for 2 as a
f i off 1 is:
function i
1  r 
θ2  ln  
  r  e 1 
θ1
Generally r needs to be chosen so that 1  1800.
Conveyor Idler Rolls 40
Types of Conveyor Idler Rolls

RECOMMENDED AVERAGE CARRYING IDLER SPACING (m) 41
Table 2 – Section 4
Belt Width Material Weight - Kilograms per cubic metre
mm (Inch) 480 800 1200 1600 2000 2400
350-400 (14-16) 1.7 1.7 1.5 - - -

450-500 (18-20) 1.7 1.7 1.5 1.5 - -
600 (24) 1.7 1.7 1.5 1.5 1.4 1.0
650 (26) 1.5 1.5 1.4 1.4 1.3 1.0
750 (30) 1.5 1.5 1.4 1.4 1.3 1.0

800 (32) 1.5 1.5 1.4 1.4 1.2 1.0
900 (36) 1.5 1.5 1.4 1.4 1.2 1.0
1000 (40) 1.5 1.4 1.2 1.2 1.0 0.9
1050 (42) 1.5 1.4 1.2 1.2 1.0 0.9
1200 ((48)) 1.5 1.4 1.0 1.0 0.9 0.8
1350 (54) 1.4 1.2 0.9 0.9 0.8 0.8

1400 (56) 1.2 1.2 0.9 0.9 0.8 0.8
1500 (60) 1.2 1.2 0.9 0.9 0.8 0.8
1600 (64) 1.2 1.2 0.8 0.8 0.8 0.6
1700 (66) 1.2 1.2 0.8 0.8 0.8 0.6
1800 (72) 1.2 1.2 0.8 0.8 0.8 0.6
2000 (80) 1.2 1.2 0.8 0.8 0.8 0.6
GUIDE ONLY !
Idler Spacing – Deflection Model

y
M M + dM
a
x dx
dx
F
V + dV
F + dF
y V
x
(a) Belt Deflection (b) Segment of Belt
Let:  2 y = acceleration of belt element

t 2
EI = belt stiffness
q = total mass per unit length
F = tension
a = idler spacing
g = acceleration due to gravity


Considering the dynamic equilibrium of the element, then the
differential equation for the belt under dynamic conditions is:
4 y 2 y 2 y
EI  F   q
x 4 x 2 t 2
For the belt sagging under static conditions, the acceleration is
2 y
g
t 2
The deflection can be given by:
q g x2 qga
y(x) = 2F + a [1 - cosh ( x) ]
2  F sinh( )
2
F
Where: =
EI

a
The maximum deflection occurs at x = 2 .
Hence, q g a2 qga a
ymax = + a [1 - cosh( )]
8F 2
2  F sinh( )
2
This equation approximates to:
q g a2 4 EI
ymax = 8 F [1 - a F ]
Often the belt stiffness is considered negligible leading to a
simplified, more conservative analysis.
q g a2
ymax =
8F


Therefore the tension to limit the percentage sag is:
qga
F = 8K
s
a
y
Where: Ks =
a
= Sag ratio x
dx
For the carrying side of the belt:

q = qb + qm y
F th
For the return
t side:
id (a) Belt Deflection
q = qb
Where: qb = mass of belt per unit length
qm = mass of bulk material on belt per unit length
Other Idler Roll Considerations

•Selection of roll diameter, size of bearing and size of shaft is
based on the load,
load belt speed and operating conditions.
conditions
•Rim drag values should be considered in conjunction with
labyrinth seal design and appropriate grease selection for the
operating conditions.
•To reduce induced vibrations and noise use dynamically
balanced and machined idler rolls for high speed applications.
applications

Unbalanced Idler Rolls
Rim Drag

Contaminant Ingress Test Facility
Noise Measurement

Noise Measurement
steel 70 Fast Inst 125ms A TUE 02/19/08 21h43m47s375 68.9dB 0h00m46s875 SEL 85.6dB
90
85
80
75
70
65
60
55
50
45
40
35
30
21h42 21h44 21h46 21h48 21h50 21h52 21h54
Noise Measurement
Overall Noise Level Comparison
90
85
80
Sound Level (dB)
75
Polymer Idlers
70 Steel Idlers
No Idlers
65
60
55
50
1 2 3 4 5 6
Conveyor Velocity (m/s)

Noise Measurement
Noise Pressure Comparison
(Background Conveyor Noise Subtracted)
0.3
0.25 Conveyor
Velocity
(m/s) Noise Ratio
Sound Pressure (Pa)
0.2
1 2.5
Polymer Idlers 2 3.1
0.15
Steel Idlers
3 2.6
0.1 4 3.1
5 3.4
0.05
6 2.8
0
1 2 3 4 5 6
Conveyor Velocity (m/s)
Conveyor Power Requirements 54
The power required to convey a bulk material is utilised in

overcoming the several resistances to motion that are present.
These resistances may be classified into five groups:
(i) Main Resistances FH
(ii) Secondary Resistances FN
(iii) Special Main Resistances Fsl
(iv) Special Secondary Resistances Fs2
(v) Slope Resistance Fst
FU = FH + Fst + FN + Fs1 + Fs2

Since Fu = Fe the required driving power is :
P = Fu v

Main and Secondary Resistances
FM
FN1 FB FI FR
FN2 FN2
Main Resistances Secondary Resistances
FI Indentation rolling resistance of the belt FN1 Charging resistances
FB Belt flexure resistance FN2 Wrapping resistance of the belt
FM Material flexure resistance around the pulleys
FR Rotational resistance of the idler bearings
and seals
Indentation Rolling Resistance 56
Belt Indentation

Bulk Solid Flexure 57
Act Act A
Pas
B
A to C: Belt C
Opening y D
E
z
vb x
Pas
Act
Pas
C to E: Belt
Closing
58
Bulk Solid Flexure Resistance

Idler Roll Rotating Resistance 59
Frictional Drag of the

Labyrinth Seal Contact Lipp Seals
Viscous Drag
Frictional Drag of the

Contact Lip Seals Friction of the Rolling
Elements in the Bearings
Main and Secondary Resistances
FM
FN1 FB FI FR
FN2 FN2
Main Resistances Secondary Resistances
FI Indentation rolling resistance of the belt FN1 Charging resistances
FB Belt flexure resistance FN2 Wrapping resistance of the belt
FM Material flexure resistance around the pulleys
FR Rotational resistance of the idler bearings
and seals

Conveyor Power – Main Resistances 61
Resistance to Rotation of Idlers and Movement of Empty Belt

Resistances combined and expressed in terms of an artificial
Coulomb type friction coefficient fr1.
mass per unit length
FH1 = (qro + qru + 2qb cos ) fr1 L g

qro = Mass per unit length of idler rotating parts along carrying side of conveyor
qru = Mass per unit length of idler rotating parts along return side of conveyor
qb = Mass per unit length of conveyor belt
 = Angle of elevation (Note: Typically since ≤15o use cos  =1)
L = Conveyor length, centre to centre
g = Acceleration due to gravity
fr1 = Artificial friction factor due to idlers for unloaded belt
Conveyor Power 62
ESTIMATED (qro + qru + 2qb) kg/m

IDLER DIAMETER ESTIMATED
(qro + qru + 2qb)
(kg/m)
102 mm 50 B
127 mm 60 B
152 mm 71 B
178 mm 105 B
B = Belt Width (m)

Mass of Rotating Idler Components, mro,ru of 3, 2 and 1
63
Part Idler Set (kg)
Belt Width (mm) Outer Idler Roll Diameter (mm)
108 133 159 194
650 12.2 / 10.7 / 8.9
800 14.1 12.3 / 10.9
1000 16.0 / 15.0 / 12.8 24.6 / 21.6 / 17.4
1200 18.6 / 16.9 / 15.3 27.6 / 24.0 / 20.4 34.5 / 30.0 / 25.1
1400 20.4 / 18.8 / 17.2 30.0 / 26.4 / 22.8 37.5 / 32.8 / 28.0
1600 32.4 / 28.8 / 25.3 40.5 / 38.6 / 30.9
1800 46.2 / 40.4 / 34.6 79.1 / 71.9 / 62.4
2000 49.5 / 43.2 / 37.5 86.7 / 78.8 / 67.4
2200 51.9 / 47.6 / 41.9 92.4 / 84.0 / 74.9
2400 97 9 / 89
97.9 89.0
0 / 80
80.4
4
2600 103.4 / 94.1 / 85.9
2800 108.9 / 98.9 / 91.4
3000 114.4 / 103.9 / 96.9
3200 120.0 / 109.1 / 102.4
Ref: Phoenix Conveyor Belts Design Fundamentals (2004)
Mass of Rotating Idler Components 64
mro mru
qro  and qru 
ao au
mro = Mass of carry side rotating idler roll components (kg)

mru = Mass of return side rotating idler roll components (kg)
ao = Carry side idler set spacing (m)
au = Return side idler set spacing (m)

Mass of Rotating Idler Components 65
Example: Belt width = 1400mm

Idler diameter = 133mm
Carryy side idler set spacing
p g = 2m
Return side idler set spacing = 4m
Mass of rotating components for a three roll carry side idler set:
mro 30.0
qro    15.0 kg / m
ao 2
Mass of rotating components for a single roll return side idler:
mru 22.8
qru    5.7 kg / m
au 4
Mass of Belt 66
Reference: Prok Catalogue

Friction Factor Determination 67
ISO5048 - Artificial Friction Factors (Ref: Vierling)

f= 0.017 for well aligned conveyors with smoothly running
idl andd bulk
idlers b lk materials
t i l with
ith low
l internal
i t l friction
f i ti
f= 0.020 for normal applications
f= 0.023 to 0.027 for unfavourable operating conditions,
dusty environments and materials with high internal
friction and occasional overloading
Note: For downhill regenerative conveyors reduce f by 40% of
that used for driven belt conveyors. This results in a normal
value of f = 0.012.
The friction factors should be corrected for conveyor speed:

v (m/s) 6 5 4 3
Correction +10 % 0% -10 % -15 %
Idler diameter correction:

For idlers 89 mm - 194 mm - no correction
For each step in diameter exceeding 194 mm a 10% reduction in fr is permissible.
Temperature influence:
Values of fr shown are valid to approximately 20oC, adjust as follows:
C 5
f r  f 20o  t  
 6 6
where Ct is obtained from the following table:
Temp. oC 20 10 0 -10 -20 -25 -30
Ct 1.0 1.1 1.4 2.0 2.7 3.2 3.8
For garland suspended type idlers, it is suggested from field studies that fr = 0.025.
While fr1 for the carrying side idlers is normally taken to be the same as fr2 for the return idlers, fr2
will tend to be slightly higher than fr1.

DIN22101 Friction Factor Determination for Carry and Return Side

Characteristic Classification
Internal Friction of Bulk Material medium low high
Conveyor Alignment medium good poor
Belt Tension medium high low
Operational Conditions (dusty, cohesive) medium good poor
Idler Roll Diameter (mm) 108 to 159 > 159 < 108
Carry Side Idler Roll Spacing (m) 1.0 to 1.5 < 1.0 > 1.5
Return Side Idler Roll Spacing (m) 2.5 to 3.5 < 2.5 > 3.5
Belt Speed (m/s) 4 to 6 <4 >6
Troughing Angle (o) 25 to 35 < 25 > 35
Ambient Temperature
p (oC)) 15 to 25 > 25 < 15
Results in
A Decrease An Increase
Friction Factor Normal Value
Of the Friction Factor, f
≈ 0.020
Down to Up to
 0.010 ≤ 0.040
DIN22101 Friction Factor Determination for Carry and Return Side

DIN specifies that the use of the friction factor f, is only
justifiable when there are no exacting requirements. If
measurements t for
f the
th running
i resistance
it off idler
idl rolls
ll FR andd
the indentation rolling resistance of the conveyor belt FI are
available, this allows for the following analysis:
1 1
FHo  FRo  FIo  and FHu  FRu  FIu 
co cu
Where: c is the coefficient to determine the primary resistances.

Return Side: cu = 0.9
Carry Side: 0.5 ≤ co ≤ 0.85

DIN22101 Coefficient co for Main Resistance Determination of

Loaded Carry Side
Characteristic Classification
Relative Belt Sag medium high, but ≤ 1% low
Internal Friction of Bulk Material medium high low
Rolling Resistance of Idler Rolls medium low high
Indentation Rolling Resistance of Belt medium low high
Results in
A Decrease An Increase
Friction Factor Suggested Value
Of the Coefficient, co
≈ 0.7
Down to Up to
 0.5 ≤ 0.85
Resistance to Movement of Material Horizontally
The resistance FH2 is:

FH2 = qm L g fr2 cos 
qm = Mass of material conveyed per unit length
fr2 = Artificial friction factor for loaded condition
(Note: Typically since ≤15o use cos  =1)
Qm
qm = v
Qm = Capacity or throughput
v = Belt velocity

Slope Resistance
The resistance Fst is:
Fst = ± qm H g
Where: H = Net change in elevation

+ denotes raising the material
- denotes loweringg the material
Conveyor Power – Secondary Resistances 74
Resistance due to Acceleration of Material onto the Belt

m
Lb
Acceleration Length

1 mg
m
N = m g
v = Belt Velocity vo
The force required to accelerate the material is equal to the time rate
of change of momentum of the material in the direction of the belt:
FN1 = qm v (v - vo)

Resistance due to Skirtplate in Acceleration Zone
s
b h
ds
Kv g h
The drag force for skirtplate resistance is:

4 2 Kv g Lb1 Qm2
FN2 =  b2 (v - vo )2
2 = Friction coefficient between the bulk material and skirtplates = 0.5 to 0.7
Lb1 = Acceleration length (next slide)
Kv = Lateral pressure ratio (Kv = 1.0 for conservative design)
Resistance due to Skirtplate in Acceleration Zone
Acceleration length is:
1 (v2 - vo2 ) v-v

Lb1 = 
1g
{ 2
+ vo min (v - vo ) + vo min2 ln [ vo - vo omin ]}
Where:
2 Kv Qm
vo =   2
min 1 b
1 = Friction coefficient between the bulk material and belt = 0.5 to 0.7

Other Secondary Resistances
• Pulley bearing resistances with the exception of the drive

pulley bearings.
• Resistance due to the wrapping of the belt on the pulleys.
Conveyor Power 78
Special Main Resistances
Special Main Resistances comprise of the following:
• Drag resistance due to the forward tilt of the idler in the

direction of belt movement.
• Resistance due to friction against chute flaps or skirtplates, if

these are ppresent over the full length
g of the conveyor.
y
4 2 Kv g L s Qm2
F S1-2 =
 b2 v 2

Conveyor Power 79
Special Secondary Resistances
Special Secondary Resistances include of the following:

• Resistance due to friction of belt cleaners
• Resistance due to friction with skirtplates present only part of
the length of the conveyor
• Resistance due to inverting the return strand of the belt
• Resistance due to discharge ploughs
• Resistance due to trippers
pp
Conveyor Power 80
Special Secondary Resistances

Resistances due to Belt Cleaners:
s2 1 = A p 3
F s2-1
Where: A = Contact area between belt and belt cleaner
p = Pressure between belt cleaner and belt
3 = Friction coefficient
Resistances due to Discharge Plough:

F s2-2 = B ka
Where: B = Belt width
ka = Scraping factor (usually 1500 N/m)

Conveyor Power 81
Conveyor Driving Force

An expression may be developed for the total conveyor driving
force FU. The total sum of resistances ppresent is ggiven by:
y
That is:
FU = L g [(qro + qru + 2qb cos ) f r1 + qm fr2 cos ] ± qm H g + FN + Fs1 + Fs2
For long conveyors, the secondary resistances FN are of low order

p
compared with the main installation resistances. To account for the
secondary resistances, a coefficient C is introduced as a main
resistance factor dependent on the length of the belt conveyor.
FU = C L g [(qro + qru + 2qb cos fr1 + qm fr2 cos ] ± qm H g + Fs1 + Fs2
Conveyor Power 82
Secondary Resistance Coefficient (Ref. ISO5048)

4.5
For numerical purposes an

4 expression
i for
f C is:
i
3.5
C = 0.85 + 13.31 L - 0.576

COEFFICIENT C
3 for 10 < L < 1500 m
2.5
C = 1.025
for 1500 < L < 5000 m
C
1.5
1
4
10 100 1000 10
CONVEYOR LENGTH L (m)

Conveyor Power 83
Conveyor Driving Force

The operating power required at the driving pulley(s) is:
PA = FU v
Therefore motor power, taking into account the efficiency of the
transmission equipment is:
(i) For conveyors requiring Input power:
P
PM  A
1
(ii) For conveyors operating in Regenerative mode:
PM = PA 2
Where generally: 1 = 0.85 - 0.95

and  = 1.0 - 0.95
Steady State Belt Tension Distribution 84
Tension Analysis
As discussed previously, the total conveyor driving force FU is the
total sum
s m of resistances present:
Using the coefficient, C to account for the secondary resistances

the total driving force may be expressed as:
FU = C L g [(qro + qru + 2qb cos fr1 + qm fr2 cos ] ± qm H g + Fs1 + Fs2
Now graphically !

Carry Side Tensions Return Side Tensions 85
Ffu = C fr1L g (qru + qb)

Ffo = C fr1L g (qro + qb)
Ffu + Ffo = FH1

Ffu Ffu
Empty Belt / Idler Friction Tension
Ffm = C fr2 L g qm
Load Friction Tension
Fst = H g qm
Load Slope Tension
Fsb = H g qb
Belt Slope Tension
Total Tension Distribution
Carry Side Tensions Return Side Tensions
Fe = FU
F1
F2 Ftail Ftail


For the configuration shown, the minimum tension occurs at the tail
end. Hence this end is critical as far as the belt sagg is concerned.
It is important that the tension F2 is sufficient to provide a
corresponding value at the tail to ensure that the belt sag is within
the prescribed maximum value. Two criteria need to be met:
Minimum value to prevent drive slip:
F2 = CW Fe
Required F2 to provide requisite belt sag tension Fo:
F2 = Fo + Fsb –Ffu
The minimum tension F2(min) is the larger of the values obtained.
Fe = FU
F1
F2(min)
Ref. Ftail
Ftail Ftake-up
L L

Conveyor Belt Selection 89
Fabric and Steel Cable Conveyor Belts
Steel Cable – Fabric Reinforced

Conveyor Belt
Fabric Conveyor Belt
Steel Cable Conveyor Belt
Fabric and Steel Cord Conveyor Belts

Belt selection is based on:
• Maximum operating tension F1 and a factor of safety.
• Carcass (steel cable or fabric) determined by maximum tension
and acceptable length changes during operation.
• Bulk material properties (lump size, temperature, etc) and belt
speed will determine the cover type and thickness.
• Operating conditions.
• Loading conditions.
• Minimum number of plies to support load.
• Maximum number of plies for troughing.
• Thickness of top and bottom cover.
• Grade of cover rubber.

Thee des
design ess b o
g sstress of thee be
belt iss g
given
ve by:
bu
b =
fs.
bu = ultimate strength
fs. = factor of safety
y

(a) Fabric Reinforced Belts
For given belt width B(m) the minimum number of piles is given
by:
Fmax
p= for fabric belt
B b
(b) Steel Cord Belts

Th required
The i d strength
t th rating
ti SR (or
( ST) is
i given
i b
by:
Fmax fs
ST = B
ST = maximum strength rating in (kN/m)

Belt Safety Factors DIN22101(1982)

Steady state operating conditions:
1
S sta 
1  r0  r1  r2 
Where: ro = Basic reduction considering fatigue strength of splice
r1 = Reduction for additional elongations due to deflections
of pulleys, troughing transitions and curves
r2 = R d ti d
Reduction due tto d
dynamic
i lloads
d ((starting
t ti andd stopping)
t i )
Non-permanent peak loading conditions:

1
Sinsta 
1  r0  r1 
Belt Safety Factors DIN22101(1982)

Safety factors and reductions
Carcass Operating
p g Basic Non permanent
Non-permanent Maximum loading in the
Material Condition reduction peak loading steady operating condition
kinst ksta
r0 r1 Sinst r1 r2 Ssta
B (cotton) favourable 0.691 0.100 4.8 0.100 0.060 6.7
P (polyamide) normal 0.715 5.4 8.0
E (polyester) unfavourable 0.734 6.0 9.6
Steel cords favourable 0.641 0.150 4.8 0.150 0.060 6.7
normal 0.665 5.4 8.0
unfavourable 0.684 6.0 9.6
1 1
S sta    6.7
1  r0  r1  r2  1  0.641  0.150  0.060 

95
Used for early conveyor

belts.
Common 20 years ago but
Kuralon subject to Bacterial
attack and rarely used.
Nylon << E than Polyester
Good for high impact and
entrapment, but higher belt
stretch will occur.
Currently >95%
of Fabric Belts
PN = EP
Designation for
ISO and
European
Standards
Reference: APEX / Fenner Conveyor Handbook (2000)
96
Reference: APEX/Fenner Conveyor Services (2007)

97
Reference: Goodyear Engineered Products (2007)
98
Reference: APEX/Fenner Conveyor Handbook (2000)

99
100

101
Reference: Goodyear Engineered Products (2007)
Pulley Selection 102
Drive, Tail and Snub Pulley Selection
Pulleyy selection is based on:

• Maximum operating tension Fmax .
• Type of conveyor belt to be used.
• Normally guided by manufacturers recommendations.
• Operating conditions and environment.

Minimum Pulley Diameters (DIN 22101) 103
The pulley diameters in a belt conveyor system depend on the design, on

strains and on the type of splice of the conveyor belt. For minimum diameter
calculations, the following pulley groups will be distinguished:
– Groupp A: Drive ppulleys
y and other pulleys
p y in the range g of high
g belt tensions
– Group B: Deflection pulleys in the range of low belt tensions
– Group C: Snub pulleys (change in belt moving direction ≤30°)
The minimum pulley diameter, DTr can be determined given the thickness of
the belt carcass dGk and a coefficient cTr, which is determined by the material
of the tensile member in the belt:
DTr= cTr· dGk
Material of the tensile member Coefficient cTr
Coefficient,
B(cotton) 80
E(polyester) 108
P(polyamide) 90
St(steel cords) 145
Minimum Pulley Diameters (DIN 22101) 104
Minimum Pulley Diameter in mm (without lagging)

DTr= cTr· dGk
Pulley Load Factor = (kmax / kN ) . 8 . 100 in %
 100% 60% to 100% 30% to 60% ≤ 30%
A B C A B C A B C A B C
100 125 100 100
125 160 125 100 125 100 100
160 200 160 125 160 125 100 125 100 100 100
200 250 200 160 200 160 125 160 125 100 125 125 100
250 315 250 200 250 200 160 200 160 125 160 160 125
315 400 315 250 315 250 200 250 200 160 200 200 160
400 500 400 315 400 315 250 315 250 200 250 250 200
500 630 500 400 500 400 315 400 315 250 315 315 250
630 800 630 500 630 500 400 500 400 315 400 400 315
800 1000 800 630 800 630 500 630 500 400 500 500 400
1000 1250 1000 800 1000 800 630 800 630 500 630 630 500
1250 1400 1250 1000 1250 1000 800 1000 800 630 800 800 630
1400 1600 1400 1000 1400 1250 1000 1250 1000 800 1000 1000 800
1600 1800 1600 1250 1600 1250 1000 1250 1000 800 1000 1000 800
1800 2000 1800 1250 1800 1400 1250 1600 1250 1000 1250 1250 1000
2000 2200 2000 1400 2000 1600 1250 1600 1250 1000 1250 1250 1000
Where: kmax = maximum belt tension in area of pulley under static operating conditions
kN = nominal breaking strength of belt

Other Considerations 105
Other factors to consider during design:

• Loading and discharging the conveyor:
• Feed and transfer chute design
design, eg: belt and lining material wear during
loading, potential for blockages (blocked chutes, flooding).
• Discharge trajectories
• Vertical and horizontal curves:
• Induced belt tensions
• Minimum radii
• M
Maximum
i and
d minimum
i i belt
b lt ttensions,
i eg: different
diff t loading
l di
scenarios.
• Dynamic tension induced by stopping and starting.
Other Considerations 106
• Belt vibrations and noise generation:

• Induced by out-of-balance, non-concentric idlers
• Noise ggenerated by
y motors and ggearboxes.
• Dust generation.
• Influence of varying operating and environmental conditions.
• Life cycle costs:
• Capital costs
• Operational costs

Lecture 3 - Belt Conveying - Static Design Procedure

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Lecture 3 - Belt Conveying - Static Design Procedure

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Belt Conveying of Bulk Solids

This module provides the fundamental design

CBSPT University of Newcastle 1

Static analysis methods include:

Belt Conveyor Carrying Capacity 4

The carrying capacity or throughput for a belt conveyor is given

Where:  = Bulk density of material being carried

CBSPT University of Newcastle 2

Cross-sectional area depends on the belt width and idler

The cross sectional area is a function of the contact or 'wetted'

where b = Contact perimeter

Belt Conveyor Carrying Capacity 6

Shape Factor for a Flat Belt - Single Idler System

b = 0.9 B - 0.05 (m)

Defining  as the surcharge angle and assuming the surface

CBSPT University of Newcastle 3

Surcharge angle is best measured.

Belt Conveyor Carrying Capacity 8

Shape Factor for a Three Idler System

Again assuming symmetrical loading and that the surcharge

CBSPT University of Newcastle 4

Shape Factors - Three Idler System

Belt Conveyor Carrying Capacity 10

Optimisation of Carrying Capacity

CBSPT University of Newcastle 5

Optimum * for Maximum U3 as a Function of  and 

Belt Conveyor Carrying Capacity 12

Optimum * for Maximum U3 as a Function of  and 

= 0.75 &  = 35o

CBSPT University of Newcastle 6

The carrying capacity for a belt conveyor is given by:

Belt Conveyor Carrying Capacity 14

Slope Factor, k (ISO and DIN)

CBSPT University of Newcastle 7

Slope Factor, k (ISO and DIN)

CBSPT University of Newcastle 8

Advantages and Disadvantages

Recommended Max. Belt Speeds

300 (12) 2.0 - -

CBSPT University of Newcastle 9

Conveyor Belt Width 20

Determining Belt Width

CBSPT University of Newcastle 10

Recommended Lump Size Relative to Belt Width (CEMA)

Belt Width and Velocity - Throughput 22

2500  2500

Belt Width [mm]

2000  2000

Throughput @ vb = 1m/s [m 3/h] Throughput [m 3/h]

CBSPT University of Newcastle 11

Annual Equivalent Cost per Unit Length as Function

Cost versus Belt Width Cost versus Belt Velocity

• Belt Carrying Capacity • Power Requirements

CBSPT University of Newcastle 12

The force required to drive a belt must be transmitted from the

Where Power is transmitted

CBSPT University of Newcastle 13

Consider an element of the belt whose position is defined by angle .

Drive Tension Relationship 28

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Considering the equilibrium of the element shown and setting

Drive Tension Relationship 30

The effective driving force Fe, is the difference between F1

Where: Cw = Wrap Factor (which determines how much tension Fe