Belt Conveyor1

Belt Conveyors
• General Requirements of a transport system:

1. Provide continuity of mineral clearance from the
point of production with maximum safety and
reliability to ensure that the production is not
restricted by transport considerations.
2. Capable of handling peak production.
3. Minimise dust and degradation problem.
4. Eliminate spillage or at least incorporate means of for
its collection and reintroduction in the transport
system.
Thursday, January 5, 2023 Conveyors 1

5. Provide economy in labour requirement.
In general belt conveyor systems satisfy these criteria. The
limiting conditions for using the belt conveyors are:
6. The maximum angle of inclination is 25o ( 1 in 4).
7. The maximum lump size is half the belt width.

Maximum recommended lump size for different belt
widths
Belt width (mm) If uniform lumps If mixed with 80%
(mm) fines (mm)
400 75 125
450 100 150
500 100 175
600 125 200
650 125 250
700 150 300

widths
(mm) fines (mm)
800 150 300

900 175 325
1000 200 375
1050 200 375
1200 300 450
1350 300 500

widths
(mm) fines (mm)
1400 300 600

1500 350 600
1600 375 600
1800 450 600
2000 450 600
2200 475 650

Typical belt speeds
Belt Width Free flowing Run-of-Mine Hard

(mm material Ore/stones
400 2.0 1.5 --
450 2.5 2.25 1.75
500 3.0 2.25 1.75
600 3.0 2.5 2.25
650 3.25 2.75 2.50
700 3.5 3.0-3.5 2.75

Typical belt speeds

800 3.75 3.0-3.5 2.75
900 4.0 3.0-3.5 3.0
1000 4.0 3.0-3.5 3.0
1050 4.0 3.0-3.5 3.0
1200 4.0 3.25-4.0 3.0-3.5
1350 4.5 3.25-4.0 3.0-3.5

Typical belt speeds

1400 4.5 3.25-4.0 3.0-3.5
1500 4.5 3.25-4.0 3.0-3.5
1600 5.0 3.75-4.25 3.0-3.5
1800 5.0 3.75-4.25 3.25-4.0
2000 -- 3.75-4.25 3.25-4.0
2200 -- 3.75-4.25 3.25-4.0

Conveyor belt
• It can be defined as a number of load carrying members
bonded together with polymeric compounds and
protected from mechanical and chemical damage by
elastomeric compounds.
• The load carrying members usually consist of either a
number of plies of woven fabric, a single solid woven
fabric carcass or a single layer of parallel equidistant
cables.
• The belt for the conveyor must be fire resistant for the
underground applications. e.g. PVC belting is used for
underground belts. Rubber belts are prohibited.
CARCASS TYPES
One ply carcass, solid woven.

Impregnated with PVC.
Two-ply carcass With or

without cushion rubber
Multiple carcass
Steel cord carcass. With

damage protection layer in
top cover.
CARCASS TYPES
Woven steel cord or steel strand carcass.
Steel cord conveyor belt with transverse protection cords

CONVEYOR CALCULATIONS
• Belt capacity is dependent on the following factors:
a. Belt width: Minimum belt width may be influenced
by loading or transfer requirements or by the size
distribution of the ROM (refer the table showing the
belt width and size of material). Troughability and
load support restrictions also influence the belt
width.
b. Belt speed: Belt speed is influenced by many factors
important being loading, discharge and transfer
arrangements, maintenance standards, lump size
etc.
CONVEYOR CALCULATIONS (contd.)
c. Material bulk density and surcharge angle: Due to
undulations of belt passing over the conveyor idlers,
the natural angle of repose decreases. The
decreased angle of repose is known as angle of
surcharge. The angle is one of the most important
factors governing the belt capacity as it governs the
area of cross section of the materials being
transported and hence their volume. (Refer Table 7)

When fines are being transported; they slump
quickly or material when being transported on long
conveyers they settle down. This reduces the angle
of surcharge. Hence the capacity may be increased
by increasing belt speed and/or width. Similarly the
bulk density also determines the volume of the
material.
d. Angle of inclination: The angle changes the carrying
capacity. The cross section area of inclined load is
reduced as the surcharge angle is reduced
perpendicular to the belt.
The approximation in the capacity can be done by
multiplying horizontal capacity by the cosine of the
angle. ( (Refer Table 8)
e. Troughing Angle: For standard 3 roll idlers, the most
common troughing angle is 35o. Although trough
angles in the range of 20 to 45 degrees are not
uncommon. Steeper trough angles give increased
capacity but it reduces the life of the belt.

• The capacity of belt conveyors is calculated by the
formula:
C = a× b × v
Where C is the Carrying Capacity, te/hour
a is the area of cross-section, m2
b is the bulk density, te/m3
V is the velocity, m/hour

• The area ‘a’ may be approximated as
• W2 /10 for blocky material
• W2 /11 for granular material
• W2 /12 for very fine material


Surcharge Angle, ‘α’
S
W
Radius, ‘R’
Troughing Angle, ‘β’
Edge width =
0.056b +25 mm

Material Characteristics Surcharge Angle, o
Slurry and fluid material <5
Dry, free flowing material 10
Average flowing material 20
Stable material 25
Mixed lump and fines 30

• For level conveyors, the radius can be ignored.
• The area of cross section can be taken as
Area of base trapezium + Area of Surcharge
Let the belt width be ‘b’, then
S = 0.5 * (b-W)- (0.056 b+25) mm
Area of trapezium = 2 S (Sin β) (W/2) + S2 Sin β Cos β
Which implies that
Area of trapezium = S Sin β (W + S Cos β)
Radius of surcharge = (0.5 W + S Cos β)/ Sin α

• Cross Sectional Area =
10-6 {S Sin β (W + Cos β) + 0.5 R2 (2α – Sin 2α)}
Nominal Belt Capacity in m3/h, = CSA x 3600 V. If the belts
are in other than horizontal mode, then the nominal
capacity should be reduced by the following factors:
Inclination, o Reduction factor
< 10 1
10-15 0.95
16-20 0.90
>20 0.85
• Basic belt tensions:
Let
Angle of lap = θ radians
Friction of the drum on the belt = μ
Tension in the tight belt = T1
Tension in the slack belt = T2
Belt slip is about to occur when T1 / T2 = eμθ
Let Te= T1- T2, then belt power Pe = Te x V . Power
transmitted increases if any one of the μ, θ and Te is
increased.
• Single drum drive
T1
θ
T2

• Now Te= T1- T2 which implies that Te= T2 eμθ - T2

Which further means that Te= T2 (eμθ – 1).
Thus T2 = Te/ (eμθ – 1) and T2 = K*Te where K = 1/ (eμθ – 1)
K is called the drive factor.
Assuming normal values of θ = 230o (4 radians) and
μ = 0.25; we get K =0.58 which implies that T1 = 1.58*Te
which says that the maximum tension should be
approximately 60% higher than the effective tension in
order to run the belt without slipping.

• Utilised Tension Ratio
UTR = (T1-T2)/T1; Since T1/T2 = eμθ =>As μ and/or θ are/is

increased, the UTR also increases.

• Dual drum drive T1
θ2 T2 θ1
T3

• In double drum drive Te= T1- T3; For total angle of lap of
460o and coefficient of friction at 0.25, T3= 0.155 Te and T1=
1.155 Te. The drive factor is 0.155.

• Dual drum drive: The drive is an improvement over the
double drum drive. The arrangement is shown below.
T3
Secondary
T1 T2 Drum
θs
Primary
Drum θp

• Effective tension on Primary drum:
Tep = T1-T2 But T1/T2 = eμpθp and T1 = T2* eμpθp
Tep = T2 (eμpθp -1) Similarly Tes = T2-T3 and T2/T3 = eμsθs

Thus Tes = T2 {(eμsθs-1)/ eμsθs } Thus power distribution
between primary and secondary drives will be in
proportion of eμpθp -1 to (eμsθs-1)/ eμsθs. μp = μs =0.25 and
θp = θs =230o . Substituting the values we get, the
proportion as 0.73 to 0.27. Thus Primary drum shares 73%
and secondary drum shares 27 % power transmitted.

• The ratio of
• T1/T2 is 2.727 and T2/T3 is 2.727
=>T1/2.727 = 2.727 T3
T1 = 2.7272 T3
But effective tension in the system is Te =T1-T3
=>T3 = 0.155 Te and T1 = 1.155 Te

• Conveyor Power Requirement:
The power required to drive a conveyor depends upon:
a. Quality of idler and other bearings.
b. Efficiency of drive head
c. Skill during conveyor Installation
d. Power to flex and trough the belt
e. Operating conditions, friction, mass of belt and
minerals carried

• A conveyor delivers coal at 400 te/h over a horizontal
distance of 3 km. The drive head is 70 % efficient. The
input motor power is established at 425 kW from a motor
rated at 500 kW. It is intended to install the conveyor at a
gradient 1 in 10 to convey the coal up the gradient.
Calculate the maximum distance through which the
conveyor will convey the coal.

• Solution:
Power available to convey the coal, kW = 0.7 * 425 = 297.5
Power to overcome the friction, kW/m
= 297.5/3000 = 0.09917
Maximum power available, kW = 0.7 * 500 = 350
Let ‘L’ be the maximum length on a gradient 1 in 10
Power to haul = Power to overcome the friction + Power
to raise the load
350 = {0.09917 * L + (400 * 9.81 * L)/3600 * 10)} =>
L = 1681 m.
• Power requirement of a conveyor:
The power is required in a conveyor for three purpose:
a. The power required to drive the empty conveyor (Pb)
b. The power to convey the mineral (Pm)
c. The power to raise or lower the mineral (Pr)
Thus total power requirement:
P = Pb + Pm +Pr

• Pb = mb*(L+45) *g *μe *V
• Where mb = Mass of belt conveyor and idlers, kg/m. It is
available from the manufacturer.
L is the length of conveyor; The length is corrected by
another 45 m to take care of the friction.
μe is the coefficient of friction while driving the empty
conveyor.
V is the velocity of the conveyor, m/s

• Pm = mm* L * g * μm * V
Where mm is the mass of the mineral per unit length = C/V
and C is the capacity
μm is the coefficient of friction
• Pr = C * g * h where h is the height through which the

mineral is conveyed.
• Normally μm = μe = 0.03, however under adverse
conditions it can be taken as 0.04. if η is the efficiency
then motor power is P/ η.
• A conveyor is 600 m long and conveys a mineral of bulk
density 0.8 te/m3 up a gradient of 1 in 60 at 220 te/h.
Assume that the belt width is 800 mm. Calculate the
suitable speed and belt strength.
• Solution:
Assuming the area of cross-section to be W2/ 11 and using
the formula C = a*b*v we get
(220 x 1/3600) = 0.82 x 0.8 x v/11 => v = 1.31 m/s.

• In order to calculate the belt strength, we shall first find
out the power, subsequently the tension and finally the
belt strength.
Power (P) = Pb + Pm +Pr
Pb = mb*(L+45) *g *μe *V
Assuming mb = 45 kg/m and μe= 0.03 and substituting the
values of g and V, we get Pb = 11.19 kW.
Now Pm = mm* L * g * μm * V, note that mm = C/V and
assuming μm = 0.04 we get Pm = 14.38 kW
Pr = C * g * h, substituting the values we get Pr = 6.00 kW
• Adding all the three powers we get the belt power as
31.57 kW. Taking efficiency as 90 %. We get the motor
power as 35 kW.
• Assuming double drum drive, with total angle of lap at
440o and coefficient of friction at 0.25. We take the drive
factor as 0.172. T1= 1.172 Te. But Power = Tension * V
=>Tension = 31.57/1.31 => Tension is 24 kN. ( Note that
we have to take the belt power and not the motor power
for calculation.)
• Belt strength is tension per unit width which is now 24/
0.8 and is equal to 30 kN/m.
• Approximation of belt power:
Sometimes empirical formulae can also be used to
estimate the belt power required for certain carrying
capacity and belt speed on level roadway. The same are
given below where S is belt speed in m/s and T is carrying
capacity in te/h:
Formula Belt width, mm
0.75 * S + 0.01 * T 600
Belt Power
in kW/ 100 1.28 * S + 0.01 * T 800
m length 1500
1.95 * S + 0.01 * T
• A Conveyor is having a double drum drive with a total
angle of lap of 460o. The T1/T2 ratio is 7.451. The belt has
six plies with a width of 750 mm. The maximum working
strength of the belt is 5.4 N/mm/ply. The belt carries
mineral at 240 te/h at a speed of 1.5 m/s. Determine:
a. Maximum transmitted belt power.
b. Maximum drive power with an efficiency of 90%.
c. Mass of tension drum

d. Maximum length of the conveyor when installed on a
level road.
e. Maximum length of conveyor when installed on an
adverse gradient of 1 in 6.
Solution:
f. Maximum tension that the belt can withstand:
T1 = 5.4 x 6 x 750 = 24300 N. => T2 = 24300/7.451 =
3261 N.
Belt power = (T1-T2) * V => Belt power = 31560 W =
31.56 kW




b. Drive power = Belt power/efficiency = 31.56/0.9 =
35.07 kW.
c. Mass of tension drum
T2 T2 The tension drum is installed on

empty side of the conveyor. Therefore
we have to consider tension T2. Now
mass of the drum is
m = 2T2/g => m = 665kg
W

d. Power requirement per 100 m = 1.20 * S + 0.01 * T
(since the belt is slightly less than 800 mm hence the
constant has been reduced from 1.28 to 1.20).
Substituting the values we get power requirement as
4.2 kW per 100 m.
Horizontal length = Belt power/ power per 100 m =>
Horizontal length = 31.56 * 100/4.2 = 751 m
e. Vertical lift is 100/6 = 16.67 m.
Belt power per 100 m length = Horizontal power +
Gravity component

=> Belt power per 100 m length =
4.2 + {(16.67 * 240 * 1000 *9.81)/(3600 * 1000)}
= 4.2 + 10.9 = 15.1
Therefore the belt length is 100 * 31.56/ 15.1 = 209 m
Thus the operating length of the conveyor can be
increased by:
a. Decreasing the load
b. Increasing the operating stress ( thereby reducing the
belt life)

c. Using stronger belt (thereby increasing the cost and
application of larger drums hence increased power
cost.
d. Increasing T1/T2 ratio leading to the requirement of
new drive head.
e. Increase belt speed.

• A cable belt conveyor is required to to convey coal of bulk
density 0.8 te/m3 at a rate of 1000 te/h up a drift of 1.2
km length through a vertical lift of 200m. Calculate the
FoS for the rope.

• Solution:
Let us assume the width of the conveyor be 1050 mm and
the area of cross-section be W2/11. Then applying the
formula C = a* b * V; we get V as 3.46 m/s. Assume the
mass of the idlers and other parts as 25 kg/m and the
mass of 35 mm diameter rope as 5.05 kg/m. The total
mass of the belt conveyor is 2* (25 + 5.05 + 5.05) = 70.2
kg/m.
Then Pb = 70 * 1200 * 9.81 * 0.015 * 3.46 /1000 = 42.77
kW

• Pm = 1000/3600 * 1200 * 9.81 * 0.015 = 49.05 kW

• Pr = 1000/3600 *9.81 * 200 = 545 kW
• Total Power is 642.93 kW. Assuming η = 0.9; we get motor
power as 714 kW ≈ 750 kW. Assuming the coefficient of
friction as 0.065 and total 15 radians on the wheel for the
two ropes we get the ratio of tensions as 2.65. Now T2 =
0.5 * (Pe/V) * 2.65/ (2.65-1) = 149.23 kN. Assuming the
breaking strength as 674 kN; we get 674/149.23 ≈ 4.5

BELT CONVEYOR
• A belt conveyor consists of the following:
a. A flat endless belt
b. The idlers
c. The structure of angle iron or channel iron.
d. The tensioning arrangement including loop take up
arrangement.
e. The drums at discharge end and opposite (tail) end.
f. The drive head

Conveyor belts
• There are three main constructional features of the belt:
1. Ply construction
2. Solid woven construction
3. Steel cord construction

Conveyor belts (contd.)
• There are a number of factors those must be considered
before selecting a belt or its cover:
a. Fire resistance and anti-static properties.
b. Resistance to oils and chemicals.
c. Temperature of operating environment and material
being conveyed.
d. Resistance to ageing and weathering.
e. The type of material being conveyed.
f. The lump size and shape of the material being
conveyed.

g. The mix of lumps and fines.
h. The abrasiveness of material
i. The method of loading the belt
j. The fall height of the material on the belt.
k. The cycle time of the belt for the single revolution of
the belt.
l. Performance in the similar application.
m. For replacement- performance of the similar belt.
n. Availabilty and cost.

• The solid woven carcass is typically woven with nylon or
polyester load bearing warp fibres and nylon or
nylon/cotton weft. The whole being vulcanised or fused
together with synthetic binder together with appropriate
cover. The synthetic fibres are stronger, thinner, more
flexible, allow deeper troughs, require small diameter
pulleys and have a small elongation under high working
stress. The covering is of either rubber or PVC. Minimum
thickness of the cover is 0.8 mm. For transport of coal it
should be 2.4 mm on load carrying side and 0.8 mm on
pulley side.

• For transport of more abrasive material it should be 3.6
mm on load carrying side and 1.6 mm on pulley side.
• PVC covering makes the carcass impervious to attach from
moisture, dirt, chemicals, oil and bacteria. Cotton warp
fibres cause improved impact resistance.
• After weaving the roll of carcass is vaccum impregnated
with PVC plastisol containing a blend of polymer (PVC),
plasticisers, stabilisers, fire retarders and special additives.
It is important to control the viscosity of the mixture

• Solid woven belt: In this belt the fibres of the belt are
inter woven, then impregnated to give a solid form and a
covering is applied. The fibres are high tenacity nylon
warp and cotton weft.
• The cover of rubber or PVC is applied on the belt. The
rubber offers improved frictional resistances. This
improves the traction characteristics. A surface which
does not polish which prevents from slipping.
• The solid woven belt eliminates ply construction, edge
wear, rot and oil resistant.

• Steel cord belts: they are used on conveyors where high
belt tension, available take up travel or the requirement
of high elasticity makes the fabric belt unsuitable. Steel
cords also provide excellent splice efficiency

• Material weight on the chain in kg (m1) = tonnes per hour
x distance in meters /v x 3.6.
• Power (P) = v x ( m1 x μ1 + m2 x μ2 ) x 9.81/1.000
• P = Power, kw
• μ1 = friction between steel and the product (for a smooth-
running product 0.25)
• μ2 = friction between the steel bottom and the chain
• (for steel pushers approx. 0,25 and for plastic pushers
approx. 0,15)

Textile Belt splicing
On both belt ends a chalk line
will be applied for the belt
centre line (the rectangular
datum lines, as well as the
marking lines of the splice).
For determining the centre
line, 3 centre points at
intervals of ~ 2 m will be
marked.

The fist step of the splice
should be in the bottom side
and the first to touch the
drive pulley.
Both partial lengths will be

put one on top of the other
along the whole splice
length. The lower part of the
portable heating press is
used as a working table. For
positioning the bottom
platens of the press both belt
ends will be folded back.

The splice length will be
transferred to the combined
rubber sheeting and the splice
edge will be placed to the lower
splice edge of the second belt end.
In accordance with the rectangular
datum line it will be checked
parallelly and diagonally whether
the alignment is correct. If not it
will be readjusted.
Combined rubber sheeting will be
tapped with a mallet. Cut with a
knife at a 30° angle down to the
fabric.

The rubber covers both of carrying
and running sides of both belt
ends will be removed
In the rubber cover on the
carrying side along the inner splice
line marking, cut with a knife held
at a 30° angle until it gets down to
the fabric.
The rubber edge of the belt will be
removed.
For stripping the rubber cover,
continuous strokes with a special
knife with grip tongues are used.
The rubber will be removed down
to the fabric. Tearing it off is not
permitted.

For cutting the plies a special
ply knife is used. This knife
prevents damage to the ply
underneath.
Splice edges of the carrying
and pulley side of both belt
ends will be roughened with
a wire brush.

The textile plies are coated
with rubber solution by
means of a brush or a
spatula. Let dry well!
An unvulcanized rubber sheet
will be put on the fabric. To
avoid air inclusions a hand-
roller is used.
The alignment of both belt
ends is controlled by means
of a string across the three
marked centre dots. A chalk
line will be marked and
rubber edges will be trimmed
off.

Between the lower heating
platen and the bottom
rubber cover, Vulcatrix cloth
is placed across the whole
splice area.
Edge bars will be placed at
both sides of the belt and
fastened with edge clamps
outside the splice area.
The edge bars will be
approximately 1-2 mm
thinner than the belt itself.

Between the lower heating
plateupper
The and the bottom
plates are rubber
placed
cover, aligned.
and Vulcatrix Theis placed
upper
across the
traverses will whole
be placedsplicing
in a
area.that
way Vulcatrix clothtraverses
both end should
be longer
are in bothoutside
positioned longitudinal
the
directions
splice area.and at least 50 mm
larger than the splice itself.

• The end locking bolts are positioned and tightened
slightly.
The oil pumps are connected to the upper traverses.
The end bolts are tightened thoroughly.
The electrical cables are connected to the heating platens.
A pressure of ~10 bar is applied with oil pump. The
heating platens are plugged in.
The pressure is increased as temperature rises.
Temperatures at all heating plates to be controlled.

• The temperature is adjusted by switching energy on and
off. After several minutes allow temperature to rise to
142° C. The curing time counts when temperature reaches
142 ° C.
Disconnect at 145° C!
Plug in again when temperature drops to 142°C!
The curing time is determined according to belt thickness,
i.e. 2,5 minutes per mm of belt thickness.
After the curing time has elapsed, the platens are allowed
to cool down to 60° C.

• The traverses and end bolts will be loosened and removed.
The upper heating platens are removed.
The edge clamps are loosened and the edge bars are
removed.
The spliced belt is lifted and the lower heating platens are
removed.
The working platform is removed.
Rubber overflow at both edges is trimmed off.
The belt surface, the ramps and the edges are inspected
visually.
The belt can be put into service.

Steel cord belt splicing
The components of a steel cord
conveyor belt splice:
1) Cover sheets.
2) Transverse reinforcement
embedded in unvulcanized
core rubber. It is applied like a
second core rubber sheet.
3) Core rubber sheets.
4) Steel cords with original core
rubber.
5) Intermediate rubber strips.

Setup of the working table.
For positioning of the bottom
platen(s) of the curing press
both belt ends are folded
back.
The bottom part of the
vulcanizer is used as a
working table.

The belt ends have to be
tensioned as much as possible to
avoid sag.
Both lengths will be laid one on
top of the other over the whole
splice length. If it is necessary to
shorten the belt(s), a wedge-
shaped strip of approx. 20 mm
width is cut out of the upper
cover so that the steel cords
become visible. The steel cords
will be cut with a high-speed
abrasive cutting tool with fabric
reinforced disc.

The belt centre is marked on both belt
ends and also at a minimum of three
other points that are approx. 1500 mm
(5 feet) apart. These centre points are
then joined into a centreline using a
chalked string. Approximately half a
metre behind the splice area a
crossline is drawn at right angles to the
centreline as a reference line. One
marked belt end is placed on top of
the other marked belt end. The
centrelines on each end must be
precisely aligned.

The cover is cut transversally down to the
cables. The knife is held at a 45° angle. The
rubber edges are removed as far as the first
steel cord.The belt centre is marked on both
belt ends and also at a minimum of three
other points that are approx. 1500 mm (5
feet) apart. These centre points are then
joined into a centreline using a chalked string.
Approx. half a metre behind the splice area a
crossline is drawn at right angles to the
centreline as a reference line. One marked
belt end is placed on top of the other marked
belt end. The centre lines on each end must
be precisely aligned.

By means of a tensioning tool
the cover is removed,
supported by a knife that
cuts between the cover over
the steel cords.
Do not tear the cover off! The
procedure is repeated for the
bottom sides of the belt
ends.

The rubber between the steel cords is
removed. The cords should be
carefully buffed with a rotary brush.
They remain completely covered by
rubber after this procedure. This
procedure can be done very
conveniently with a "CordStripper"
(see video on the left). "Piano wires"
or similar methods should not be
used

The top and bottom sides
and the ends of the
separated steel cords will be
brushed with a grooved wire
brush. Buffing dust be swept
off by means of a hand brush.
Do not use cleaning solvent!
The steel cords will be coated
with a special rubber
solution, and dry completely.

An unvulcanized cover rubber
sheet is placed at the bottom
of the splice on top of a
separation cloth. The cloth
should be approx. 300 mm (12
inches) longer in the
longitudinal directions.

The alignment is checked
again.
The steel cords have to be

positioned as determined by
the belt manufacturer or by
the standard
By the way; No cable has

contact to any other cable.

All gaps between the cables are carefully
filled with intermediate core rubber up to the
height of the cables.
The entire splice area will be sparingly coated
with rubber solution and dry completely.
Rubber edges are applied on both held sides,
coated with solution and dry well. The edges
are tapped thoroughly with a mallet.
Protruding rubber is cut off.
The straightness of the splice is again
checked.

Edge bars, approx. 1 mm
thinner than the belt, are
placed against both belt
edges (see video left side)
and clamped outside the
splice area.
The bars are 1-2 mm (1/16
inch) thinner than the belt.

Upper platens are placed and aligned End
locking bolts are tightened slightly.
Oil pumps will be connected to upper
traverses.
End bolts are tightened thoroughly.
Electrical cables are connected to the
heating platens.
A pressure of approx. 10 bar (150 psi) is
applied with oil pumps.

A vulcanizer setup in
a climatized working
shed. The curing time
is depending on belt
thickness and rubber
grade. As a rule of
thumb, a curing time
of 3 minutes per 1
mm belt thickness is
required.

Care of the belt
a. Protect the belt from direct sunlight during storage in
a dry, cooled and ventilated shed.
b. Use drive drums, delivery as well as tail end drums of
adequate diameter so that sharp bending is avoided.
c. During use, avoid unnecessary bending.
d. Prevent the belt from rubbing against any prop,
support and stationary items and avoid wandering of
the belt.
e. The cotton fabric belt loses its strength gradually due
to the action of moisture.

Even small punctures can permit moistures to reach
the fabric. Where the belt is joined with fasteners, the
moistures enters into the belt at these places.
f. The loading of the mineral on the belt should be
smooth. The mineral should be deposited on the belt
portion stretching between two supporting rollers so
that the elasticity of the belt takes care of the shock.
The mineral should fall on the belt in the direction of
its travel.
g. Avoid rubber covering for the material having sharp
edges. PVC belts are recommended in such cases.
Troughing idlers
• The belt travels on idlers placed at intervals. The idler is a
long pulley rotating on its axles. For the transportation of
minerals the belt should be given a troughing shape. The
shape is achieved by putting three idlers. The middle idler is
kept horizontal and the remaining put at an appropriate
angle nearly 30o. For very wide belt, five idlers are used as
troughing idlers. The idlers should be installed such that its
axle should rotate at a right angle to the belt travel. If the
belt is not running along a predetermined line; the fault
obliviously lies in idler installation. In such cases, it is
advisable to adjust the a number of idlers slightly rather than
adjusting one by larger amount.
• Idler spacing is an important aspect of their installation.
As it determines the sag. Normally the idler spacing
should be such that ratio of such sag to the idler spacing
should not exceed. 0.02. The table on the following slide
gives the spacing of idlers for different belt widths and
mineral densities.

Belt width, mm Idler spacing, mm for
Upto Density of Density of
density of 1.2 te/m3 to 2 2.0 to 2.8
1.2 te/m3 te/m3 te/m3
400-600 1680 1500 1350
600-900 1500 1350 1200
900-1200 1350 1200 1050
1200-1500 1200 900 900

• In addition to above; the following designs are also used:
a. Cushion impact idlers; They incorporate resilient
rubber disc designed to absorb impact. The nests of
such idlers are fitted under the loading points to avoid
lump breakage and damage to the belt.
b. Rubber disc return rollers: They have wide spaced
rubber discs. They are used at selected places to avoid
build up of clay etc. which may otherwise stick to the
bottom return belt.

c. Self aligning training rollers: Such idlers are installed
on a swiveling base to enable to align themselves
along the belt.

Sequence Control
• The sequence control is used when a series of conveyors
are operated.

Drive head
This consists of an electric motor, fluid coupling, gear
wheels and a drum which provides the required arc of
contact. The drum is sometimes lagged with friction
lining to increase the coefficient and snub pulleys
increase the arc of contact. The position of drive depends
on:
a. On level, uphill and undulating gradients, the drive
head is located on the delivery end. The belt is
tensioned near the drive end after it leaves.
b. On downhill conveying the drive head is not very close
to the delivery end.
• On long conveyors, the motors are located at each end.
Sometimes on conveyors having high carrying capacity the
motors are located near to each other. The motors are
sequentially arranged in case of intermediate conveyors.

Tension and Look up Arrangement
Loop take Up
Belt ke up Drum
Lo op Ta
Delivery Jib
Snub pulley
Tensioning Driving drum

Drum
Weight

• The purpose of the loop take up arrangement:
a. To maintain adequate tension in the return belt during
start up and under varying load conditions to ensure
effective operation of the belt.
b. To accommodate length variation of the belting due to
permanent and elastic stretch.
c. To act as a storage for spare belting which can be
utilised if a length of belt has to be removed due to
accidental damage or to remake a spliced joint.
d. To allow a degree of tolerance in the length of belting
installed.
• A minimum of 1% of conveyor length is stored on loop
take up.
• The loop take up arrangements can be classified as
a. Screw take up: The screw take up is used on short
length conveyors. The position of the return drum is
adjusted using the screw. The screw take up have a
limited capacity of about 900 mm and in general can
be used on the conveyors having length more than 76
m.

b. The gravity take-up: On long conveyors, gravity take up
arrangements are used. They may work in vertical,
horizontal or inclined planes. The amount of take up
varies from 1 m to 12 m. The counter weight must be
such that minimum tension is always available to avoid
the slack or sag and sufficient tension is always available
to transmit the load.
c. Vertical take up: They are natural favourite at the surface
but rarely suitable for the underground conveyors. The
vertical take up arrangement is provided in the return
belt just after behind the driving drum.

Loading the belt
• A disproportionate wear of the belt along with the
damage may take place at the transfer points. Proper
loading of the conveyor therefore becomes important.
• An ideal loading arrangement therefore should have:
a. The free flow of mineral on to the belt at
predetermined rate in the same direction and with a
transfer velocity equal to that of the conveyor.
b. Regular disposition of the mineral along the belt
centreline.
c. Freedom from the undue breakage of the mineral.

d. Minimisation of spillage and dust.
e. A low abrasive rate of the belt.
The belt should have impact idlers beneath it at the

loading point alongwith centralised skirting plate so that
the material falls mostly in the centre line. Conveyor may
be loaded by any one of the following method.
f. Transfer from another conveyor.
g. Gravity discharge from a bunker or a hopper.
h. Controlled feed gate.

d. A powered fixed or moveable tripper.
e. An electro or mechanically operated vibratory or
reciprocating conveyor
Transfer from other belts: Transfer will be effected by a
chute fixed below the discharge head pulley. The chute
should have wear resistant liners. The bottom plate of
chute should not be higher than 25 mm. So that at low
speeds during starting and stopping the mineral falls
vertically and does not damage the belt.

Speed has a considerable effect on the trajectory of the
mineral leaving the head drum. The fig shows such
trajectories of such particles leaving the drum at different
conveyor speeds. The chute length can be reduced by
deflecting the mineral on an adjustable plate shortly after
leaving the delivery drum and controlling the flow by
maximising the contact with the chute plate.

• Alternatively a plough can also be used to transfer the
mineral from the other belt. The plough consists of a
blade put inclined across to the belt. The method is useful
when the headroom is less or a proportion of mineral is to
be transferred to the other conveyor. However the plough
causes undue belt wear.
• The third method is by using a tripper. The tripper is fixed
or movable. It consists of two pulleys. The upper of which
is the discharge point. The tripper is mounted on a
carriage in case of movable one where as the fixed one is
used in case of abrupt change in gradient
Armoured Face Conveyor

AFC On LongWall Face

Armoured Face Conveyor
• Once the coal is cut, it has to be removed from the face to
the maingate, so some form of coal haulage system is
required. In early hand-working days, belt conveyors were
used, but these are not amenable to high production rates
as the whole conveyor had to be moved sideways to
advance the face.
• The major development, apart from self-advancing
supports, allowing high production longwalls to evolve
was the "Armoured Face Conveyor or AFC" which was
originally developed in Germany and was frequently (less
so nowadays) referred to as a "Panzer" conveyor.
Armoured Face Conveyor (Contd)
• Essentially an AFC is a one-sided trough scraper conveyor,
the second side of the trough being formed by the coal
face. Cut coal falls into this trough which has an endless
chain with scraper flights attached running along the base
plate and returning below the base plate in an enclosed
lower section or "race". The coal is dragged along the base
plate by the flights.

• Early AFC's had two outboard chains, one running each
side of the base plate with flights connecting them. Later
developments saw the two outboard chains replaced by a
single centre chain with flights cantilevered each side.
With increasing longwall size, the single centre chain has
now become a double or triple centre chain on almost all
longwalls.

• The outer ends of the AFC flights (or outer chains on old
AFC's) are kept in place on the base by a channel section
lip at each side of the base. A similar arrangement for the
return chain below the base leads to this part of the AFC
being known as the "Sigma Section" because of its shape.

• The chain is driven, via sprockets, by electric motors at
both ends of the face (maingate and tailgate, although
earlier AFC's were driven by maingate drives only). These
drives must sit in line with the face at each end and the
size of drive(s) required is often the limiting factor on the
practical face length (along with AFC chain strength and
size). To accommodate the sprockets and shafts, specially
shaped AFC sections have to be used at each end of the
AFC to raise the chain path.

• To provide a degree of horizontal and vertical articulation
in the AFC along the face, the AFC consists of many
individual sections joined together with flexible couplings,
these sections being known as "pans". The length of each
pan is normally the same as the chock width, so the face
has the same number of chocks as pans over most of its
length (some special arrangements are required at the
face ends). The flexibility allows the AFC pans to be
moved in differing amounts along the face so that short
lengths can be pushed towards the face forming a bend or
"snake".

• The connection between pans is by means of dumbbell
shaped bars (known as "dog bones") slotted quite loosely
into brackets mounted on the back plates and the front of
each pan.
• Pans with a removable section in the base plate, known as
"inspection pans", are spaced along the face, to allow
access to the bottom race for cleaning or repair purposes
as well as inspection.

• In order to move the AFC forward after the shearer
advances along the face, hydraulic cylinders mounted
horizontally on the support bases are attached to the steel
(or goaf) side of the AFC trough, referred to as the "back
plate" or "spill plate". These cylinders are double acting,
and besides being able to push sections of the AFC
forward, are utilized to pull forward or advance the
supports, once they are lowered from the roof.

• The main and tailgate drives are mounted on base plates
which have to be rigid (the drive trains can only have
minimal flexibility), so support attachments at the face
ends are generally via rigid structures and the drives are
pushed forward by several chocks at the same time.

• Coal is actually cut in front of the AFC, so a lot of the coal
initially sits on the base of the cut section and does not
fall directly onto the AFC. This coal is lifted onto the AFC as
it is pushed forward. Because it is necessary to cut the
maximum amount of coal on each web, it is important
that this coal is able to be cleaned up as the AFC advances
and not left on the floor, thereby preventing the AFC being
pushed right to the solid coal.

• For this reason the front edge or toe of the pan is
normally built in a wedge shape, to ramp up the coal at
the face and assist in the clean up (hence the toe of the
pan is sometimes called the "ramp plate"). In the past
small ploughs were sometimes fitted to the front of pans
and dragged along the length of the face to improve the
loading (commonly referred to as "activated ramp
plates"). Improved toe plate design on modern longwalls
has obviated the need for theses activated ramp plates.



AFC Calculations
• Power required to drive a conveyor is the sum of those
powers required to drive the empty conveyor, convey the
coal horizontally, recirculation of the fines and raising the
load.
• Power required = Effective chain pull X Chain speed.
• Effective chain pull = {( 2CLFc + (MLFm) + (mLFm) + (MLG)}g
• Where C = Chain Assembly factor, kg/m
M = Unit mass of material on the conveyor (kg/m)
L = Length of conveyor, m

• m = Mass of recirculated fines usually 0.5 to 1 % of M
• Fc = Coefficient of friction of the Chain = 0.33 (say)
• Fm = Coefficient of friction of mineral = 0.60 (say)
• G = Gradient
• The coefficient of friction varies from 0.33 in dry
anthracite to 0.8 in wet and slack Coal.
• AFC power = Chain pull (N) X Chain speed (m/s)

• A longwall face is equipped with a shearer loading at a
rate of 500 tph to a 190 X 781 mm wide conveyor of
length 220 m. The mean chain speed is 1.11 m/s. Calculate
the power of AFC. Assume chain assembly factor as 25.9
kg.

Shaker Conveyor

Shaker Conveyor
• This is essentially a downhill conveyor although it may
function satisfactorily on level roadways. It is rarely
suitable for a slightly rising roadways.
• The conveyor consists of a line of troughing in 10 to 11 ft.
sections connected to each other by bolts.
• The normal cross sections are 45, 80 and 100 sq. in. The
capacity is generally lower than that of a belt conveyor.
• The capacity of the conveyor increases with that of the
inclination.

Shaker Conveyor (Contd.)
• The line of troughing is reciprocated by an electric motor.
• The high rotary motion is converted into slow
reciprocating motion such that a quick forward stroke is
suddenly arrested and succeeded by a slow backward
stroke.
• During the backward stroke, the inertia of the coal causes
it to move forward.
• The capacity of the conveyor is controlled by gradient,
length of stroke and trough section. The inclination not
only covers the length of stroke but also the length of
trough section.
• The length of stroke decreases from 5 to 20 cm. The
number of strokes varies from 60 to 90 per minute.
• The length of conveyor is 30 m on level, nearly 50 m on
inclination of 1 in 5.
• The Coal slides in stationery troughs at 18o . The capacity
varies from 45 te on level to 110 te at 1 in 3.
• The position of engine relative to the line of troughing is
a. At the rise end.
b. In a gate at right angles to the face
c. Alongside the conveyor in intermediate position.

d. Underneath the conveyor near the bottom. The
underneath drive.
The arrangement ‘a’ is used on steeply inclined seams
whereas the ‘c’ and ‘d’ is popularly adopted in less
inclined seams.
The advantage of shaker conveyor is that it can work in
wet conditions and can negotiate small faults which
throw in the direction of coal delivery.

Chain Conveyor

Chain Conveyors
• Chain speed in m/sec (v) = z x t x n/60.000
v = chain speed, m/s
z = number of teeth
t = chain pitch
n = rotations per minute
• Capacity in kg per hour (Q) = A x v x 3600 sec.
Q = capacity, m3/hour
A = trough width x layer height, m2
v = chain speed, m/s


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Belt Conveyors

• General Requirements of a transport system:

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800 150 300

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1400 300 600

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Belt Width Free flowing Run-of-Mine Hard

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Belt Width Free flowing Run-of-Mine Hard

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Belt Width Free flowing Run-of-Mine Hard

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One ply carcass, solid woven.

Two-ply carcass With or

Steel cord carcass. With

Woven steel cord or steel strand carcass.

Steel cord conveyor belt with transverse protection cords

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Surcharge Angle, ‘α’

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• Now Te= T1- T2 which implies that Te= T2 eμθ - T2

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UTR = (T1-T2)/T1; Since T1/T2 = eμθ =>As μ and/or θ are/is

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Tep = T2 (eμpθp -1) Similarly Tes = T2-T3 and T2/T3 = eμsθs

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• Pr = C * g * h where h is the height through which the

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T2 T2 The tension drum is installed on

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• Pm = 1000/3600 * 1200 * 9.81 * 0.015 = 49.05 kW

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