Tea Beattie a1] Application iatEngineering Science And Application Design For BELT CONVEYORS By ISHWAR G. MULANI B.E. (Mechanical) (Formerly Head of Project Engg. Dept. Krupp-india) The compliment on book (manuscript); from world renown personality in the field of bulk material handling. G “We have seen this book and found to be interesting and useful for design engineers, application engineers and users of belt conveyors and bulk material handling plants. The book provides comprehensive information on design as well as application engineering for wide-ranging practical needs. We wish all the success for the book Engineeering Science And Application Design for Belt Conveyors ~ Dr, R.H.Wohibier Germany."Write / Communicate on following address to get this book : 1.G.Mulani C-1/204, Nikash Lawns, Sus Road, Pashan PUNE — 411021, India Telephone : 0091 — (0) 20 - 5882916 E-mail: parimul@pn2.vsnLnet.in Publisher : Mrs. Madhu.L.Mulani C-1/204, Nikash Lawns, Sus Road, Pashan PUNE ~ 411021, India © with Author and Publisher First Edition : October 2001 Printer : Saurabh Creation, Pune- 411030. India. Copying / photo-copying of book is immoral / illegal and spoils the book. i }ABOUT THE AUTHOR ‘The author is 1967- graduate in mechanical engineering from L.D. college of Engineering, Gujarat University, Ahmedabad, India, ‘The author has more than 31 years of experience in responsible and decision making position {cr application engineering, design and techno-commercial issues concerning belt conveyors, ther equipment and system engineering from simple to most modem plants for handling of bulk materials, in accordance with international practices. This experience has significant value as world-wide advancement inthe field of bulk material handling took place in the past three decades. The experience has been derived by working in reputed companies, who had / have work affiliation with prime German companies in this field. For the last 15 ¥ years, the author was heading Project Engineering department of M/s Krupp-India, which is a part of world: Tenowned Krupp-Germany group of companies. ‘The author has extensively travelled in the world (Germany, France, U.K., other European Countries, USA, Thailand, Malaysia, Korea, Singapore, Indonesia, Bangladesh etc.), as a part of official assignments. This has enriched the know-how and provided better understanding of the technical issues concerning designers and users of belt conveyors. The author's aforesaid back-ground hes enabled him to formulate this book to suit large scale needs, presentation of complex issues for easy understanding, in-built proofs, inclusion of Caleulation models to suit ‘design office set-up’ in business organisations; and to provide clear options for decisions by readers - who are often under time-pressure. The author has put his long term know-how in this book, which is time tested and has been extensively used during tenure of his service in realisation of many bulk material handling Plants; and obviously this know-how signifies the techno-commercial concurrence at various levelsPreface PREFACE This book deals with the fundamentals of belt conveyor design for handling of bulk materials. Any belt conveyor design mainly concerns with the calculation of capacity, belt width, belt speed, drive power and belt tensions. These parameters have profound effect on overall design, construction and ultimately the cost of conveyor as a whole. Therefore, the right design for these parameters is 01 paramount importance. Various methods and formulae are already in use for conveyor design. Much of the published information is seen all around; sometimes mismatching with each other and often without availability of Supporting derivation for designer. The designer can only make the right design if he has complete clarity on the theoretical background for the formula being used. |m view of above, this book aims at derivation / publication of various formulae and norms from first Principles of engineering-science for in-depth perception of the subject matter to the designer. This provides complete information to the designer and automatically clarifies the basic guidelines and limitation if any, for the particular design approach being followed. AAs the engineering analysis and derivations are based on basic rules; the book is likely to have long time ullity, The dynamics of belt conveyor mainly concems with motion and forces, and hence same are on the bas the subject matter by applying analytical engineering approach to various practices being followed for of very well known Newion’s law of motion. The author has tried to give new dimension to rationalization of data and thorough understanding for the readers at large. Although the book has necessary theoretical background, but itis written for the purpose of direct use for application-design for contractual requirements. This is a ‘decision making’ book for design and implementation purpose, Having done all the analysis of a particular topic, specific and clear-cut opinion {suggestions are incorporated to assist the designer / user for his quick / correct decision, to suit contract needs. . For such book to be of practical value, it needs to conform to commercially acceptable standard and ‘norms. The book design-approach primarily relies on ISO-5048, DIN-22101 and latest practices / norms being followed in this field all over the world. The readers, who are used to other standards in Europe or USA practice will also find this book very useful to get new insight into the subject and to comply to the respective standards in a more exact / easy manner. This is due to the fact that although calculation style could be different, the underlying considerations and principles are same.Preface ‘The book is written in S.1 units. However, clear notes are given at the end of certain chapters to use the ‘same in FPS units, which are presently prevailing in USA for belt conveyor technology. It is clarified that for FPS units, the force unit of poundal is used which is synonymous to Newton in S.l. units. This makes the transformation from S.1. system to FPS system quite simple, ie. it does not need any change in S. formula. Only FPS units are to be used in S.|. formula and the derived result is in poundals. This eliminates the vexing confusion whether to apply multiplier “g' in numerator or denominator during conversion between S.I. system and FPS system. Needless to mention 32.2 poundals are equal to 1 pound-force. Thus, all the S.J. formulae related to force-motion are valid when units are mass in Lb., dimension in Foot, time in second and force in poundal; instead of Kg, Metre, Second and Newton respectively. This is applicable to all the formulae, which are derived on the basis of general rules of science, and which are not unit specific empirical formulae. As stated earlier, main subject of the book is to find out belt conveyor important parameters such as capacity, belt width, belt speed, drive power and belt tensions. However, one cannot decide any one of these parameters without proper knowledge of complete conveyor. Therefore, the book contains design related necessary information about various components of conveyor. More information is given on conveyor specific components, compared to general mechanical components suct as gearbox ete. The belt conveyor rarely works in isolation. It is required to function in conjunction with directly associated other equipment and structures. Therefore the book provides conveyor related information about such equipment / structures. For example, the super structure for conveyors is a job for structural engineer, however its dimensioning and arrangement is practically fixed by conveyor designer. Hence, this book includes pertaining information about such items where certain decisions are expected from conveyor designer. The book is writen to facilitate its use by mechani familiar or not familiar to the subject. Therefore, various topics begin with this background of knowledge. engineer with usual qualification, who may be The book practically does not contain self-prociaimed assertions. It goes by engineering principles and Universally accepted practices; and creates Its own reliability by transparency. In this book, more stress is towards engineering approach and methods, which can be adopted for solution. There could be different view about the value of input data, i.e. whether to consider value of safety factor equal to 2.25 or 2.50 for particular case. The designer may adopt such values as per numerous considerations (contractual requirement / standards being followed / level of safely / reliably of available materials ete.) All the care has been taken in this book to provide impartial presentation on the subject matter. The book tries to make designer's work easy. However, bulk materials are highly varied in nature, and therefore, element of engineering judgement can not be eliminated altogether in solution to engineering problems. The designer should decide the right solution beflting to the specific need with open mind and 9Preface approach. As is the usual practice for such publications, the book and the author are not party to decision so made, ‘The author felt necessity to write this book considering the difficulty faced by engineers concerned with this subject, longer induction period, conficting stands in contract implementation and therefore the Need for rationalisation of published information. It appears that the engineering practices / tradition for this subject have multi-center evolution with too much time lag between cross-effect and wilingness to change towards common style, This is some what comparable to varied practices / standards in ‘metallurgy which was not even recognised for scientific consideration till very late stage of industrialisation, in spite of its very long time association with the human survivall The writing of this book; on not so streamlined application engineering subject, is a difficult / hazardous task due to mismatching data / practices. This makes the writing and recommendation process much more complex than anticipated; and one is likely to end the efforts before completion of work. This is particularly true for people in industrial profession. | am thankful to Dr. RH. Wéhibier of Germany for his encouragement to me in this matter, which has really helped for successful completion of this book during 2 years. {lam thankful to mechanical engineers Mr. G.M. Parmar, Mr. Jagdeep, Mr. Parikshit and Mr. Uday Singh for devoting their time and efforts in preparation of certain data and for conversion of the manuscript in t0 electronic form. | also express sincere thanks to all the fiends who have finally helped in publication of this book. The book is dedicated fo all the people who have contributed for the development in this field during ‘course of time; and to human beings’ eternal pursult for rationality and knowledge. Pune: 411 021, INDIA Ishwar G, Mulani Date: 8" November 2000 B.E, (Mechanical) Book AuthorContent Chaptor 4 1.0.0 11.0 144 412 Chapter 2 2.00 24.0 2.2.0 230 240 280 Chapter 3 3.00 34.0 320 330 3.4.0 350 366 3.70 Chapter 4 4.00 410 4.20 430 440 44a 442 443 45.0 454 452 453 454 485 489 46.4 46.2 483 484 485 CONTENT Bulk material handling plants and conveyors Need for bulk material handling plant with conveyors Introduction to buk material handling plant System description List of major equipment and structures forthe plant Introduction to belt conveyor Introduction to belt conveyor Main mechanical components in a conveyor Belt conveyor function Conveyor-profiles (conveying-paths) Method of feeding/loading belt conveyor Method of discharge from belt conveyor Bulk materials Bulk materials Bulk density Repose angle Surcharge angle Abrasiveness Material size Other characteristics Material characteristic data (table-1) Belts Belts Carcass functions and types Covers functions and types Belt types Textile fabric belts Textile fabric multi-ply conventional belts Reduced ply fabric belts (special ply fabric belts) Fabric belt data for conveyor design ‘Steel cord belts Stee! cord construction Steel cord belt construction ‘Steel cord belt characteristics and application Stoolcord belt range ‘Stee! cord belt data for conveyor design Design requirements in belt selection Stifinessiload support Impact strain Balt tension rating Troughabilty Bolt cover thickness Page number 1t09 1102 2009 4107 Ttoe 10016 10 101011 11012 12 131014 141016 17024 7 7 18 181019 19 19 19 20 to 24 251073 28 26 2610 28 28 28 to 36 301033 341035 351036 36 to 29 37 370.98 38 38 to 38 39 391061 30 39042 4210.43, 43 4310.46Content 466 Choice of carcass type 4610.47 46.7 Belt selection procedure 470.48 Examples-1, 2,3 &4 4910.59 468 Note on energy loss / carty forward factor for a lump 591061 Fabric belts’ table 2a, 2b, 20, 2d, 28, 2,29, 2h, 2f and 2) 61 to69 Steel cord belts’ table 3a, 3b, 3c and 3d 701073 Chapter5 Idlers 740134 5.0.0 Idlers 1” 5.1.0 Idlers function 74t075 520 Rolls (Rollers) 751080 624 Shell 761077 622 Housing 7 523 Sealing 7 524 Bearings T7078 525 Spindles 78 526 Greasing 78 527 Roll breathing 79 10 80 528 Roll Quality 80 53.0 Fixed frame idlers 811088 534 roughing idlers (Trough carrying idlers) 81 toaz 532 \V- trough carrying Idlers (2- roll rough carrying idlers) 83 533 Flat carying idlers 83 to 84 534 Impact idlers (Trough impact idlers) 84 635 V = type impact idlers (2 - roll impact iders) a 536 Flat impact idlers 85 537 Flat return idlers (Single roll return idlers) 85 538 V-type return idlers (2 - roll return idlers) 2510.88 539 Self aligning carrying idlors (S.A. carrying Idlers) 86 8.3.10 Soff aligning retum idlers (S.A. return idlers) 86 to 87 83.11 ‘Spacial purpose idlers 87 to88 54.0 Garland idlers 88 to95 S44 Gerland idler profile under load 1 B42 Garland 3 - roll canying idlers 81 tog2 543 Gariand 5 - roll carrying ilers 92 544 Garland 3 - rol impact ites 9210.93 545 Garland 5 - roll impact idles 4 546 Garland 2 - roll return idlers 94 t0 95 550 Main reason for belt misalignment 950.97 554 Misaligned Idlers centerline 96 552 Off conter loading of materiat 96 to. 97 583 Wind force or 554 Misaligned center line of pulleys 97 585 Faulty belt carcass o 56.0 Engineering analysis of selfaligning action by idlers 98 to 145 v oO QOContent 56.4 562 563 564 565 870 580 Chapter 6 600 61.0 620 630 640 Chapter 7 7.00 7.40 720 724 722 723 730 7.40 789 754 752 783 784 755 756 787 758 739 7.8.10 75.44 75.42 7.8.13 75.14 Pivoted setf-aligning idler (includes example-1) Inclined aligning force effect along conveyor width (includes example-2) ‘S.A. force due to trough shape and gravity (includes example-3) Forward tilt for idles (includes example-4) S.A. force due to bow - string effect (includes example-5) Rollers and idier- sets dimensions (includes table-4) Roller design (includes tablo-5 and exemple-6, 7 & 8) Table - 6 : Rotating mass of one roller Example-9 on breathing hole Capacity evaluation in system Capacity evaluation in system Guaranteed capacity Design capacity Examples-1, 2 & 3 for capacity calculation Notes on conveyor capacity (for load / forces) Bolt width, speed and capacity Design for belt width, speed and capacity Functional requirements for belt wicth Necessary belt width for lump size Belt width for material - X Bolt width for material -Y Other consideration to lump size ‘Table — 7: Permissible maxinium lump size (for belt wicth) ‘Selection of surcharge angle (includes table-8) Recommended belt speeds (guide values) Table ~ 9: Recommended maximum belt speed in m sec Necessary belt width for capacity Material cross - section on belt Cross - section on belt - 3 roll troughing idlers (for equal / unequat rol) - derivations. Cross - section on belt- 2 rll roughing idlers - derivations (Cross - section on flat bet - derivations (Cross - section on belt 5 rol roughing idles - derivations Effect on cross - section by gap between roles (includes table-10 & 11) Comparison of area, parabolic and circular are (includes table-i2) Reduction in cross section area due to belt bending radius Reduction in cross - section area due to conveyor inctination Reduction in cross - section area or conveying ability due to fil factor Conveyor potential (abilty) for capacity Principles for selection of belt width and speed Use of table - 13, 14, 15, 16, 17, 18 and 19 for cross ~ section area on belt Examples,283 Table - 13: Material cross ~ section area (parabolic arc) for 3 ~ rol idler ‘Table - 14: Material css - section area (citcular arc) for 3 rol idler Table - 15: Material cross - section area (parabotic arc) for 2 - roll idler vi 98 to 103, 103 to 408 106 to 108 108t0 141 1120 115 1150 119 119 to 123 12410 131 182 t0 134 138 to 144 138 135 135 to 136 136 to 140 140 t0 141 142 to 207 142 142 142 to 148 144 144 to 145 145 to 148 146 to 148 148 to 150 151 to 183 182 164 to 207 185 185 to 161 161 to 164 165 to 166 166 to 172 17310 174 174 175 175 t0 177 177 0178 17810 179 17810 181 181 to 182 182 to 188 169 to 193 194 to 198 199 to 200Content ‘Table - 16: Material cross - section area (circular arc) for 2— rol idler ‘Table - 17: Material cross - section area (parabolic arc) for fat rol idler ‘Table - 18: Material cross - section area (circular arc) for fat rol idler Table - 19: Material cross - section area (parabolic arc) for 5 - rol idler ‘Table - 20: Conveyor inclination factor Chapter8 Material behaviour on belt ‘Material behaviour on belt for transverse load Liquid side pressure I force Rankine theory Active pressure force Passive pressure / force Material side thrust on inclined face Rankine theory application to material on belt “Table - 21: Rankine factors 83.0 Coulomb - Rebhann wedge theory (coulomb theory) 83.4 ‘Active force Fa per meter 832 Passive force Fp per meter length of conveyor, 838 Etfectve force Fs on side roller, per meter length of conveyor 834 Derivation of wedge slope B ‘Table - 22: Coulomb factors 840 Method - 3 (Empirical method) 850 Method - 4 (i$0 formula) 880 Load on midle roller (includes table-23) 870 Concluding remark 88.0 Bett edge clearaice “Cat 90 % uit of material crs section on 3 - roller idler set (includes table-24 & 25) 89.0 Examples, 2,3,4,5,6,7&8 Chapter9 Bott cleaners 9.00 Belt cleaners 24.0 External belt cleaner et Single blade external belt scraper (cleaner) 942 Double blade external belt scraper (leaner) 913 ‘Skew mult - blade external belt scraper (leaner) 914 Cleaning free analysis 945 ‘Specialised extemal belt scraper (leaner) 8.16 ‘Comparison between conventional and specialised blade scraper ear Other extemal cleaners 920: Internal bet cleaner 930 Pulley cleaner 9.40 ‘Scraper design parameters Chapter 10 Bolt tractive pull and power 10.0.0 Belt tractive pull and power 10.1.0 Symbols for engineering quanties vil 201 to 202 203 204 208 to 206 207 208 to 261 208 0 210 an 21210 224 21210213, 21310216 216 10.217 217 to 221 218 224 t0 295 22310 224 228 22510 226 226 to 234 235 235 to 236 237 287 to 238 238 to 230, 239 to 240 240 to 261 262 to 280, 262 262 to 278 263 to 264 264 264 to 265 2650 271 27110274 27410 275 2750 278 27810 279 279 t0 280 280 281 to 364 281 to 282 282 to 285 oO 2 ) °Basic engineering rules on friction 285 10 287 ‘Method adopted for calculation of the tractive pull at steady state 287 Slope resistance, Fs 287 to 280 A Slope resistance carrying run, Fslc 287 to 288 Return run slope resistance, Fsir 288 to 289 Material acceleration resistance, Fa 289 to 200, Main resistance 290 to 315 Rotational resistance of idlers 280 to 203, i Balt flexure resistance 293 t0 294 Material flexure resistance 294 t0 295 Basis for artificial friction coefficient of conveying, 295 to 298 106.5 Calculation of # for conveyor with positive power 296 to 298, 10.6.6 Calculation of for conveyor with negative power 298 to 209 106.7 Division of into constituent coefficients (includes table-26, 26A, 27 & 27A) 299 0 303, 1068 Reasons for earlier said + increment in? (includes table-28, Ex. 1,2,3,4,5&6) 303 10 315 10.2.0 Idlers tit resistance 316 to 328 10.7.4 Tilt resistance by a roller 316 t0 317, 10.72 Tiltresistance for 2 - roll return idlers 317 to 318 10.73 Tilt resistance for 2 - roll carying idlers 318 to 320, 10.74 Tit resistance for 3 - roll roughing idlers (includes example-7 & 8) 320 to 322 10.75 Forward tt for garland idlers due to inclination (includes example-9) 328 t0 326 10.8.0 Skit board resistance, Fskt and Fsk2 328 to 339) 10.8.1 Acceleration zone length La within skirt - board (includes example-10, 14, 12 & 13) 927 to 336 108.2 Skit - board resistance, Fekt 336 to 337 1083 Skirt - board resistance, Fsk2 (includes example-14) 337 to 339 10.9.0 Belt scrapers (cleaners) resistance 339 10 341 10.9.4 External belt cleaner resistance, Foe 340 109.2 Internal belt cleaner resistance, Fei (Includes example-15) 340 10 341 10.10.0 Rotary nylon brush cleaner (external belt cleaner), Fes 341 10.110 Rotary rubber blades cleaner (external belt cleaner), Foe 341 10 342 10.12,0 Pulley cleaner resistance, Fp 342 10.13.0 Discharge plough resistance (includes exampie-16 & 17) 342 10347 10.14.0 Resistance due to related machine 347 t0 349) 10.14.41 Plough feader 37 10.14.2 Traveling trigper (includes example-18) 348 10.143 Recialmer machine 349 10.144 Fixed tripper 349 10.18.0 Pulley turning resistance, Ft 349 t0 350 10.18.0 ~ Belt wrap resistance around pulleys , Fw 350 to 352 4 10.17.0 Conveyor running resistance summary 352 10.18.0 Conveyor resistance summary table-29 353 t0 355, 10.19.0 This chapter and conveyor design 356 t Example-9 356 to 384 vilContent a Chapter 11) Take - up devices 365 to 385 a, 11.0.0 Take-up devices 365 3 144.0 Screw take-up 365 to 366 7 11.2.0 Vertical gravity take - up 366 to 367 9 11.3.0 Horizontal gravity take - up device 368 10 370 a: 11.4.0 Winch take - up device (fixed type) 37016 373 1144 ‘Stretching the belt for tension 372 a: 114.2 Winch take - up operation 372 At 14.3 Application 373 d 14.5.0 Principles for take up etfecton belt tensions 373 to 377 o 11.5.1 Floating take - up pulley (gravity force) 373 10 374 . 11.5.2 Non loating take - up pulley 37410 377 a} 11.6.0 Active winch take - up device 377 10 378 4 11.7.0 Accidental fal of gravity take - up mass (includes example-1), 378 to 381 ; 11.8.0 Tako up stroke (Includes table-80 & 31, example-2) 381 to 983 Oo 11.9.0 Rope and sheave system particulars for take up 384 1110.0 heave frictional resistance effect on take up force 384 10 385 : Chapter 12 Drive units 386 to 408 " 120.0 Drveunits 386 to 387 121.0 Electrie motor 387 : 1220 Gearboxes 388 0304 ° 12.2.1, Foot mounted worm gear box 386 0 389 42.2.2 Shaft mounted worm gear box 389 0 390 12.2.3 Horizontal foot mounted geared motor 390 to 391 ; 12.2.4 Parallel shaft helical goar box 31 } 12.2.6 Bevel helical gear box foot mounted 891 to 992 1226 Bevel - helical gear box shaft mounted 392 to 393, 423.0 Chain drive 393 0 394 124.0 V-belt drive 394 125.0 Mechanical power transmission efficiency of speed reduction mechanism (includes table-32) 394 to 395 . Flexible coupling 395 to 308 7 Pin & rubber bush coupling 307 | Geared type fiexible coupling 397 to 388 Grid type flexible coupling 398 to 309 Fluid coupling 309 to 404 f ‘Traction type fiuid coupling 399 | ‘Traction type fluid coupling with delay chamber 400 to 404 | Three chambers traction type special fui coupling 401 i Scoop type fluid coupling 402 to 403 Fill controlled turbo fuid coupling 403 to 404 Back stop (hold back) 404 to 406 } Pawi and ratchet type 405 - Differential band brake type 405Content 12.83 1284 1290 1210.0 12.14.0 Chapter 13 13.0.0 13, 13.102 13.110 13.120 13.124 13.122 13.130 13:13.4 13.132 13.133 13.134 13.14.0 13.150 Free wheel type (Roller hold back and sprag type hold back) Hold back (back stop) mounting Guards Base frame Notes on drive units Bolt tensions and conveyor design Belt tonsions and conveyor design Minimum tension in belt ‘Minimum tension for application of tractive pull to belt ‘Minimum tension in belt to limit sag Pulley belt fiction coefficient and wrap angle {includes table-33, 34, 35 & 96) Belt tension symbols Principles for calculating tensions in belt at various locations Ts during steady state operation Ts during starting / stopping of conveyor Calculation of tension Te Belt tension Tx at any point along conveyor Effect on belt tensions due to number of drives Drive listibution arrangement for conveyor Drive distribution based on reduction in tension alone ‘Commonly used drive distribution (for economy, etc.) Notes on drive distribution in conveyor ‘Take-up effect on tension calculation Floating take-up pulley (gravity take-up) Fixed take-up pulley (screw / winch take-up) Equivalent ineerly moving mass of belt conveyor Equivalent moving mass for idlers pulleys, Equivalent moving mass for drive unit Material loading on paral lengthis of conveyor Relationship among conveyor starting (braking) factors Starting factors relationship (for conveyors of + resistance during steady state) (includes example-1) Braking factors relationship (for conveyors of + resistance during steady state) Idier spacing (Includes tebte-37) ‘Adjustment in value of conveying resistance to suit calculation purpose Bolt conveyor of positive power Belt conveyor of negative power (regenerative conveyor) Belt carcass selection for longitudinal strength Safety factors for belt tensions Bolt unit strength at joint Joint efficiency Balt strength selection (includes example-2) How to proceed with design Conveyor length coefficient-C 405 to 408 408 407 407 407 to 408, 409 to 537 409 0 411 41110415 41110413, 41310415 41610418 418 41910 422 419 10 420 420 424 421 t0 422 42210 423, 423 10 427, 423 10 424 424 to 428 427 427 0 431 428 to 429 429 0 431 43110433, 432 432 t0 433, 433 43410439 435 10437 437 t0 499 440 10 444 441 10443, 442 44210443, 443 t0 447 443 10 445, 445; 445 10 448, 447 447 '0 448, 448 to 449Content 13.161 13.162 13.163 13.164 13.165 13.166 13.167 13.183 13.184 13.185 13.190 13.200 13.210 13.220 13.224 13.222 19.223 Chapter 14 140.0 (14.1.0 Maa 1442 1413 14.20 1424 1422 14.3.0 Design input basic quantity calculation Conveyor drawing / sketch with basic features ‘Material load per meter length on belt, Mm kg / m Carrying side Idlers rotating mass per meter length of conveying route. Me kg / m Retum idlers rotating mass per meter length of conveying route. Mr kg /m Volumetric conveying capacity design, Im® / sec ‘Astificial friction coefficient of conveying * Bolt mass per meter length, Mb ‘Table-38 Values of coefficient C" (average) Design procedure for belt conveyor tractive pull and belt tensions Original design input: 1P-1 Generation of design inputiP-2 Generation of design inputiP-3 Conveyor design stage! Conveyor design stage-t! Use of ft. f52, fot and fhe for conveyor design Drive type-1, without fluid coupling Drive type-2, with fluid coupling Example-3 & 4 Starting factors relationship (for conveyor of negative resistance steady state) Braking factors relationship (for conveyor of negative resistance steady state) Conventional values of belt line starting factor (includes table-39 & 40) Use of standards / codes in conveyor design Example-5 ‘The design capacity for load on conveyor Examples Material stabiliy on belt under acceleration / deceleration Example” Tension diagram Piotting/depiction of tension diagram ‘Type of tension diagrams ‘Some tension diagrams Drive unit functionat requirements. Drive unit functional requirements Electric motor Conveyor load torque - speed curves (without acceleration) deal torque - speed curve of a prime mover ‘Squirrel cage induction motor torque - speed curve Basic guide lines for drive / motor selection ‘Type - 1 drive (without fluid coupling) ‘Type 2 ative (with fuid coupling) Calculation for starting time 449 to 454 ‘449 to 450 450 450 to 454 451 t0 452 452 482 45210 454 454 484 10 405, 454 to 455 455 455 to 456, 458 0 484 464 to 465, 465 to 479 466 t0 468 468 to 470 47010475 47510 476 47810 477 ATT10 479 479 t0 480 480 to 499 499 to 501 501 to 518 518 10 520, 520 to 532 583 to 537 533 533 t0 534 534 to 537 538 to S47 538 598 to 540 539 539 1539 to 540 540 to 545, 54110 543, 543 to 545, 845 to 547 uContent Chapter 15 1500 154.0 15.4.4 15.4.2 15.13 18.1.4 18.2.0 153.0 183.4 18.3.2 183.3 15.4.0 155.0 155.1 155.2 1553 Chapter 16 16.0.0 16.1.0 16.1.4 16.1.2 16.13 16.1.4 1645 16.1.6 16.17 16.18 16.2.0 16.2.1 1622 16.23 1624 1625 16.26 1627 Chapter 17 17.00 17.4.0 1720 1730 17.46 1744 Pulleys Pulleys (includes table-41) Conventional pulleys (pulleys with plate diaphragms) Pulley construction Plummer blocks Rubber lagging (includes table-42) Pulley crowning Pulley behaviour under load (brief information) Pulley with turbo — diaphragms Pulley construction Taper lock elements ‘Other components of turbo diaphragms pulley External forces acting on pulley Pulley shaft design Basic information on forces, torque and bending moment acting on pulley shaft ‘Theories on shaft design based on stresses Shaft deflection Example: Conveyor frame Conveyor frame Frame fo stationary conveyor Head terminal Tail terminal Bend-pulleys support ‘Stingers ‘Stands Decking plate Wind guard Bott cover Conveyor frame for shittable conveyors Application Composition of shiftable conveyor fame Drive head station (OH) Retum station / Tal station (RS) Modules (Intermediate stations) Approach bridge Intermediate feed station ‘Supor structure ‘Super structure (Elevated structure) ‘Conveying system needs super structures lems of super structure Design norms end requirements ‘Super structure specification with respect to application Gantry (Open gantry) 548 to 568 548 to 549 549 to 554 550 to 551 551 to 552 552 to 583 553 to 854 554 to 585 955 10 558, 956 10 557 557 10 558 558 558 to 559 1559 to 568 559 to 564 561 to 565 566 567 to 568 569 to 587 569 569 1 576 570 svt 872 572 57210 574 874 10 875 57510576 576 878 10 587, 57710579 579 10 580 580 to 584 584 to 595 585 to 587 587 587 588 to 603 588 588 to $89 589 10 590 590 to 591 590 to 603, 591 to 592Content 1742 Gallery (Closed type gantry) 592 to 594 1743 Trestles, 594 t0 595 174.4 Houses for conveying system (Also includes some information on 1595 to 601 springs and viscous dampers vibration isolation) 174.5 Sheds 601 to 603 174.6 Cross over 603 Chapter 18 Conveyor profile in vertical plane 604 to 612 18.0.0 Conveyor profile in vertical plane 604 48.1.0 Curvature effect on tension distribution within belt 604 to 605 1820 Nomenclature 605 to 608 18.3.0 Concave curvature / radius 606 to 608 18.4.0 Convex curvature / radius 608 to 608 18.5.0 Transition length (Includes table-43) 609 10 611 Example 611 to 612 Chapter 19 Introductory information on equipment associated with belt conveyor 613 t0 625 19.0.0 Introductory information on equipment associated with belt conveyors 613 19.1.0 Feeders (belt feeders, vibrating feeders, apron feeders, and paddle feeders) 613 10615 1920 Bet weigher 61510616 19.3.0 ° Magnetic separators (suspension magnet, cross belt type and in ine belt type) «616 10 618 19.4.0 ‘Dust control equipment (dust extraction / collection type and dust suppression type) 618 to 619 19.5.0 ‘Sampling system 619 10 620, 196.0 Unloading equipment (wagon tipple, truck tippler and ship unloader) 620 to 624 19.7.0 Stockyard machines 621 10 625 Stackers 621 Reclaimers (side scraper rectaimer, portal scraper reclaimer, bridge type 621 10 623, scraper rectaimer, bucket- wheel on boom and bucket wheel on bridge) Blending / homogenization of bulk materials. 623 to 625 19.8.0 Horizontal curved conveyor 625 19.9.0 Cylindrical belt conveyor (pipe conveyor / tube conveyor) 625 Advertisement section 1. Krupp Industries india Ltd., Pune 44. Voith India Pvt. Ltd., Hyderabad 2. Mahindra (MECP Ltd. Engg. Division), Pun: 15. Rathi Transpower Pvt. Ltd., Pune 3. Concept Engineering Projects Pvt. Lid., Pune: 16. Saya ron & Engg. Co. Lid., Baroda 4. Magnetic Corporation Of India, Bangatore 47. Sinex Primemovers, Mumbai 5. Kaveri Ultra Polymers Ltd., Mumbai 18, Hosch Equipment (India) Put. Ltd, Kolkata 6. Jayashree Electrodevices Pvt. Lid., Pune 19, RIECO Industries Ltd,, Pune Jayashree Electron Pvt. Ltd,, Pune 20. Kali Material Handling Systems, Chennai 7. Eagle Agro Industries, Rajkot 21. North Land Rubber Mills, New Delhi 8. Oriente! Rubber Industries Ltd., Pune 22, Electromag Devices Pvt. Ltd., Mumbai 9. Fluidomat Ltd., Dowas, M.P. 40, Shaw Aimex India Pvt. Ltd. Faridabad, Haryana 24, GER Vibration Control Systems Pvt. Lid., Noida 11, Electro Zavod (India) Pvt. Ltd, Kolkata 25. Naveen Projects Ltd., New Delhi 12. Elmech Engineers, Mumbai 26. Siemens Ltd., Mumbai 18. Suniron Technique Put, Ld, Pune xii Nilos India Pvt. Lid., ChennaiBulk material handling plants and conveyors Chaptert: BULK MATERIAL HANDLING PLANTS AND CONVEYORS 1.0.0NEEDS FOR BULK MATERIAL HANDLING PLANTS WITH CONVEYORS Modern civilization requires handling of bulk materials in huge quantity. Our present civization aims at producing innumerable items for utlity and comfort of human race. All these items aie produced from raw materials from our unique planet with appropriate process / modification To cite some examples, we need huge-quantity of cement, which is made from mined materials. We need steel to make simple kitchen knife to steamers, which requires movement of huge quantity of iron ore at national 2s well as global level. Every man needs electric power at his disposal, which demands generation of electric power on mega scale. Hence requirement for movement of huge quantity of coal, from mine to thermal power station. The above examples need installation of special bulk material handling system at source of the raw material, and also at process (consumption) unit. The raw materials being mined has to be temporarily stored in gigantic piles, to be retrieved on need and to be loaded into railway-wagons / trucks. When such materials arrive at cement / steel / power plant, same are to be unloaded, stored, retrieved and finally to be consumed for making end product. Again, if the end product is @ new bulk material, it will require further handling for storage, reclamation and onward transport Not to forget food grains; often these are produced in one area, but surplus are to be transported to other area / country. This can demand bringing the food-grains to por, temporary storage, retrieval from storage and loading into ships (steamers). The reverse will happen at the port of receipt Le. unloading from ships, temporary storage at port, retrieval from such storage and dispatch by rail/ road. This needs buik material handling system of sophisticated nature, as quantity involved could be few tens of thousand tonnes in a day. Above are only few examples. The bulk material handling systems have innumerabie areas of application. tn the former time, the handling of bulk materials was manual when tonnage involved were very small. The effect of industrialization now reaching practically to every human being; the bulk materials turn over is now counted in millions of tonnes instead of hundred of tonnes in former times. ‘This demands bulk material handling systems for varied applications. ‘The bulk material handling system consists of numerous equipment, which work in @ coordinated preplanned manner to achieve ultimate functional need. The belt conveyors Bre very prominent and important equipment in such system, to ensure flow of material through various parts of the system. The 1Bulk material handling plants and conveyors designer's first choice is to use belt conveyors for this purpose due to its reliability and ruggednes: ‘except when system layout or nature of the material does not permit use of belt conveyors. 4.4.0 INTRODUCTION TO BULK MATERIAL HANDLING PLANT Bulk material handiing equipment, which also include conveyors, can rarely work in isolation. The bulk material handling equipment generally functions 2s an integral part of system / plant, Such system / plant are commonly known by any of the following names. = Bulk material handling system ~ ‘Material handling system = Bulk material handling plant - ‘Material handling plant The bulk material handling system consists Material inflow | - Boundary limit of “Bulk material handling system’ of many equipment and auxiliary services to achieve required functional needs. The belt conveyors are most populous equipment in such system to achieve material flow from | Materia stacking section starting to end point, in the whole set-up. + The material handling systems are generally ‘Material reclaiming section oe ~ tailor-made to fit into available land-area / + | Material outflow section | portarea / plant-area etc, Therefore, one rarely finds the two systems as an exact —__}—— i i Material outfiow replica of each other. However, all the I atansen tow desperet vehiies) eee eee eens | Bulk material handling system fiowogic | fundamental functions, and accordingly, * a OL Figure A most of the material handling system will have following basic features; as depicted in figure-A System has a section to receive incoming material. This can be ranging from simple manual unloading of truck, to highly sophisticated ship-unloader. System has a section creating some storage. This can be ranging from simple plow-discharge / tripper-discharge storage to complicated stacker to form large stockpiles with varied travel motions. under automatic command. ‘System has & Section for reclaiming the stored material. This can be achieved by simple means such as small hopper at ground level to be fed by bulldozer, or it can include expensive reciaimer machine as per fieeds ‘System will have material outflow section to feed material into consumption unit or into dispatch system / vehicles. : Aforesaid each section of the material handling system will have suitable equipment and conveyors. The equipment and conveyors of each section function in a preplanned coordinated manner for specific 2 oC