The Pipe Conveyor

The Pipe Conveyor

The convincing Transport System for every type of bulk material

Costumers

Coal and Lignite Power Plants Cement Plants Steel Works Chemical Plants Wood And Paper Industry Mines Processing Plants

Market
Wet and fly ash, slag, REA gypsum, FGD, filter cake. Limestone, lime, gypsum, chalk, cement, clinker, clay, pozzolan. Woodchips, wood pellets, straw pellets, bark chips, paper pulp, sewage sludge, wood waste, saw dust, biomass, garbage, dried sewage, substitute fuel. Coal, coal dust, lignite, tailings, muck. Bauxite ore, bauxite, alumina, petcoke. Iron ore, sinter, chromite, slag sand, gold ore, copper concentrate, zinc and lead concentrate, nickel, Kieserite, dolomite, crushed hard rock, slate Raw phosphate, phosphate, urea, fertilizer, sulphur, Plastic granulate,

Strength

For almost all bulk materials Long reference list capacity up to 8000 T/H length up to 8200 M built diameter up to 650 mm built

No spillage on return sector of conveyor Simultaneous conveying in upper and lower conveyor strand Optimal adaption to extreme field conditions ddue to horizontal, vertical and 3-dimensional curves Safe and technologically perfect adaption to existing industrial facilities Special applications Maximum protection of the transported material and the surrounding environment Long distance transport Low space requirement 50 % higher inclination compared to conventional conveying systems Safe downhill transportation with high percent of slope

Pipe Conveyor References > 2300 m length Client Pingyuan Petrozuata DMW - Shaw / Cleco JPMC Eshidia Mine SAIL - Bhilai, Chhattisgarh. EVN AG - KW Drnrohr Birla Copper, Dahej Country China Venezuela USA Jordan India Austria India Pipe mm Length m Capacity t/h Material clinker, coal petrol coke, sulfur petrol coke, limestone phosphate lime coal copper concentrate, rock phosphate, coal coal gypsum FGD limestone alumina fines port handling power raw material steel power mining Industry Year of comm. 2004 1999 2008 1995 2012 2010 1999

350 500 500 400 200 300 450 350 300 350 400 250 650 400 300 350 300

2274 2301 2458 2834 2912 3160 3200 3600 3870 4050 4334 4350 4353 4875 5420 6200 8200

1000 1500 1361 1250 100 550 1760 1540 1100 600 453 1100

VINACOMIN DMW - First Energy Sammis Penna Cement, Tandur, Andhra Pradesh Vedanta Alumina Ltd, Orissa Taiyuan NTPC - Vallur, Tamil Nadu Vedanta Alumina Ltd., Lanjigarh Orissa Ausenco Services Pty Ltd Holcim Shurova Cementos Lima Lanjigarh

Vietnam USA India India China India India Papua New Guinea Russia Peru

mining power cement alumina steel power alumina mining cement cement

2009 2009 2012 2009 2006 2012 2007 2009 2009 2008
8

200 4000 1150 800 1400 690 515

limestone burnt coal bauxite ore gold ore limestone cement or clinker ; coal or limestone

Weaknesses

Sensitive to overfilling and oversize material Higher power consumption Higher investment costs.

Main Components
Conveyor Belt
ply: steel or fabric running side carrying side molded edge Fabric insert for curve-going ability Rigidity to stabilize All common properties available Diam.(150) 200 to 650 (800) mm Tensile strength up to 5000 N/mm Different suppliers EP or ST type possible Special edge structure

11

Conveyor Pulleys
Bigger pulley diameter Wider pulley face The ceramic pulley lagging ensures a high coefficient of friction

12

Idlers
permanent lubrication multiple labyrinth seal Low friction factor Exposed to rain water Site conditions to consider Usage of different bearings Axial forces to consider Gaps in placing possible

13

Drive Unit
Bevel helical design reduces space hollow shaft for low size Bigger sized gear boxes connect by coupling Multiple drives are possible Intermediates drives are possible VFD controlled, torque controlled Fluid couplings Gear motors Back stop devices Creeping speed by additional gear motor Forced lubrication can be required due to lower speed, Forced cooling Full torque required
.

Load distribution to reduce forces Load combinations to consider

.

14

Drive Unit
Brakes
At high speed side At low speed side Consider throttle valves Controlled brake torque over time ramp With power back-up For downhill applications To manage full and empty conditions

15

Take-up systems

screw-type tail take-up

gravity head take-up vertical

gravity tail take-up

winch type take-up

gravity head take-up horizontal

16

Take-up systems
Cap stan brake to increases take-up tension while braking

Tower with drive unit and take-up Take-up with controlled winch

17

Belt Cleaning System

18

Pipe Conveyor Belt Scale

integration in the standard cross section for weighing and control of the transported material Conventional scales possible in transition area

19

Design of Pipe Conveyor

Feeding area
Skirt board Width = 1,6 to 2 x PC diam. Shorter length due to transition area Variable idler stations necessary Finger rollers to close the belt

20

Feeding spoon to accelerate material and avoid dust

21

Transport in upper strand

Transport in upper strand and lower strand

22

Intermediate feeding

23

Multiple feeding

24

Double Transport Patented Pretzel

25

Double Transport

26

Safety devices feeding area

Overfill Paddle at Skirtboard

Overfill Paddle to avoid Belt Overloading

27

Safety Flap Panel

flap panel opens automatically if the belt is overfilled with either the product or with foreign material

28

Mechanical Belt Rip Detection

Feeding Table

Conveyor is stopped when foreign material penetrates the belt

29

Electronical Belt Rip Detection

PHOENIX

CHARGE COIL BELT COIL

PHOENIX-STEEL-CORD-BELT

CHARGE COIL

with sensor loop

BELT RIP SCANNER

~350
06.05.97 Name: labus

~25
loop cords

COMPUTER

LOOP CORDS Loop marks LOOP MARKS

belt width

BELT WIDTH
C-Sheet: CL 060597 Date:

S1

S1

30

Discharging area
Belt opens automatically at the discharge area After material discharge the belt is closed again

Idler stations in front of discharge pulley to prevent belt turnovers caused by belt twisting
31

How to design the PC

PC inquiry data sheet
General data Regarding Location Climatic conditions Material properties General design data Electric, control Standards and regulations Scope of supply; Interfaces Time schedule Etc. No Data - no Offer

32

Diameter of Pipe Conveyor

Consider lowest density for volumetric flow Max. 50 to 75 % filling ratio, depend on lump size Diameter = 3x max.lumps Consider additional max. lump
Job outer diameter Belt width belt thickness neutrale layer R0 NTPC 685 mm 2400 mm 22,4 mm 13,5 mm 336,5 mm 329,0 mm 314,1 mm 306,6 mm 12,9326 mm 63,0 30,763 dm 4000 t/h 0,8 t/m 5000,00 m/h 6,00 m/s 80% % 0,23148 dm 75,2% % 94,1% % Straight Curve
33

PC is very specific No standards in Europe Free to offer acc. Own standards Safety to consider CEMA 6`th design recommendations

R1 R2 R3 L1 overlapping cross section.100% Capacity Density Volumetric flow Velocity Reduction due Curve Cross section Filling ratio Filling ratio

Recommendations done by CEMA 6th edition to give thumb values

PC is very sensitive against overfilling due to oversized lumps. For critical material measurements have to be taken crusher, screen
34

Maximal transport capacity of Pipe Conveyors

Coal Density [t/m] Density [lb/ft] Diam Pipe Conveyor in mm 150 200 250 300 350 400 450 500 550 600 650 700 in inch 6 8 10 12 14 16 18 20 22 24 26 28 Velocity in m/s 2,1 2,1 3,0 3,0 3,0 3,7 3,7 3,7 4,5 4,5 4,5 5,4 in ft/min 421 421 594 594 594 722 722 722 890 890 890 1065 Capacity in in m/h ft/min 94 165 366 520 716 1131 1430 1761 2630 3152 3675 5103 55 97 215 306 421 665 841 1036 1547 1854 2162 3002 0,8 50 Iron ore 2,4 150

Capacity Capacity in t/h 75 132 292 416 573 904 1144 1409 2104 2521 2940 4083 in t/h 224 396 877 1248 1718 2713 3432 4227 6312 7564 8820 12248

To be competitive Low diameter and high velocity

Attention to be paid to Lump size Pre-acceleration of material

35

Recommendations done by CEMA 6th edition to give thumb values

36

Power consumption and Belt Type

PC calculation
Capacity Density Grain size Velocity angle of deviation PC diameter Panel distance Idler diameter Pulley diameter Temperature / F-value Number Transition areas Wrap angle pulley Friction factor Drive power head/tail Time start/stop Take-up force Belt data Strength/weight
P r o j e c t Number :K2.0395 dazugehrige Z e i c h n u n g:
Route A-I_in Arbeit_RevB fr Berechnung

Datum

05.09.2011

Client

Ausenco PNG Papa New Guinea : Morobe Hidden Valley 07MP092

0stph 173,91304 Conveying Capacity bulk density grain size conveying speed-v max. angle deviation in selected Pipe 10434,78 cfph : : : : : : 1200mm belt width : 1,80m max distance betw. Idlers : 1,50m idler / length idler speed Panel: height / width drive pulley min. drive pulley speed DI STANCE LOADS material belt per cord rollers per cord ambient temperature : : : : 133,0mm / : : : : 574,4UpM 1252mm / 800mm Pulley diam = 74,2UpM 1865UpM 55,6kg / m 32,3kg / m 17,2kg / m 30 C 0,02430 Motor-rpm =OK 615,4m / h 1300kg/m 100mm 4,00m/sec ====> Gold ore ====>

1pcf

0,000m3/h

0,000t/h resistance factor in curves

16,018kg/m3 0,03075 : 0,02446 36,08 : : : : 10297 2502 207515 207515 m N N N N Fc Fw lo F1 F2 F3 LF3

ergibt

800,0t/h am OG 0t/h am UG

resistance factor additional resistance length Pipe shape keeping force Pipe shape force total 4curve resistance total curve resistance total empty

erf. Pipe

319,2 289m 92,1 66%vom Nenn- durchmesser

90necessary min. radius R 300effective filling rate in % calculation area

chosen Panel dist.

1,50m

motor power empty operation

1390,04

kW N1

chosen Panel dist.Curve

1,50m

necessary motor power hor.

284,40

kW N2

290mm Gew. min. Anzahl 626mm Anzahl

4,31kg 43080Quantity 3588Quantity 1030mm inkl. Reibb.

necessary motor power vert.

-772,70 28,92

kW N3

C1 = C2 = C3 = C4 = 99,0658 C5 = C6 beladen = C6 leer= T1=

63598N -191063N -152406N 5148N 834N 111386N 111386N 265kN

R1= R2= R3= R4= R5= R6= R6= T2=

63598N 0N 152406N 5148N 1668N 96129N 96129N 113kN

total load belt + rollers / m = w

average friction value - 'f'

T4=

319kN

T3=

391kN

amount belt closing upper belt

Belt

T1=

326kN

T2=

113kN

amount belt closing lower belt material on return strand :

: : input inclination

2 0,0kg / m see system sketch

EP oder ST

ST

T4= deflection angle in :

258kN

T3=

391kN 710,73

Part Sec 1 2 3 4 5 6

length / m 67,40

+/height / m 0,000 0,000 0,000

radius / m vertikal

o,u, so, su, sou

a in
9,13

radius / m horizontal

+/height / m

horiz. resp vertical curve length / m 0,00

actual horiz. curve radius 0,00 0,00 324,11 0,00 0,00 0,00

actual length in m 67,40 47,80 28,51 157,80 119,69 57,91

actual inclination lifting height in m in 0,00 -9,13 -9,13 -9,13 13,73 2,67 0,00 -3,80 -8,32 -33,36 -28,59 -20,34

0,0 0,0 -9,1 -9,1 300,00 300,00 suu sou 22,86 11,06 300,00 u 0,00 320,00 5,04 -4,52 0,00 0,00 0,00

47,80 28,15 0,00 119,69 57,91

155,80

-25,039 0,000 0,000

47 48 49 50 196,68

0,000 0,000 0,000 8,515 3,0 3,0 2,5

300,00

sou

2,19 230,00 260,00 8,37 25,47

0,00 1,76 6,06 0,00

11,47 33,60 115,58 0,00

0,00 230,32 260,36 0,00

11,47 33,65 115,74 196,86

3,00 3,00 3,00 2,48 0

-370,80 -369,04 -362,98 -354,47

total length conveying height average inclination max. height theor. drive power empty theor. drive power full mech. efficience min. nec. drive power installed drive power

: : : : : : : : :

5399,20m -354,47m -3,80 -481,03m 1.390,1kW 901,8kW 0,9000 1002,0kW 2520,0kW = 996,4 1387,0 896,7

horizontale Lnge ====>

5332,79

Power inclined loaded Art des Anlaufes ==> h = sanft s = starr h Power declined loaded

2051kW 487kW

1544,5556

leer

2520 kW bei +30 C Head kW 1260 Tail kW 1260 0

friction factor Belt/Drive pulley wrap angle calculated by

: :

0,55<<=== 200

========= 197,1

0,10-0,15= 0,30-0,40= 0,45-0,60=

plain and wet checkered rubber but dirty checkered rubber dirty until dry

kW

:Dr. Wiedenroth

37

P r o j e c t Number Client

:K2.0395 :Ausenco

Route A-I_in dazugehrige Z e i c h n u n g: Arbeit_RevB fr Berechnung 0,000m3/h

Datum

05.09.2011

173,91304 10434,78 cfph Conveying Capacity : bulk density : grain size conveying speed-v max. angle deviation in selected Pipe belt width max distance betw. Idlers idler / length idler speed Panel: height / width drive pulley min. drive pulley speed DISTANCE LOAD S material belt per cord rollers per cord ambient temperature average friction value - 'f' amount belt closing upper belt amount belt closing lower belt material on return strand : : : : : : : : : : :

0stph 1pcf 615,4m / h Gold ore 1300kg/m ====> ergibt 100mm 4,00m/sec ====> erf. Pipe

90necessary min. radius R 300effective filling rate in % calculation area 1200mm chosen Panel dist. chosen Panel dist.Curve

: : : : : : :

1,80m 1,50m

290mm Gew. 133,0mm / min. Anzahl 574,4UpM =OK 626mm Anzahl 1252mm / 800mm Pulley diam = 74,2UpM

0,000t/h 16,018kg/m3 resistance factor in curves 0,03075 800,0t/h am OG resistance factor : 0,02446 0t/h am UG additional resistance length 36,08 m Pipe shape keeping 319,2 : 10297 N force 289m Pipe shape force total : 2502 N 92,1 4curve resistance total : 207515 N vom Nenncurve resistance total 66%durchmess 207515 N : empty er motor power empty 1,50m : 1390,04 kW operation necessary motor power 1,50m 284,40 kW : hor. necessary motor power 4,31kg -772,70 kW : vert. 43080Quantity 28,92 3588Quantity C1= 63598N R1= 63598N 1030mm C2= -191063N R2= 0N inkl. Reibb. C3= -152406N C4= 99,0658 5148N R3= R4= R5= R6= R6= T2= T3= T2= T3= : 152406N 5148N 1668N 96129N 96129N 113kN 391kN 113kN 391kN 710,73

Fc Fw lo F1 F2 F3 LF3 N1 N2 N3

Motor-rpm 1865 UpM 55,6kg / m total load belt + rollers / m = w 32,3kg / m 17,2kg / m 30 C 0,02430 1 2 0,0kg / m Belt EP oder ST ST

C5= 834N C6 = 111386N beladen C6 leer= 111386N k T1= 265 N k T4= 319 N k T1= 326 N k T4= 258 N deflection angle in

38

Height profile
0 0 1000 2000 3000 4000 5000 6000

-100

-200 Relative height in m

-300

-400

-500

Local peaks in belt tension

-600

Different loading cases tension and power consumption vary

Distance from the feeding point in m

39

: inclination

input o,u, so, su, sou u

see system sketch horiz. resp vertical radius / m +/curve a in horizontal height / m length / m 0,00 9,13 0,00 47,80 320,00 5,04 -4,52 28,15 0,00 0,00 22,86 0,00 119,69 11,06 0,00 57,91 2,19 230,00 260,00 8,37 25,47 0,00 1,76 6,06 0,00 11,47 33,60 115,58 0,00 5332,79 Power inclined loaded Power declined loaded 2501kW 487kW actual horiz. curve radius 0,00 0,00 324,11 0,00 0,00 0,00 0,00 230,32 260,36 0,00

Par t +/radius / m Se vertikal c length / m height / m 1 67,40 0,000 0,0 2 0,000 0,0 300,00 3 0,000 -9,1 4 155,80 -25,039 -9,1 5 0,000 300,00 6 0,000 300,00 47 48 49 50 0,000 0,000 0,000 8,515

suu sou

actual lifting actual length in inclination height in in m m 67,40 0,00 0,00 47,80 -9,13 -3,80 28,51 -9,13 -8,32 157,80 -9,13 -33,36 119,69 13,73 -28,59 57,91 2,67 -20,34 11,47 33,65 115,74 196,86 3,00 3,00 3,00 2,48 -370,80 -369,04 -362,98 -354,47 0

300,00 sou 3,0 3,0 2,5

196,68

total length conveying height average inclination max. height theor. drive power empty theor. drive power full mech. efficience min. nec. drive power installed drive power friction factor Belt/Drive pulley wrap angle calculated by

: 5399,20m : -354,47m : -3,80 : -481,03m : 1.390,1kW 1387,0 : 901,8kW 896,7 : 0,9000 : 1002,0kW 996,4 : 2520,0kW =

horizontale Lnge ====>

Art des Anlaufes ==> h = sanft s = starr 1544,5556 leer

2520kW bei +30 C Head kW Tail kW 1260 1260 kW 0

0,55<<===

======== 0,10-0,15= plain and wet = 197,1

: 200 :Dr. Wiedenroth

0,30-0,40= checkered rubber but dirty 0,45-0,60= checkered rubber dirty until dry
40

Belt tension steady operation

500 450 400 350 Belttension in kN 300 250 200 150 100 50 0 0 1000 2000 3000 4000 Distance from the feeding point in m 5000 6000
Upper Strand loaded Lower Strand loaded Upper Strand empty Lower Strand empty

Drops in belt tension to be considered

41

Belt Tension and Elongation for Curved Sections

Compression of the belt - buckling

42

Dynamical Analyses

Belt Tension [N]

Belt Speed [m/s]

Identifies belt tension at various points along the conveyor over short time increments during acceleration and stopping.
43

Pipe Conveyor Geometry

Routing

Avoid compound curves Consider min. radii Inclination/declination approx 30 Follow Ground profile Eaquel gantries / Structure Eaquel Trestles Smooth routing

Top View

Side Elevation

Thumb values are Fabric belt: 300 x PC diam = curve radius Steel cord belt: 600 x PC diam = curve radius
44

RECOMENDED MINIMAL RADII FOR CURVES

Belt Carcasse

Diameter d in mm < 25 300 d 400 d 400 d 500 d 500 d 600 d 700 d 800 d

Curve radius R 25 bis 50 400 d 500 d 500 d 600 d 600 d 700 d 800 d 900 d 50 bis 75 500 d 600 d 600 d 700 d 700 d 800 d 900 d 1000 d 75 bis 100 600 d 700 d 700 d 800 d 800 d 900 d 1000 d 1100 d

Nylon (PP)

150 300 350 500

Polyester Nylon (EP) Aramid (D)

150 300 350 500 150 300 350 500

Steel cord (St)

150 300 350 - 500

45

Inclination up to 30

46

Conveyor Routing

Smooth conveyor line Following ground elevation Optimization of steel consumption and abilities of PC

47

Road crossing Smooth design required Causes instability

48

Eaquel gantries / Structure Eaquel Trestles X

49

Head end

Tail end
50

3-D-MODEL TOPOGRAPHIE PIPE CONVEYOR

51

Optimiziation of gantries and trestles

52

Optimiziation of gantries and trestles

53

Optimiziation of gantries and trestles

54

Optimiziation of gantries and trestles

55

Optimiziation of gantries and trestles

56

Optimiziation of gantries and trestles

57

Internal PC Standards
Pipe Conveyor Manual
Design rules Standard Dimensions Standard Components

58

Conveyor structure
Light structure On sleepers

Light structure suspended

59

Light structure L-pofile panels

Light structure Plate panels

60

Light modules onto supporting structure

Light gantry
61

Standard gantries

62

Standard gantries

63

Conveyor inside Galleries

64

Triangular Galleries

65

Triangular Galleries
66

Special application

67

Supports
1-leg support steel

A-support

portal support

1-leg support concrete

68

Optimized trestle design

69

Transition Area
Thumb values are Fabric belt: length = 30 x PC diam Steel cord belt: length = 60 x PC diam Has to be straight Declined for critical materials

70

Safety Flap Panels

If blockages can occurs Number of Panels according stopping way Section has to be straight

71

Belt Turn-over

72

Belt Turn-over

the unguided turn-over

the guided type by vertical middle roller

the Mordstein Type with supports guiding the belt over the length of the turn-over section

73

Walkways
Walkway at one side <350 mm PC Diam. Walkway loads 150 kg/m respectively 300 kg single load are preferred.

74

Safety covers Plates Meshes Roof cover

75

Trolley
Limited Access Max. Inclination 12

76

Miscellaneous
Cold climate conditions
Conglomeration of material Blockage of Pipe Conveyor Freezing of Material inside Closed Belt High Power consumption

Construction, commissioning
Time consuming belt pulling Adjustment of rollers Adjustment of Belt

Noise emission
More idlers more noise emission Values up to 88 db(A) sound pressure

77

Alignment Of Pipe Conveyor Belt

The above sketch shows an overlapping located too far left. Correction has to be carried out by adjusting the carrying idler (as shown). The selection of idler(s) to be adjusted depends on the local line and the pressing of the belt on each idler. *Note: numbers in brackets refer to the lower strand

78