Pipe Conveyor

The Pipe Conveyor is the modern bulk material handling system solving a
number of serious problems in training, scattering & spillage of materials and
the limited angle of inclination of conventional belt conveyor systems.
The development of the Pipe Conveyor is a result of designers attempt to
overcome numerous problems associated with transportation of bulk materials
with conventional belt conveyor systems. In addition, suitable high resilient
flexible belting are also simultaneously developed which act as a catalyst for the
growth and popularity of Pipe Conveyor installations for several industries.
The tail end and material-receiving area of the pipe conveyor is similar to that of
a conventional belt conveyor. The flat belt after the tail pulley is slowly shaped
to the trough belt through 10 Deg. & 20 Deg. Transition and 30 Deg. Carrying
idlers. At the end of loading zone, the process of pipe formation is gradually
achieved sequentially in steps from the trough shape as follows:
- 45 Deg. Idler

To increase the troughing angle to 45 Deg.

- Variable Off Set Rollers

To increase further the troughing angle in steps from 45 Deg. upto

90 Deg.
- Finger Rollers

To press and hold one edge below the other as the belt edges
overlap each other thereby eliminating any abrasion and allowing
proper overlap closing of the belt.
- Pipe Forming Idler

6 rollers arranged as offset hexagons with the belt taking the pipe
shape inside the rolls with overlapping edges at top in carrying side
and at bottom in return side.
In the straight portion of a pipe conveyor without any vertical or horizontal
curves, the bottom three rollers at the carrying side support the belt and
material load whereas the top three rollers maintain the belt in its pipe shape. At
the horizontal and vertical curved sections, the other rollers of the pipe forming
idlers surrounding the belt act as the load supporting ones depending on the
direction of resultant force at the curved portion while the remaining rollers
maintain the belt in pipe shape. The same applies to the bottom or return belt
side of the pipe conveyor.
The reason behind pipe forming of the bottom or return strand of the belt is to
permit use of same structure and to guide the belt through the vertical or
horizontal curves.
The belt again takes conventional trough shape ahead of take-up tower. Idlers
are arranged in reverse sequence to facilitate the belt taking trough shape from
pipe form.
The salient features of pipe conveyor, the versatile bulk material conveying
system, are summarized as follows:

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1.

Unlimited capability for direct transfer of materials between two points

which are not possible with conventional means eliminating multiple
transfer points and longer conveying path.

2.

Possibility of multiple curvatures in both horizontal and vertical planes

associated with steeper angle of inclination.

3.

Even a horizontal angle of 90 Deg. possible with the current technology.

4.

Fully enclosed clean & environment friendly transportation eliminating all

spillage, scattering & return side dropping of materials.

5.

Reduction in transfer points and non-exposure to atmosphere result in

retention of material properties while conveying.

6.

Possibility of transporting second material through return side pipe of the

system thereby reducing capital & operating cost.

7.

Overall savings in space requirement, structural and foundation cost

thereby making the investment decision easier.

MACMET has the distinction of being the first Indian Engineering Company for
indigenous design, manufacture, supply, erection, testing & commissioning of
the Pipe Conveyor System in India for Madukkarai Cement Works of Associated
Cement Companies Limited.
Thereafter, two more Conveyors, one for Chaibasa Cement Works of Associated
Cement Companies Limited and the other for Jindal Vijayanagar Steel Limited
have been installed and commissioned.
The Pipe Conveyor for Chaibasa is the longest conveyor in the world with Textile
Belting.

In a Pipe Conveyor system, at the loading point, the Pipe Conveyor is open in a
conventional trough form after which it is formed into a pipe shape for the
transport length with materials completely enclosed.
At the end of the transport run and just before the discharge pulley the belt
again opens thus allowing materials to be discharged in the normal fashion.
With the Pipe Conveyor, horizontal as well as vertical curves can be negotiated
easily, quite difficult with conventional troughed belt conveyors.
Due to the enclosed nature of the Pipe Conveyor system, scattering, dropping or
leaking of material is eliminated thus making this system pollution free.
Since the belt is in pipe shape on the return side as well, there is no dropping of
materials that may still adhere to the belt even after discharge. The pipe shape
also prevents foreign matter from getting in to pollute the transported material.
Conventional Belt Conveyor systems call for multiple transfer points meaning
more space and higher related costs, Not with the Pipe Conveyor. The curved
transport capability of the Pipe Conveyor system eliminates the need for multiple

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transfer points, thus doing away with potential trouble spots.

transfer points also reduces the chances for pollution.

Elimination of

Due to increased friction with the pipe shape, the angle of inclination can be
higher in pipe conveyors. With the steep-inclined transport capabilities up to 22
degrees, the conveying length in a Pipe Conveyor can be reduced, thus reducing
costs.

And the initial capital outlay for a pipe conveyor is generally higher than a
comparable length moulded conveyor.

Spillage, pilferage and environmental issues are adequately addressed by the

installation of a Pipe Conveyor.
Case Study
Most recently a Pipe Conveyor of 7 km in length, carrying 1500 tph of crushed
coal has been commissioned for a Power company in Chattisgarh. This conveyor
is the longest of its kind in Asia and the second longest in the world. It has a
pipe dia of 500 mm. The belt is ST1800, 1800 mm wide steel cord belt, driven
by four 650 kW drives controlled by a VFD. The pipe conveyor negotiates 9
horizontal curves and 33 vertical curves. In this case the customer was
transporting the required amount of coal using trucks by paying Rs.65 per ton.
It is now estimated that, running at 2 shifts per day, the cost of transporting a
ton of coal will come down to a mere Rs.8 per ton.
Modern technologies and research into conveying systems have made cross
country conveying and pipe conveying the obvious choice for transporting bulk
solid material quickly, reliably and cheaply over long distances. Most large
power plants and cement plants are now investing into long distance curved
conveyors and long distance pipe conveyors. These systems are now gaining
prominence in India and in Asia. There are a few select Indian companies that
can today provide cost effective bulk material conveying solutions.

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