A N AT O M Y OF THE A G G R E G AT E S INDUSTRY

QUALITY CONVEYOR COMPONENTS

BRYANT PRODUCTS, INC.

ANATOMY OF THE AGGREGATES INDUSTRY
INTRODUCTION
The aggregates industry is in the business of mining and processing rock. The aggregates industry encompasses rock quarries, sand and gravel plants, concrete manufacturing and asphalt processing facilities; their end products include crushed stone, sand & gravel, cement and asphalt. These products are used in applications ranging from road and bridge construction to building construction. The industry produced over 1.7 billion tons of crushed stone and 1.4 billion tons of sand and gravel per year; it represents over 90% of the non-metallic mining production in the United States. The industry is key to the growth of world economies, since its products are used in developing the infrastructure required to support economic growth. In addition, a recent development in this industry is the recycling of asphalt and concrete. Today, many states require that a percentage of new asphalt and cement contain recycled material. In non-technical terms, the aggregates industry turns big rocks into little rocks". In a typical aggregates processing plant, belt conveyors are the transportation systems, moving the rock products between feeder/breakers, crushers, screens, classifiers, storage piles and load-out terminals. An aggregates plant cannot operate efficiently and cost-effectively without belt conveyors providing the material handling. In this article, we will review the following topics: a) Products of the aggregates industry b) An overview of a typical aggregates quarry c) The applicability of the Bryant Telescoper take-up assemblies to the conveyors in an aggregates quarry

AGGREGATE PRODUCTS
The basic product of the aggregate industry is rock. Aggregate is defined as any combination of sand, gravel and crushed stone in their natural or processed state. The basic tasks of this industry are to: (1) mine the aggregate (2) size the material (3) classify the materials

Some of the primary products of this industry include: Coarse Aggregate: This is typically defined as aggregate materials that are retained by a #4 sieve with a 0.187" square opening. Fine Aggregate: This is aggregate that passes a #4 sieve (0.187" square opening) but is predominately retained by a #200 sieve. RipRap: This aggregate product has an average size of between 6" and 30". It is large, irregularly shaped rock and is often used to stabilize slopes or shorelines. Gravel: This is a granular, pebbly material that results from natural disintegration of rock. Usually coarser than 1/4" diameter, it is found intermixed with fine sand and clay; it can be classified as bank, river or pea gravel. Its rounded character is normally created by the stream action of water. Base Aggregate: This is crushed rock that is sized for use as the foundation for pavement. Ballast: This is broken stone or gravel that is often used to stabilize a road or rail bed. Boulders: Material that is greater than 8" in diameter. The National Stone Association (NSA) provides the material classification definitions for the aggregates industry. The above listing is just a sampling of the many categories defined by NSA. The construction industry is the largest user of aggregate products. Road, bridge, airport and dam construction account for over 50% of all aggregate products produced in the United States. Aggregate products are used for sub-base and base materials, concrete and asphalt for road construction. Building construction, both commercial and government, represents about 30% of aggregate product usage. The remaining 20% is spread out among residential construction, erosion control and railroad construction.

THE FLOW OF A TYPICAL QUARRY

As stated earlier, the basic process of an aggregates plant is to turn big rocks into little rocks". Although the processes to do that are quite technically sophisticated, the basic flow of an aggregates quarry includes A) Mining of the natural rock deposits, B) Feeding, C) Crushing, D) Screening, E) Classifying, F) Storage, G) Load-out, and H) Conveying. Figure 1 is a schematic of a typical aggregates plant. It shows the flow of the material through the various processes in the plant. The symbols shown are used in the aggregates industry to display each operation. It is obvious from reviewing the plant layout that conveyor systems are the transportation systems of an aggregates plant, moving the material from process to process. They are the most efficient method available for this transportation task.

MINING:
The mining of the rock is normally done by blasting out the natural deposits. This blasting operation is a science in itself, developed by specialists who consider the consistency of the rock, the depth and the surrounding terrain. The basic process is a) to drill (bore) a series of deep holes in a specific pattern, b) to fill the holes with explosive material, and c) to detonate the explosives in a controlled manner. This blasting process will create a pile of large rocks which must then be processed into more usable product. Front-end loaders typically load huge dump trucks, which transport this blasted material to the processing plant. In many western states, mining is accomplished by dredging or scraping riverbeds, as this is the source of their aggregate products.

FEEDING:
The blasted material is delivered to the processing area of the plant via the large dump trucks. This material is dumped into feeder-breakers that prepare the material for the primary crushers. These feederbreakers are extremely heavy-duty devices since they are subjected to tremendous forces from the impact of the dumped rock. They can be static or vibratory, horizontal or inclined. Their job is to feed the rock into the crusher at the proper rate so as not to overload the crusher. They are often designed to do some preliminary sorting", so that smaller pieces of rock can bypass the crushing operation. The most common feeder ahead of the primary crusher is a Grizzly bar feeder.

CRUSHING:
Crushing is the operation of sizing the rock. In a typical aggregates plant, material may go through three crushing stages, depending on the material to be produced. Each crushing step further reduces the size of the material. The crushing operations are typically defined as a) Primary Crushing of the mined rock, b) Secondary Crushing, and c) Tertiary (third stage) Crushing. Different types of crushers have been developed for the variety of crushing applications. The selection of the proper crusher design for a given application is a function of the material size, material composition (hardness and abrasiveness), the reduction in size required and the volume of material to be processed. JAW CRUSHERS are the most universally applicable primary crusher. It is an eccentric jaw, compression machine that works within a 6 to 1 reduction ratio range, accepting rock up to about 20 in size. IMPACT CRUSHERS are typically used for limestone or lower abrasive applications. Working in the 20 to 1 reduction range, these crushers utilize single or double impact impellers. GYRATORY CRUSHERS are typically used as a primary crusher when high production is required. CONE CRUSHERS are the crushers of choice for most secondary and tertiary crushing applications, although they can be used as primary crushers in smaller operations. Generally operating in the 6 to 1 reduction ratio range, they generally accept material up to 4" in size. HORIZONTAL SECONDARY IMPACT CRUSHERS utilize the benefits of impact crushing to provide a tighter tolerance product. With reduction ratios of up to 12 to 1, these machines can handle the more abrasive materials. ROLL CRUSHERS are compression type machines that are limited to 2-1/2 to 1 reduction ratios. They are capable of producing material sizes within close tolerances. VERTICAL SHAFT IMPACT CRUSHERS combine impacting benefits with high chrome metallurgy. Typically used as a finish crusher, they accept material up to 3" in size and with high abrasive makeup. HAMMERMILLS (LIMEMILLS) are typically used in a secondary crushing application with material size up to 8" and provide a reduction ratio of up to 20 to 1.

CRUSHERS
JAW CRUSHERS

Dodge

Overhead Pivot (double-toggle)

Overhead Eccentric (single-toggle)

Blake (double-toggle)

IMPACT CRUSHERS

Hammer Mills

Cage Disintegrators

Impactors

Vertical Spindle

GYRATORY CRUSHERS

True Gyratory Cone Gyradisc

ROTARY BREAKER

ROLL CRUSHERS

Double Rolls

Single Rolls 6

SCREENING:
Screens are the sieves that separate the aggregates by size. In their simplest form, they are meshes that allow a certain size material to drop through, while retaining material that is too large to pass the mesh opening. They are typically vibrating devices that are horizontal or inclined. They are often multi-deck designs with progressively smaller mesh sizes on each deck. There are many designs for these vibrating machines, each attempting to maximize material separation. The screen itself can be made from a number of different materials and in a variety of patterns. Some of the most common are: WOVEN WIRE CLOTH: This is the most common screening material and is used in all phases of screening. It is designated by the clearance in the mesh or by its square mesh (defined as the number of openings in one inch). The openings are typically either square or rectangular, and can be weaved in a variety of manners. Wires used to manufacture woven wire cloth are usually steel alloys, copper alloys, nickel alloys or stainless steels. PLASTICS: Plastics can we woven similar to wire cloth. They are commonly used in the chemical industry due to their corrosion resistance. They are best suited for light materials with low abrasion. PROFILE DECKS: This is a screening medium consisting of wires in various shapes, running substantially parallel to each other. They are used primarily in dewatering applications and for small particle separation. ROD DECKS: These decks are constructed of round rods arranged parallel to each other. They are designed to handle high volumes of wet or dry abrasive materials. GRIZZLY BARS: This is a heavy duty screening surface consisting of spaced bar, rail or pipe members running in the direction of material flow. The bars can be either cast or fabricated, and are used for sizing with openings greater than 1-1/2". They are primarily used in heavy-duty operations ahead of the primary crusher, where accuracy of separation is not important; they are extremely effective with very abrasive materials. PERFORATED PLATE: These screens are used when the material being screened is heavy or highly abrasive. They are available in a wide variety of opening shapes and sizes, and are constructed from a variety of materials, including steel, bronze, brass, copper and aluminum. They can also be cast rather than fabricated. Some applications require a rubber cladding for extra abrasion resistance. PERFORATED RUBBER or POLYURETHANE DECKS: Similar to perforated plate decks, these screens are made from rubber or polyurethane materials. They both offer the advantage of increased abrasion and impact resistance.

The major advantages of the standard Bryant Telescoper are Elimination of adjuster rod thread damage due to rust, corrosion and material build-up Elimination of take-up assembly freeze up due to its truly protected screw design Rigid structure due to the tube sizes utilized and close tolerances achieved Allows utilization of standard pillow block bearings both 2 bolt and 4 bolt types resulting in lower bearing cost, easier bearing change-out and, therefore, reduced maintenance costs Longer life expectancy than other manual take-up devices Simple mounting to the conveyor frame: standard feet, mounting studs or direct weld Easily customized to customer's unique requirements Powder coat finish for durability Use of ACME threaded rod on Series 350HD, 400 and 500 units for high load and thrust capacity Pinned Adjustment Nut design on Series 350HD, 400 and 500 units for higher adjustment torque and easier disassembly

SPRING COMPRESSION TELESCOPERS

Bryant Products has developed a spring compression version of their popular Bryant Telescoper take-up assembly. The Bryant Spring Compression Telescoper automatically compensates for belt stretch and wear through a unique design utilizing a compression spring within the tube assembly. By selecting the proper spring size and rate, the thrust capacity of the Bryant Telescoper can be matched to the customer's specific application. On Series 300, 350HD, 400 and 500, Bryant Spring Compression Telescopers are fitted with a direct reading tension scale". This feature allows accurate determination of belt tension by relating the amount of spring compression and the selected spring compression rate. Users specify a Bryant Spring Compression Telescoper when they Require automatic compensation for belt stretch and wear Require constant belt tension under varying thermal conditions Require accurate determination of actual belt tension at the tail pulley Require absorption of shock and impact loads The Bryant Spring Compression Telescoper provides a major advantage over conventional manual take-up devices: it can be adjusted by the conveyor user to provide a specific slack-side belt tension.

CLASSIFYING:
Almost all aggregate products contain fines or sands. Classifying equipment is designed to separate the fines from the aggregates, dewater it and separate the fines by size. Water is used in the aggregate processing to wash the rocks/stones throughout the plant. The water cleans away the sand (fines) into classifying tanks. These systems are designed to separate (classify) the sand by size and to remove the water. There are a number of different ways to perform this classifying; the most common method is to utilize a screw type classifier. They are normally an inclined trough or box. The screw flight turns within the trough, conveying the material up the incline. The discs on the flight have holes in them, which allows the water to separate and flow downhill. The sand is then separated by size by running it through a series of sieves of varying size.

STORAGE:
Once the aggregates and fines are sized, they are conveyed to storage areas to await delivery to the end customer. Storage is typically done in (a) open piles, (b) silos or (c) bins. They are simply staging areas for the various materials.

LOAD OUT FACILITIES:

Loading out the products of a typical aggregates plant entails (a) weighing/measuring the material and (b) conveying it into the transportation vehicle. Load out is typically accomplished with a front-end loader, by bin release or by conveyor. Transportation vehicles include trucks, trains, barges and ships.

BELT CONVEYORS:
As stated earlier, conveyors are the transportation systems of an aggregate plant. They move the various materials along between the crushers, screens, classifiers, storage facilities and load out. An aggregates plant could not efficiently operate without conveyors. Belt conveyors have attained a favored position in transporting bulk materials due to their economy, reliability, safety, versatility and almost unlimited range of capacities. They can convey a wide variety of materials, from fine dusty chemicals to large lumpy ore. Belt conveyors can operate continuously, offering an economy of scale dramatically superior to trucks or other forms of haulage. The Conveyor Equipment Manufacturers Association (CEMA) has played an important role in the development of standards for the design of conveyor systems. Their Belt Conveyors for Bulk Materials manual has become the accepted reference for conveyor designers worldwide. In addition, the technical committees within CEMA have developed rigorous standards for the design and manufacture of many belt conveyor components, most notably conveyor pulleys and idlers. Belt conveyors can be designed to follow an almost unlimited number of profiles (paths of travel). They can be horizontal, inclined, or declined, and even incorporate curves. In addition, they can be configured for a variety of loading and unloading conditions. The proper design of a belt conveyor requires an understanding of the characteristics of the material to be handled, since its behavior while being carried, loaded and discharged affects the conveyor's design. In its simplest terms, a conveyor can be described by its rated capacity; that is, the total weight of material that it can convey in one hour. This is commonly referred to as the conveyor's Tons per Hour (TPH) capacity; it assumes a conveyor belt carrying a uniform cross section of material and traveling at a uniform speed. This TPH capacity is a function of the belt width, the troughing angle of the idlers/belt and the speed that the belt is moving, normally described in feet per minute (FPM)". As any (or all) of these factors increase, the capacity of the conveyor will increase. However, there are limits for belt width, troughing angle and belt speed; they are both independent and interdependent. The conveyor designer's task is to find the best combination of these factors for the optimum conveyor design for their given application. Sounds simple but conveyor design becomes a series of iterations and compromises to find that best design. Once the basic parameters of belt width, troughing angle and belt speed have been selected, there are a number of other decisions that the designer must make. Included in this process is the selection of a) The conveyor belt, b) The idlers, c) The pulleys, shafts and bearing assemblies, d) The conveyor drive mechanism (motor, gear reducer, etc), e) The conveyor control system, f) The belt take-up system, and g) The miscellaneous equipment, such as belt cleaners, skirtboards, loading chutes, safety devices, etc. Most of these selections are inter-related; as such, modern conveyor design is an iterative process. Many combinations of these components are evaluated, typically by high-speed computers, to hone in on the optimum package.

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CONVEYOR TAKE-UP SYSTEMS:

All properly designed conveyor systems require some type of take-up device. The purpose of a take-up system is a) To insure the proper amount of slackside tension (T2) at the drive pulley to prevent belt slippage, b) To insure proper belt tension at loading and other points along the conveyor, so as to prevent the loss of troughing contour of the belt between idlers, thus avoiding spillage of the material from the belt, c) To compensate for changes in belt length due to belt stretch, and d) To allow belt storage for making replacement splices. Any conveyor can be expected to have stretch in the conveyor belt. Some belt stretch is temporary, often due to changes in the belt tensions caused by starting or braking conditions, or caused by changing thermal conditions. Other belt stretch is permanent, caused by elongation in the fibers and fabrics used in the belt construction. Take-up systems allow the conveyor designer to compensate for these changes in overall belt length without having to cut out sections of the belt. The required distance of take-up movement is a function of several factors, including a) The type of starting or braking that is employed in the conveyor. Acrossthe-line motor starting requires more take-up movement than a controlled soft start, b) The number of starts and stops with the belt fully loaded, c) Elongation characteristics of the conveyor belt, and d) The running tensions of the conveyor system. The take-up system should provide sufficient movement to accommodate acceleration or deceleration surges without having the take-up strike against its stops. It should also allow for some storage of belting, in case the belt must be repaired. The design of the take-up system should ensure its smooth movement and even tension across the face of the belt. There are two basic types of take-up systems used on belt conveyors: (1) Manual take-up systems, and (2) Automatic take-up systems.

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MANUAL TAKE-UPS:
Typically used on conveyors up to 100 feet in length, manual systems have the advantage of compactness and low cost. Manual take-ups are recommended where an automatic take-up is not practical because of space limitations or because of cost. The major limitation of most manual take-up systems is the infrequency of manual retensioning. This creates a situation where the belt is either tensioned too tight or too loose most of the time. In addition, most manual take-up devices do not offer a way to monitor belt tension, so the operator does not really know how much belt tension he has. Because of this limitation, most conveyor designers will apply a service factor of 1.3 to 1.5 when selecting tail pulley/shaft/bearing sizes. This is to compensate for the additional tension that commonly occurs with manual take-up systems. The most common type of manual take-up is the screw take-up. They utilize a threaded rod that moves the bearing or a bearing mounting surface through the take-up travel. Manual screw take-ups are typically available in industry standard travel lengths, such as 12, 18, 24, 30 and 36 inches. However, take-up manufacturers frequently build special screw take-ups in different travel lengths. Most manual screw type take-up devices are prone to freeze-ups as material spillage and corrosion attack the adjusting screw mechanism; after a short period of operation, many frame designs become almost impossible to adjust due to damage to the adjusting screw. In addition, most manual take-up devices require the use of special take-up bearings, which fit only into a particular manufacturer's take-up frame. These guide rail mounted take-up bearings are more expensive than the more common pillow block bearings used on most conveyor pulley assemblies in a belt conveyor. As stated previously, the main problem with manual take-ups is that they require frequent attention from a trained maintenance person. Evaluation must be made as to whether the conveyor requires additional take-up action, and then the operator must adjust the manual take-up to the proper tension. Most manual screw take-ups do not have a gauge or index to guide the operator in this tensioning process. It becomes a hit or miss process, and the tendency is to overtension the belt. This overtensioning, if severe enough, has the potential to cause component failures in the conveyor; pulleys are especially susceptible to overtensioning of the screw take-ups.

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Manual take-ups are almost always used at the tail end of the conveyor, at the opposite end from the drive pulley. Most conveyors using screw take-ups are simple, two or three pulley systems. There are a variety of screw take-up styles available from a number of manufacturers. These styles include: a) Heavy Duty, Protected Screw Take-up Frames: These frames are typically of a welded and bolted steel construction, with an adjusting screw that is somewhat protected under an angle iron member. They typically accept a variety of pillow block bearing types, bore sizes and are available in various travel lengths. b) Light Duty, Protected Screw Take-up Frames: Similar to heavy duty frames, they are designed as an economical frame for lighter conveyors. Accepting ball, tapered roller, spherical roller and sleeve pillow block bearings, they offer an adjusting screw protected from falling material by an angle iron member. c) Center Pull Take-up Frames: Center pull frames are of welded steel construction with reinforced steel end plates. The hinged cap rail allows access for bearing installation. They require a special style bearing available from most major bearing manufacturers. d) Top Angle Take-up Frames: Top angle frames are of welded steel construction, with the adjusting screw normally plated to resist corrosion. The screw is protected from falling material by the top rail. They accept a variety of manufacturer's special take-up bearings, with a typical bore range of 1-3/4" through 4". e) Wide Slot Side Mount Take-up Frames: Used with ball bearings, this style frame provides a compact solution to belt tensioning. They accept a variety of manufacturer's bearing cartridges, with a bore range of 1/2" through 3-1/2". f) Bryant Telescoper Take-up Frames: These frames utilize an adjusting screw enclosed within two or more telescoping steel tubes. Pillow block bearings are typically mounted to the inner tube which telescopes out of the outer tube via the action of the adjusting screw. This design virtually eliminates contamination reaching the screw assembly, due to the screw being completely protected within the telescoping tubes.

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AUTOMATIC TAKE-UPS:
Automatic take-ups are the preferred method for maintaining belt tension in most belt conveyors over 100 feet in length. They can be installed horizontally, vertically or on an incline. They are typically gravity operated, although there are power operated systems utilizing hydraulic, electric or pneumatic mechanisms. The most common type of automatic take-up system is a gravity take-up, which utilizes a heavy counterweight hanging from a take-up pulley carriage.

The conveyor designer has three key decisions to make relative to an automatic take-up system: 1) Location of the take-up system within the conveyor, 2) The amount of weight (or force) required for proper operation, and 3) The amount of take-up travel required. Automatic take-ups can be located at almost any place on the return run of the conveyor belt. The key factor in take-up system location is to try to keep belt tension at a minimum; this entails keeping the take-up system as close to the drive pulley as possible. Ease of maintenance access and economics are other considerations to take-up location. On long, horizontal or inclined conveyors, the gravity take-up should be located near the drive, where it will act quickly enough to prevent slippage of the belt on the drive pulley during acceleration at startup. An automatic gravity take-up system must provide a force equal to twice the required belt tension at the location of the take-up. This force is usually supplied by a counterweight made of steel, concrete, cast iron or some other heavy material. If a system of wire ropes and pulleys are used to suspend this counterweight, their mechanical effect must be factored into the calculation of the hanging weight. Gravity take-up counterweights are typically constructed such that weight can be added or removed as conveyor operating conditions change.

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Gravity take-up system movement (or travel) is determined by (a) the conveyor center-tocenter distance, (b) the construction of the conveyor belt, (c) environmental conditions, and (d) amount of belt storage required. CEMA has developed some recommended values of take-up movement for automatic take-up systems. Not all automatic take-up systems utilize a counterweight. Systems utilizing electric cable drum drives with tension sensing devices are often used in applications where vertical space is at a premium. The take-up pulley is bolted to a sliding carriage that is attached to the cable tensioning system. Based on outputs from the tension monitors, the cable drum drive adjusts the cable length, thus increasing or decreasing the belt tension. Hydraulic and pneumatic automatic take-up systems utilize hydraulic or pneumatic cylinders to increase or decrease the belt tension based on similar sensor information. There are some manual take-up devices that deliver many of the advantages of an automatic take-up system. The Bryant Spring Compression Telescoper and the Bryant Hydraulic Telescoper are systems that meet this criteria. These devices provide the conveyor user with the ability to (a) set the belt slack-side tension at a specific value, (b) compensate for transient loads through their shock absorption capabilities, and (c) compensate for belt stretch.

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BRYANT TELESCOPER
The Bryant Telescoper represents an innovative approach to manual belt tensioning. The unique design eliminates the biggest shortcomings of other manual take-up devices: freeze up of the screw assembly, the need for special take-up bearings, and difficulty of bearing maintenance/replacement. The Bryant Telescoper utilizes a tube within a tube approach with the adjusting screw totally enclosed within the tubes. This design virtually eliminates contamination reaching the screw assembly. Fitted with the optional grease fitting, Bryant guarantees no freeze up conditions for five years.

STANDARD TELESCOPER
The standard Bryant Telescoper consists of a three piece modular construction, including: The outer tube body assembly, which mounts to the conveyor frame, The inner tube slider assembly, which includes the floating adjuster nut assembly and the pillow block bearing mounting plate, and The adjuster assembly with the threaded adjusting rod factory treated with anti-seize compound prior to assembly. The slider assembly telescopes within the outer body tube as the adjuster rod is rotated. Due to the close tolerances of the mating tubes, the Bryant Telescoper offers a smooth, non-binding operation of the take-up over its entire adjustment range. With the optional grease zerk fitting installed, the design provides a lubricant reservoir within the slider tube to provide additional protection for the threaded adjuster rod assembly. In addition, the slider tube is ported to allow grease to flow into the area of slider/ body interface. This provides a grease barrier to the ingress of outside contaminants. Grease zerk fitted Bryant Telescopers are recommended for those especially dirty environments typically found in many aggregates operations and/or where conveyor washdowns are common.

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THE HYDRAULIC TELESCOPER

For the higher belt tension applications that are becoming more common in aggregates mining applications, Bryant has developed a line of Hydraulic Telescopers, utilizing the proven features of their dependable Telescoper take-up assembly. Designed with a no leak hydraulic cylinder, the Bryant Hydraulic Telescoper offers a compact design with the cylinder totally enclosed within the tubes for safety and protection from contamination. All units are fitted with pressure gauges for accurate monitoring of hydraulic pressure and belt tension. Bryant offers the Hydraulic Telescoper as a stand alone unit, or with an engineered hydraulic power system. Advantages of the Bryant Hydraulic Telescoper include Remote actuation of the devices Accurate determination and monitoring of belt tension Automatic compensation for belt wear and stretch Easy tensioning of high tension conveyor systems

THE TOP MOUNT TELESCOPER

The Bryant Top Mount Telescoper is the newest addition to their take-up line. The Bryant Top Mount Telescoper places the pillow block bearing mount over the tube while the threaded adjustment rod remains completely protected within the body tube. The rod is protected from material build-up, rust, corrosion and thread damage common to aggregate industry applications. In fact, the Bryant Top Mount Telescoper was specifically developed for the tough applications of aggregate industry conveyor systems. Available in models 350TM, 400TM and 500TM, the Bryant Top Mount Telescoper accommodates pillow block bearings up to 6" bore. The Bryant Top Mount Telescoper is designed to mount within the side frame of most aggregate industry conveyors.

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BRYANT TELESCOPERS IN AGGREGATE APPLICATIONS

As we have seen from the information presented above, an aggregates plant is made up of a multitude of processes, all connected by a material transportation system consisting of trucks and conveyors. This transportation system moves the processed material around the facility and eventually out to the customer. Conveyors are an important part of these facilities, and their trouble free operation is critical to the successful and profitable operation of an aggregates quarry. Referring to Figure 1, we can view schematically a typical aggregates quarry. It shows the movement and processing of the rock from the truck dump into the primary crusher (upper left) through to the load-out of trucks carrying the finished products to the end customers (lower right). The conveyors utilized in this plant include: 48" Primary Conveyor takes the output of the Grizzly feeder and/or primary jaw crusher to a surge pile and/or the Rip-Rap storage pile. This will typically be the highest horsepower conveyor in the facility, driven by a 100 horsepower or larger motor. It is an incline conveyor, typically 150 feet or more in length, and is equipped with a gravity type automatic take-up system. 36" Conveyor A runs from under the primary crusher surge pile to the 6 x 16 2D screen. This is an inclined conveyor, normally between 25 to 100 horsepower, that utilizes a gravity type automatic take-up system. 36" Conveyor B carries the output from the screen and/or the secondary cone crusher up to the 9 x 24 3D secondary screen. This is also an inclined conveyor, normally between 50 to 100 horsepower, that utilizes a gravity type automatic take-up system. 24" Conveyor E-1 carries the output of the secondary screen to the 24" Conveyor E-5 that feeds onto Conveyor D"; it also moves material to the overflow chute that feeds Conveyor E-2". This conveyor is under 100 feet in length, under 25 horsepower, and utilizes a manual screw type take-up system. 24" Conveyor E-2 takes the overflow material from Conveyor E-1 to the fines stock pile. This is an inclined conveyor, probably under 25 horsepower. It utilizes either a gravity take-up system or a manual take-up system, determined by the traffic flow under this conveyor. 24" Conveyor E-5 also moves the overflow material from Conveyor E-1 to Conveyor D for reprocessing through the secondary screen. This is a short inclined conveyor, less than 25 horsepower, utilizing a manual take-up system.

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30" Conveyor D carries the sorted material from the secondary screen and the tertiary (third stage) crushers back up to Conveyor B for reprocessing through the secondary screen. This is likely an inclined conveyor of under 25 horsepower utilizing a gravity take-up system. 24" Conveyor F moves material from a feeder hopper into the surge bins adjacent to the secondary screen. It is a relatively short conveyor, under 25 horsepower, equipped with a manual take-up system. 30" Conveyor C takes the output of the secondary screen to the third stage screen, for final sorting of the material before placement in the load-out bins. This conveyor is an inclined belt, with between 25 to 50 horsepower. It is equipped with a gravity type automatic take-up system. 24" Conveyors E-3 and E-4 move material from the overflow chute of Conveyor E-1 through the screw classifier to the washed screenings stockpile. These conveyors are usually under 100 feet in length, under 25 horsepower, and utilize manual type take-up systems. 36" Load-Out Conveyors LO-1 and LO-2 run from the load-out bins to the transport trucks. They are horizontal conveyors with 25 or less horsepower, utilizing manual take-up systems. 30" Conveyors CR-1 and CR-2 move material from the output of the primary screen to the crusher run storage pile. They are inclined conveyors, under 25 horsepower, which can utilize either automatic or manual take-up systems. 30" Conveyors PM-1 and PM-2 move material from either the fines stock pile or the crusher run stock pile into the pugmill for processing. These conveyors are normally short in length, under 25 horsepower, and utilize manual take-up systems. All of the conveyors that utilize manual take-up systems are candidates for Bryant Telescoper take-up systems. The determination of which Bryant Telescoper model is applicable can be a function of the conveyor frame configuration, the bearing size, environmental and operational considerations and the operator's preference. The original Standard Bryant Telescoper, the Bryant Spring Compression Telescoper, the Bryant Hydraulic Telescoper and the Bryant Top Mount Telescoper have all been used on aggregate industry conveyors.

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The aggregates industry has some of the most demanding applications for belt conveyors in industry today. The production, environmental and cost requirements of the industry requires careful selection of conveyor components that will meet their needs. The Bryant Telescoper is a product that continues to meet and exceed the challenges of the aggregates industry. The advantages of the Bryant Telescoper are:

Long life due to rigid, protected screw design Reduced maintenance costs through utilization of pillow block bearings Cost effective design Modular design offering customized configurations Spring Compression Model for accurate tensioning Hydraulic Model for extra tough applications Top Mount Model for fitment to most conveyor frames Backed by a No Freeze Up warranty

SUMMARY
The aggregates industry provides our economy with the raw materials required for infrastructure development, such as the construction of roads, bridges, railbeds, buildings and a multitude of other uses. Conveyors are the lifelines of aggregate processing plants, efficiently moving the mined rock between crushers, screens, classifying screws, surge piles, storage bins and load-out facilities. Bryant Products Inc. provides a high performance, dependable take-up system that insures long life and trouble free operation for the plant operators.

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F IGURE 1
PRIMARY GRIZZLY FEEDER DUMP POINT
4 V. ON C Y PH AR 0 T M 0 I 6 PR 8"

PRIMARY JAW CRUSHER

36 A . H NV TP O 0 C 60

"

RIP - RAP CLASS 1

SURGE PILE AND TUNNEL WITH FEEDER

CON V. C R-2 30"

CON

V. C R-1

CRUSHER RUN STOCKPILE

PM-2 CONV.

30"

24"

CEMENT SILO AND BAGHOUSE 6X16 3D TERIARTY SCREENS

FINES STOCK PILE AND TUNNEL WITH PAN FEEDER

CEMENT METERING SYSTEM

. PM-1 CONV

30"

FINES STOCK PILE AND TUNNEL WITH PAN FEEDER

PUGMILL

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TRANSPORT TRUCK

FEEDER HOPPER 6X16 2D PRIMARY SCREEN

9X24 3D SECONDARY SCREEN

CON V. 250 F .24" TPH

SURGE BIN

SECONDARY FEEDER 400 TPH SECONDARY CONE CRUSHER

" 36 B PH V. 0 T N 0 CO 10

CONV. E - 24"
FEEDER HOPPER

160 TPH SURGE BINS

CO

CON

OVER FLOW CHUTE

V. E2 24 "

NV. E 250 - 5 2 TPH 4"

TERTIARY FEEDERS 300 TPH TERTIARY CRUSHERS 200 TPH

FINES STOCK PILE CONV. D 30"

24" E-3 . V N CO PH 160 T
30"

CON

V. C

400

TPH

LOAD OUT BINS

CONV. LO - 1 36"

54 X 32 SCREW CLASSIFIER

. CONV

E-4

24"

CONV. LO - 2 36"

TRANSPORT TRUCKS

WASHED SCREENINGS STOCK PILE

Table of Contents
- Introduction PG. 1-2 - Flow of a Typical Quarry PG. 3-7

- Belt Conveyors

PG. 8

- Conveyor Take-up Systems

PG. 9-13

- Bryant Telescoper

PG. 14-16

- Bryant Telescoper in Aggregate Applications

PG. 17-19

- Aggregate Chart

PG. 20-21

Our Products, Services and Tradenames....

NEW! AirFormTM Tapered Steel Conveyor Rollers
Greatly improved TIR, angle of taper and bearing pocket accuracy. Diameters to 8", lengths to 60", up to 10 gauge material with or without drive belt grooves. Our tapered steel rollers require no tooling so special profiles and tapers are available.

Telescoper Takeups
Available in low carbon or stainless steel. Only takeup with a fully protected adjustment rod. Guaranteed to adjust in any environment for up to 5 years. Simple modular design allows for a wide range of readily available options. Standard products shipped same day from factory. Optional constructions and special designs available in one week lead time or less.

Custom Machining & Fabricating

Full CNC machining and programming - CAD and solid modeling capabilities. CNC Lathes - bar feed and chuckinglengths to 60", diameters to 14", tolerances to .0004". CNC Vertical Machining - 20" by 48" swing, tolerances to .0004". MIG and TIG Welding - low carbon, stainless and aluminum. Tube forming and fabricating, press and CNC sawing.

Teletrack TM Conveyor Rollers

Thermoplastic designs available in PVC, Nylon, Polypropylene, and UHMW (some materials available with steel reinforcing for higher load capacities). Low carbon steel, pre-plated steel and stainless available in a variety of wall thickness and pipe sizes - diameters from 11/16" to 6". All common bearing options - plastic race, sealed precision, UHMW or wood sleeve, stamped steel/full complement - available with or without axles in a variety of sizes and forms.

Teletrack TM Custom Conveyor Frame Components

All components engineered and built to order. Available in one week lead time or less. Side rails, leveling feet, belt and drive guards.

Teletrack TM Conveyor Pulleys

Available in PVC, UHMW, stainless or low carbon steel in a wide array of tubing and pipe sizes. Diameters to 10", lengths to 60". Straight, crowned or trapezoidal face configurations - lagging in rubber, white rubber or polyurethane. Machined face or NEW high precision formed face process that meets machined tolerances without the cost. Bryant offers the only forming process capable of producing trapezoidal crowns. Fixed shaft, through hole precision bearing with or without labyrinth and dust seals, QD or XT type hubs.

FOOD PROCESSING (FIELD HANDLING, PREPARATION, PACKAGING), AGGREGATES, CONCRETE, ASPHALT, MINING, ORE CARRYING, UNIT HANDLING CONVEYOR SYSTEMS, WASTE MANAGEMENT & RECYCLING, CONVEYOR TURNS, FERTILIZER & PHOSPHATE PRODUCTION, CHEMICAL PROCESSING.

FPM&SA

MEMBER

QUALITY CONVEYOR COMPONENTS

fax: 920.206.6929 www.bryantpro.com email: inquiry@bryantpro.com P.O. Box 270 W1388 Elmwood Ave. Ixonia, WI 53036

800.825.3874