Belt Conveyor

Belt conveyors conserve energy because they are driven by electric motors with an efficiency of near 95% and their payload to-dead load ratio is approximately 4:1. By comparison, the efficiency of the diesel engine in a haulage truck does not exceed 40% and a trucks payload-to-dead load ratio is no better than 1:1. Belt conveyor systems are less flexible than truck haulage and require a high initial investment. Usually, this means that belt conveyors are the economical choice only when there is a relatively high production rate and the transport distance is significant. Belt capacity is dependent upon these inter-related factors: 1. Belt width

2. Belt speed 3. Material bulk density and surcharge angle 4. Inclination angle 5. Troughing angle 6. Idler configuration

1. Belt width Minimum belt width may be influenced by loading or transfer point requirements, or by material lump size and fines mix refer to the next table. Troughability and load support restrictions, will also influence final belt width selection

2. Belt speed Possible belt speed is influenced by many factors, importantly the loading, discharge and transfer arrangements, maintenance standards, lump sizes etc. Typical belt speeds are shown in the next table

3. Material bulk density and surcharge angle Due to undulations of the belt passing over the conveyor idlers, the natural angle of repose of the material is decreased. This decreased angle known as ANGLE OF SURCHARGE is one of the most important characteristics in determining carrying capacity as it directly governs the cross sectional area of material on the belt and hence the "volume" being conveyed. The next table shows bulk density and surcharge angles for some common materials. With materials which slump readily, such as fine powders or dust, or on long conveyors where the load may settle, consideration should be given to using a reduced surcharge angle for capacity determination, and may require the compensatory use of other factors (such as greater belt width or speed) to provide the required capacity

4. Inclination angle The angle of inclination of a conveyor changes the carrying capacity. The load cross-section area of an inclined load is reduced when viewed in a vertical plane as the surcharge angle is reduced perpendicular to the belt. An approximation of the reduced capacity can be determined by multiplying the horizontal capacity by the Cosine of the inclination angle.

The table shows maximum inclination angle for some common materials. Effectively the capacity reduction is usually less than 3%.

5. Troughing angle For standard 3 roll idlers, the most common trough angle is 35 although trough angles from 20 to 45 are not uncommon. Steeper trough angles give increased capacity but can have consequences. 6. Idler configuration The most common configuration for idler rollers is 3 rolls of equal length. This configuration and normal clearances are shown in the figure. 6. Idler configuration Other configurations from flat belt to 5 roll idlers and with unequal roll lengths are sometimes used. For wide belts, 5 roll suspended idlers are not uncommon and the next table 4 shows capacity for different trough and surcharge angles

General formula: The general formula for capacity is: Capacity - tonnes per hour =3.6 x Load Cross Section Area* (m2 ) x Belt Speed (m/s) x Material Density (kg/m3) (* perpendicular to the belt)

Capacities for conveyors using other troughing angles or materials can be obtained by multiplying the capacity shown in the last table by the appropriate CAPACITY FACTOR obtained from table below. 5

Capacity- 3 or 5 equal roll idlers: Capacity - tonnes per hour = Capacity (3 or 5 from its table) x Material Density (kg/m 3 ) / 1000 x Capacity factor (from its table) x Belt Speed (m/s) An underground mine is more economically served by a belt conveyor than railcars or trucks when the daily mine production exceeds 5,000 tons. As a rule, a belt conveyor operation is more economical than truck haulage if the conveying distance exceeds 1kilometer. The ton-mile cost of transport by belt conveyor may be as low as one-tenth the cost by haul truck. Operating maintenance cost per year for a belt conveyor is 2% of the purchase cost of equipment plus 5% of the belt cost. To this should be added belt replacement every five to 15 years (five for underground hard rock mines). The free fall of crushed ore to a belt must not exceed 4 feet. The horsepower requirements for feeders listed by manufacturers are generally low. They should be increased by a factor of 30 to 50% to take into account considerations like starting torque, starting when cold, when the bearings are sticky, and when the bearings become worn. On well-engineered systems, using appropriate controls to limit acceleration, the (static) factor of safety for belt tension can be reduced from 10:1 to 8:1 for fabric belts and from 7:1 to 6:1 for steel cord belts. The standard troughing angles in North America are 20, 35, and 45 degrees. In Europe, they are 20, 30, and 40 degrees. A 20-degree troughing angle permits the use of the thickest belts, so the heaviest material and maximum lump size can be carried. A troughing angle of 35 degrees is typically employed for conveying crushed ore. For conveying crushed ore, the cross-section of the material load on the belt can usually be accurately calculated using a 20-degree surcharge angle.

It should be considered that when conveying over a long distance, the dynamic settling of the load could reduce the surcharge angle to 15 degrees. The availability of a belt conveyor is 90%; if coupled with a crusher, the availability of the system is 85%. In-pit conveyors should not be inclined more than 16 degrees (29%) from the horizontal. A downhill conveyor should not be designed steeper than 20%. The pulley face should be at least 1 inch wider than the belt for belts up to 24 inches wide and 3 inches wider for belts greater than 24 inches. The first step in designing a belt conveyor is to determine the following design criteria: Capacity (tph). Layout dimensions (length, lift, and azimuth). Material origin (ROM, grizzly, jaw crusher, cone crusher, etc.). Material description (SG, bulk density, angle of repose, abrasion, foliation, moisture content, pH, and contaminants). Material size . Ambient conditions (temperature range, humidity, etc.). Applicable statutory mine regulations. Applicable insurance stipulations (FM). Access dimension and weight restrictions to reach the workplace. Belt width is typically first dimensioned on the basis of capacity. Final determination often depends on the characteristics of the material on the belt, particularly particle size distribution.

The following procedure provides a good approximation of the drive HP required. The procedure is based on the assumption that conveyor power requirements may be determined by adding the power required to actually lift the material to the power required to lift the material a distance equivalent to the friction losses sustained by a level installation. Total Lift, H = Hg + Hf

Example: Determine the drive power requirements for the following conditions. A flat (level) conveyor Facts: 1. The belt length is 1,000 feet 2. The belt speed is 300 fpm 3. The conveyor output is 300 tph 4. The drive train efficiency, E is 88.5% 8

Solution: Output, Q = 300 tph = 10,000 Lbs./minute H = Hg + Hf = 0 + 60.2 = 60.2 feet Belt Horsepower = QH/33,000 = 10,000 x 60.2/33,000 = 18.2 BHP Drive HP = BHP/E = 18.2/0.885 = 20.6 HP Select 25 HP motor Example: Determine the drive power requirements for the following conditions. An uphill gradient of 20% Facts: 1. The belt length is 1,000 feet 2. The belt speed is 300 fpm 3. The conveyor output is 300 tph 4. The drive train efficiency, E is 88.5% Solution: Output, Q = 300 tph = 10,000 Lbs./minute H = Hg + Hf = 200 + 60.2 = 260.2 feet Belt Horsepower = QH/33,000 = 10,000 x 260.2/33,000 = 78.8 BHP Drive HP = BHP/E = 78.8/0.885 = 89.1 HP Select 100 HP motor Example: Determine the power generation potential for the following condition. A downhill gradient of 20% Facts: 1. The belt length is 1,000 feet 2. The belt speed is 300 fpm 3. The conveyor output is 300 tph 9

4. The drive train efficiency, E is 88.5% Solution: Output, Q = 300 tph = 10,000 Lbs./minute H = Hg + Hf = -200 + 60.2 = -139.8 feet Belt Horsepower = QH/33,000 = 10,000 x -199.8/33,000 = -60.5 BHP Power generation = -BHP x E = 60.5 x 0.885 = 53.5 HP Equivalent generator output = 53.5 X 0.746 40 kW A belt conveyor production capacity is normally measured by installing a belt scale (weightometer). The material is weighed as it passes over a weigh bridge, the belt speed is measured, and the results are electronically integrated to provide a rate output. An accuracy of over 99% may be obtained with proper calibration. A simple system was developed to verify the weightometer results or to determine the output when no weightometer is installed. In this method, the loaded conveyor is stopped and a measured length of material on the belt is removed and weighed. The length of material removed is compared with a specified length that will result in short tons from a measurement in pounds. The specified length may be obtained from the following formula. L= 3V/100 In which L= specified length (feet) and V =belt speed (fpm) Example: Determine the conveyor output for the following case. Facts: 1. The belt speed is 200 fpm 2. The material on a 5-0 length of belt weighs 250 Lbs. L= 3V/100 In which L= specified length (feet) and V =belt speed (fpm) Solution: The specified belt length = 3 x 200/100 = 6.00 feet 10

The weight on the specified length = 250 x 6/5 = 300 Lbs. The conveyor output = 300 tph The following relationship can be used to relate the tensions to friction around the drum of a conveyor drive pulley. = Coefficient of friction = Contact angle (in radians)

For rubber belts on a bare steel drum, = 0.30 (dry), =0.18 (wet) For rubber belts on a ribbed, rubber-lined drum, = 0.42 Example: Determine T1/T2 ratio for following conditions: Coefficient of friction= 0.30 A. Contact angle= 3 radians B. A. Contact angle= 4 radians

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