BELT DESIGN

Capacity Q2 1000 t/h continuous operation

Lump Size 50 250 mm
Centre distance 500m
Bulk Density - 1.4 t/cu.m
Angle of inclination = 150
Belt Width & Belt Speed
B Belt Width 800mm (Table-1,unsorted material), v- Belt Speed 2.5m/sec(Table-2,moderate,abrasive)

Capacity Qt (cu.m/h)
Required Capacity - Q2 1000 t/h continuous operation
Theoretical Capacity - Qt - Q2 / (v x x k) 1000 /(2.5 x 1.4 x 0.99) = 288 cu.m/h
With Qt = 288 cu.m/h, - Basic Angle = 150, by taking 3-sectioned idler & trough angle = 450(max.).
(From-table)

Note - The belt size is found not suitable for this application.
So we will have to go next higher size of the belt width i.e B=1000mm & taking 3 sectioned idler with
- Basic Angle = 150 & trough angle = 200, required capacity can be achieved.
For establishing the assumption
Qt = Qt * v * k = 337 * 2.5 * 0.98 = 825.65 cu.m/h
Q = Qt * = 825.65 * 1.4 = 1155.91 t/h > Q2
So, We require to reduce the belt speed to convey 1000t/h.
1155.91/2.5 = 1000/v (req)
v (req) = 2500/1155.91 = 2.16 m/sec
Hence, belt width B=1000mm & taking 3 sectioned idler with - Basic Angle = 150 & trough angle= 200
& v = 2.16 m/sec is suitable to convey 1000t/h in continuous operation.

Power Requirement
Power required to drive the empty conveyor - N1
N1 = {G (L + l)f * v}/102 = {31(500 + 100)*0.02 * 2.16}/102 = 7.87 kw
G(Kg/mt) = 2Gb + (Gro/s1)+ (Gru/s2) = 31kg/m -------------from table

Gb = weight of belt (kg/mt)

Gro= weight of carrying idlers (kg)
Gru= weight of return idlers (kg)
l = additional length introduced with L to include resistance caused by bending of belt over pulleys =100m
s1= distance between carrying idlers = 1.5 mtr
s2= distance between carrying idlers = 3 mtr
f = coefficient of friction of rolling parts = 0.02 (from table)
Power required to convey the material on the level N2
N2 = {Q (L+ l)f}/367 = (1000 x 600 x 0.02)/367 = 32.7 Kw

 Power required to elevate the material N3

This is the most important factor to increase the power.
Case -1 The material is required to elevate the material in the total length ,then the height of elvetion is
H = L sin = 129mm
Then the power required is = (Q * H)/367
= 351 Kw

L
H

Case-2 The material is being elevated gradually & reaches the angle of inclination after 250 m.

Then = H = L(inclined) sin = 250 sin150 = 64.7m

Then the power required is = (Q * H)/367 = 176 Kw
Additional power requirement N4
N4 = 0.08 * v * length of the skirt board = 0.08 * 2.16 * 12 = 2.07 Kw
Length of skirt board 6m each side.

 Theoretically necessary motor capacity Nn (Kw)

Nn (Kw) N1 + N2 + N3 + N4 = 7.87 + 32.7 + 176(case-2) + 2.07 = 218.64 Kw

Motor Capacity Nm(Kw)

Nm = Nn/0.85 = 257.22 = 260 Kw

Effective Tension P(N)

P = (Nn * 1020)/v = (218 * 1020)/2.16 = 102944 N
Max.Belt tension T1(N)
T1 = P * m = 102944 * 1.35 = 138975N
Working Tension p(N/mm)
P = T1/B = 138975/1000 = 138.9 N/mm
Pre Tension Gk(Kg)
Gk = {2 * Nn(m-1)102}/v + 2{ L1 ( Gb + Gru/s2)f H1 * Gb}
= {2 * 218(1.35 -1)102}/2.16 + 2{ 100(9 + 13/3)0.02-25 * 9}
= 7206 171.66 = 7034 kg
Max.permissible belt sag (q/s)perm. = 0.01
Required min. tension for the belt = T min = {s1(Gb + Gm)g}/{8 * (q/s)perm.}
= {1.5(9 + 128)10}/{8 * 0.01}
= 25800 N
Belt Tension at head pulley= T = Gk * g/2 = 7034 * 10 /2 = 35170 > T min
To keep the belt sag at permissible limit,the pre-tension must be decreased by = T - Tmin
= 35170 25800
= 9370N
Gk = 7034 2 (9370/10) = 5160 kg (load required at gravity to get the permissible belt sag)
Then T1 changes to = 138975 9370 = 129605N
Then p = 129605 / 100 = 129 N/mm (working tension)

The belt should be selected by referring to the catalogues issued by belt manufacturers according to the
calculated working tension.

Belt Nomenclature