An Approved Continuing Education Provider

PDHonline Course M360 (1 PDH)

Chain Conveyors
Practical Calculations
J urandir Primo, P.E.

2009
PDH Online | PDH Center

5272 Meadow Estates Drive
Fairfax, VA 22030-6658
Phone & Fax: 703-988-0088
www.PDHonline.org
www.PDHcenter.com













1

R
a
m

T
d

A

D








P

T
sp

T
tw













www.PD

1. INTRODU
Roller Chain
another. This m
metric and imp
The main fun
dynamics of th
Arrangement
Drive chains a
Position of Sp
The sprockets
procket. In th
The two shaft
wo sprockets
DHcenter.com
Jurandir Pri
UCTION:
Conveyors o
manual for pr
perial system
nction is inf
his segment o
t:
are ideally ins
prockets:
s should be "k
his way the sp
ts should be p
are installed
m
imo
Chain
or Apron Cha
ractical applic
m.
formative for
of Material Ha
stalled with th
key-wayed a
procket can po
parallel and t
along the sam
PDHonl
n Conveyo
ain Conveyor
cation indicat
r both experi
andling.
he shaft in the
and matched
osition itself i
the sprockets
me horizontal
ine Course

ors - Pract
rs are used t
tes the chain c
ienced profe
e horizontal p
in pairs. Sinc
if uneven wea
should be fir
level. This is
M360

tical Calcu
to transfer he
conveyor basi
ssionals and
osition, as sh
ce the tail sha
ar takes place
rmly installed
s illustrated in
w
ulations
eavy bulk ma
ic calculation
beginners in
hown below:
aft is an idlin
e in the chain
d. Use a strai
n Figure 1 and
www.PDHon
2 of
aterials from
ns for Bulk M
nterested in
ng shaft, key i
strands.
ight edge to c
d 2 below:
nline.org
10
one point to
Materials in the
knowing the
it to only one
check that the
o
e
e
e
e

C

C
d


2

A
fo

T
u
o

T
c
re

T
m

V

A



C

www.PD

Chain Convey
Commonly th
during convey
CONVEYO

Continuous B
Centrifugal B
Slat or flat to
Assembly lin
Drag and Scr
Apron Conve

2. APRON CH
Apron feeders
for the most h
These types o
up to 2000 mm
of the skirts. T
The presence
conditions of
eserve of mot
The basic fo
manufacturing
Velocity, Wid
As the transpo
Considering th
DHcenter.com
Jurandir Pri
yor Speed:
he Chain Con
ying. The tabl
R
Bucket Elevat
Bucket Elevat
op Conveyor
ne Conveyor
raper Convey
eyors
HAIN CONV
s are used in t
ard condition
f conveyors h
m. The large
The presence
of receiving
exploatation
tor power.
rmulae for A
g has its own
dth an Heigh
orted material

he following d
m
imo
nveyor speed
le below show
SP
tor
tor
yors
2
VEYORS
the mining in
ns of exploata
have capacitie
size of materi
of fixed skirts
g hopper caus
and the gre
Apron Chain
n methodology
ht of Skirts
l is lumpy, it
data:
PDHonl
is dictated b
ws the basic c
PEED (fpm)
75 to150
200 to 300
50 to 150
5 to 15
50 to 100
10 to 60
ndustry for the
tion to feed th
es up to 6000
ial lumps is th
s cause additi
ses additiona
at starting re
n Feeders ca
y for calculat
s maximum lu
ine Course

by how it is
onveyors and
e transportatio
he crushers at
0 t/h and are a
he cause for t
ional resistanc
al resistance d
esistances are

alculation are
tion.
ump size will
M360

loaded and u
d their typical
on of heavy a
t quarry and s
able to transp
the increase o
ces due to ski
due to the pr
e the cause f
e given for
l determine th
w
unloaded and
operating sp
and lumpy ma
storage bins.
port materials
of the width o
irt friction.
ressure of the
for the introd

references, s
he apron widt
www.PDHon
3 of
d what is don
eeds.
aterials. They
s with maxim
f the aprons a
e material in
duction of a c
since that ea
th B [m]:
nline.org
10
ne to the load
y are designed
mum lump size
and the heigh
n it. The hard
coefficient of
ach company
d
d
e
t
d
f
y


T


W
th


w

Q

c


T
T
m

S
g

If
v
th


www.PD

The formula fo
When width B
he capacity:
where:
Qh = capacity
= density of
= 0,75 ext
c = 100 - i
100
The coefficien
The reason fo
material will f
Speed is limit
great dynamic
f the calculat
variation of th
he use of var
DHcenter.com
Jurandir Pri
for the determ
(1 m = 3.28
B and height
y in t/h
f the transport
traction effici
inclination fac
nt c, as indi
or the inclina
fall directly on
ed to 0.25 m/
c loads in the
ed speed is g
he speed in th
iable speed D
m
imo
mination of the
8 ft)
of the skirts
(1 m/s = 3.2
ted material in
iency factor
ctor ( ang
icated above,
ation is the fa
n it.
/s (0.82 ft/s),
track chains a
greater than lim
he work diapa
DC, AC and h
PDHonl
e height of the
h are determ
28 ft/s)
n t/m (t/ft)
le of inclinati
must be take
acilitation of
and in some
and the high a
mited, the sk
ason v = 0.03
hydraulic mo
ine Course

e skirts h, is
mined, the apr
ion).
en into accoun
f truck discha
e cases to 0,4
abrasion wear
kirt height h
3 0.16 m/s (
otors.
M360

given h for ap
ron speed v is
nt, when feed
arge and the
m/s (1.3 ft/s)
r of the apron
must be inc
(0.1 0.5 ft/s
w
pron conveyo
s determined

ding are inclin
protection of
). The reason
ns.
creased. The c
s) for differen
www.PDHon
4 of

ors, as:
by the know
ned (usually
f the equipm
ns for the limi
contemporary
nt capacities,
nline.org
10
wn formula for
= 15 - 25)
ment when the
itation are the
y drives allow
realized with
r
.
e
e
w
h
www.PDHcenter.com PDHonline Course M360 www.PDHonline.org

Jurandir Primo 5 of 10

Apron Chain and Rollers:

Apron feeders use heavy duty crawler tractor chains (Caterpillar tractor type), commonly sized to suit the
application. The chain links are forged for increased load capacity. Pins and bushes are hardened on the wearing
surface.

The carrying rollers are spaced to eliminate the sag, mounted on support frames to permit easy removal for
maintenance and replacement. The apron plates are bolted on flat top of the chain links, as shown below:



Special design and exclusive metal to metal allows continuous pan contact through articulation minimizes spillage
and leakage, as indicated below:



Drag and Flight Conveyors

Drag conveyors are used where multiple loading or discharge points are required and a totally enclosed conveyor is
needed for dust containment, capable of handling ne materials ranging from dust to 6 inch (150 mm) lumps, where
capacity requirements are high, 200 - 400 TPH.



They are used and when the material is somewhat uid. The typical materials conveyed are TSP (fertilizer), raw meal,
and nish cement.

www.PDHcenter.com PDHonline Course M360 www.PDHonline.org

Jurandir Primo 6 of 10

3. FORMULAS FOR EASY CALCULATIONS:

1) Chain conveyor or apron chain conveyor calculation system. The load tensions are calculated as indicated below:

T = Fs + Fi + Fk (Kgf) (lbf)

Fs = (Qt x L) + (Pch x L) x f =

Fi = Pch x L x f1 =
2

Fk = (Qt + Pch) x L1 x sen x f2

2) To calculate the driving power (CV or HP), use the following formulas:

N = T x v (m/s) (metric) and T x v (fpm) (imperial).
75 33000

Where:

T = Total chain force or total work chain tension (kgf) (lbf);
Fs = Upper chain tension (kgf) (lbf)
Fi = Under chain tension (kgf) (lbf)
Fk = Lift chain tension (kgf) (lbf)
Q = Conveyor total load - (t/h) (tph)
Qt = Conveyed material weight (kg/m) (lb/ft)
L = Total conveyor direct length (including inclined/declined) - (m) (ft)
L1 = Conveyor horizontal direct length (m) (ft)
L2 = Conveyor slope (inclined / declined) extension direct length (m) (ft)
Pch = Total chain weight (see manufacturers tables according to chain types);
N = Driving power (kW) - (HP)

f = Upper chain friction factor 0.25 ~ 0.35;
f1 = Down chain friction factor 0.10 ~ 0.15;
f2 = Lift chain friction factor 0.25 ~ 0.35;
v = Chain conveyor speed (m/s) - (fpm)
= Driving sprocket diameter (mm) - (in)
= Conveyor slope angle;
= Bulk density of conveyed material (kg/m) - (lb/ft)



www.PDHcenter.com PDHonline Course M360 www.PDHonline.org

Jurandir Primo 7 of 10
4. PRACTICAL EXAMPLE:

Calculate the driving power of a Drag Roller Chain Conveyor, commonly used in Sugar Plants considering the
following sketch below:




















Where:

Q - Chain conveyor capacity = 90 tph
- Sugar cane bulk density = 900 kg/m - (56 lb/ft)
v Conveyor speed = 5 m/min (0.083 m/s) (16.3 fpm)
- Driving sprocket diameter = 270 mm (10.6 in)
1 Driving pulley on driving shaft = 290 mm (11.4 in)
Pch -Total drag chain weight = 160 kg/m (both sides) (107.5 lb/ft)
L1 - Conveyor horizontal direct length = 2.5 m (8.2 ft)
L2 = Conveyor slope (inclined) direct length = 14.5 m (47,5 ft)
= Conveyor slope angle = 28

Solution:

1). CALCULATION ACCORDING TO MATERIAL FLOW:

kg/h = kg/m or lb/h = lb/ft
m/h ft/h

Q - 90 tph = 90,000 kg/h (198,450 lb/h)
v 5 m/min = 5 x 60 = 300 m/h (984 ft/h)


Qt = 90,000 kg/h = 300 kg/m Qt = 198,450 lb/h = 202 lb/ft
300 m/h 984 ft/h

1
4
5
0
0

(
4
7
,
5

f
t
)
2500 (8,2 ft)

2
7
0

m
m
PESO DO MATERIAL = 300 kg/m
CONVEYOR CAPACITY = 90 tph
DRIVING PULLEY DIA = 270 mm
TOTAL CHAIN WEIGHT = 160 kg/m
SPROCKETS DIAMETER = 270 mm
CONVEYOR SPEED = 6 m/min
2
8

www.PDHcenter.com PDHonline Course M360 www.PDHonline.org

Jurandir Primo 8 of 10
L = L1 + L2 = 17.0 m (55.7 ft)

a) Fs = (Qt x L) + (Pch x L) x f =

Fs = (300 x 17.0) + (160 x 17.0) x 0.25 = 1955 kgf (4310 lbf)

b) Fi = Pch x L x f1 = 160 x 17.0 x 0.15 =
2 2

Fi = 2720 x 0.15 = 204 kgf (450 lbf)
2

c) Fk = (Qt + Pch) x L2 x sin 28 x f2 =

Fk = (300 + 160) x 14.5 x sin 28 x 0.35 = 1096 kgf (2416 lbf)

d) T = Fs + Fi + Fk = 1955 + 204 + 1096 =

T = 3255 kgf (7177 lb.ft)


N = T x v = 3255 x 0.083 = 3.6 ~ 5.0 CV
75 75

Or:

N = T x v = 7177 x 16.3 = 3.5 ~ 5.0 HP
33000 33000


2). CALCULATION ACCORDING TO TSUBAKI FORMULA:

T = [(Qt + 2.1.Pch) x f1 x L1] + [(Qt + Pch) x (f1 x L2 x cos + L2 x sin ) + [1.1.Pch (f1 x L2 x cos L2 x sin )]
= (kgf) (lbf)

Using the data above, calculate the tension using the Tsubaki formula:

T = [(300 + 2.1x 160) x 0.15 x 2,5] + [(300 +160) x (0.15 x 14.5 x cos 28 + 14.5 x sin 28)]+ [1.1 x 160 (0.15 x 14,5
x cos 28 - 14.5 x sin 28)] =

T = 4254 kgf (9380 lbf)


N = T x v = 4254 x 0.083 = 4.7 ~ 5.0 CV
75 75


N = T x v = 9380 x 16.3 = 4.6 ~ 5,0 HP
33000 33000




3

A
w


W

P

R

F

R

C


a
b
c

W


P
F


N



N





www.PD

3) CALCULA
According to
windlass arm t
F x R
Where:
P = Conveyor
R = Driving sp
F = Pulley per
R1 = Driving
Calculate the d
F x R
a) P is the forc

P = Fs + F


P = 3255

Or,

P = 4254

b) The convey

c) The diamete
We need to fin
P = R1 = 3255
F R F
N = F x v = 30
75
N = F x v = 6
33000 3
DHcenter.com
Jurandir Pri
ATION ACC
applied mec
to pull the bu
1 = P x R
r chain force t
procket radiu
ripheral force
pulley radius
driving chain
1 = P x R
ce to carry up
Fi + Fk = 195
kgf (7177 lbf
(9380 lbf) ac
yor data abov
er of the drivi
nd the force F
5 = 0,145 = F
0, 135
030 x 0,083 =
75
6673 x 16.3 =
33000
m
imo
CORDING T
chanics the to
ucket is:
to pull the loa
us, m;
e on driving sh
s, m
n conveyor po
p the sugar ca
55 + 204 +10
f)
ccording to Ts
e indicate the
ing pulley on
F to move the
F = 3030 kgf

= 3,35 ~ 5.0 C

3.3 ~ 5.0 HP
PDHonl
TO THE WIN
orque calcula
ad, kgf;
haft, m
wer, using th
ne plus the ch
96 =
subaki formul
e sprockets di
n driving shaft
driving shaft
and, 7177 =
F
CV

P
ine Course

NDLASS TO
ation to revol
he data above.
hain weight, a
la.
ameters, =
t is, 1 = 290
t, so:
5.7 = 6673 lb
5.3
M360

ORQUE:
lve the drivin

as we calculat
270 mm, the
0 mm, then: R
bf
w
ng chain con
ted before:
n: R = 0,135
R1 = 0,145 (5
www.PDHon
9 of
nveyor pulley
(5.3 in).
.7 in).
nline.org
10
y just like thee
www.PDHcenter.com PDHonline Course M360 www.PDHonline.org

Jurandir Primo 10 of 10
SUMMARY:

Chain Conveyors:

Chain conveyors are commonly used in siderurgy and mining industries to transport heavy minerals The
manufacturing industry also use widely chain conveyors to carry unit loads, pallets, grid boxes and general industrial
containers. These conveyors can be single or double chain strand or Catterpillar type chains. Single chain conveyors
are generally easy to install and have very minimun maintenance for users.

Many industry sectors use chain conveyor technology in their production lines.The automotive industry commonly
use chain conveyor systems to convey car parts through paint plants. Chain conveyors also have widespread use in the
white and brown goods, metal finishing and distribution industries.

Chain conveyors are also used in the painting and coating industry, ceramics, thermal treatment of metals, feed and
discharge systems of boilers. In automatic painting systems the products are attached to an above head chain
conveyor, keeping products off of the floor allows for higher productivity levels.

References:

Sugar Cane Handling and Process Equipment, Dedini, 1
st
Edition, 1975
Tsubaki Manufacturer, Chain Conveyor Calculations
Grinding Manual, Technical Publication, Fao/Allis-Chalmers, 4th Edition, 1985