Belt Conveyors - Capacity of Belt Conveyors

athematical modeling of the
conveyor belt capacity

Tsakalakis K.G.*and Michalakopoulos Th.
National Technical University of Athens (NTUA)-Greece
School of Mining and Metallurgical Engineering
* kostsakg@metal.ntua.gr
CHoPS 2015, The 8th International Conference for Conveying and Handling of Particulate Solids
Tel-Aviv, Israel, 3-7 May 2015
Objective of the work

In this work we try to formulate and present a
new poly-parametric empirical model, which
can be used for the prediction of the conveyor
belt capacity Q, facilitating the whole
mathematical work, especially for design
purposes of mining industry treatment plants.
It is performed also an assessment of the
accuracy and the adequacy of the proposed
model.
CHoPS 2015, The 8th International Conference for Conveying and Handling of Particulate
Solids Tel-Aviv, Israel, 3-7 May 2015
Outline of the presentation
Belt conveyor applications

Aggregates processing plant layout
Belt Conveyor Advantages
Conveyor belt design
Physical properties and features of solid bulk materials affecting
their handling
Angle of repose (a) and angle of surcharge (b)
During material transport
Cross Sectional Area / Comparison for Various Forms of Troughing
configurations
Geometrical calculation of the cross-sectional area (profile) of a
conveyed load
Outline of the presentation

Equation for the capacity factor CF in three roll equal-length trough
idlers belt designation
Capacity factor CF (Data given compared to computed values)
Relationship of the cross-sectional area S and the belt width W
Assessment of the cross sectional area S model
Integrated model for the calculation of the conveyor belt capacity
Q (m3/h)
Remarks-suggestions referred to the model
Assessment of the proposed model using CEMA data
RESULTS
CONCLUSIONS
Acknowledgement
Belt conveyor applications

Belt conveyors play a major role
in bulk materials handling
operations (especially in the
extractive industry).
They may be used effectively for
the transportation of bulk
materials over both short and long
distances.
In the latter case, the adaptability
of their design and construction
permits them to operate over
undulating terrain.
http://www.bulksolids.com.au/beltconveying.html
Aggregates processing plant - layout
After Pathak K., Belt Conveyors

CHoPS 2015, The 8th International Conference for Conveying and Handling of Particulate Solids Tel-Aviv, Israel, 3-7 May 2015
Belt Conveyor Advantages

Belt conveyors are used throughout the world for the conveying of bulk materials
and have many advantages over other types of bulk material handling equipment
Capable of handling a wide range of bulk materials from very fine (cement
powder) to large lump sizes (coarse lumps of coal)
Capable to handle capacities for any operation (e.g. from 10,000 tons/h to a
small amount of material between processes)
Longer distances can be covered more economically than any other
transportation system by means of a single or a series of belt conveyors
Can be configured to fit almost any application (horizontal material convey, on
an incline or a combination of both)
Can be used to stock-pile or reclaim bulk materials from large stockpiles
Require less horsepower to operate than other types of conveyors, due to the
fact that the carried bulk materials are on top of the belt and remain static
Reliable method of conveying bulk materials.
Conveyor belt design

The proper design of a belt conveyor requires:
an understanding of the characteristics (bulk density, PSD, etc. ) of
the material to be conveyed
The material behavior, during transportation, affects the conveyor's
capacity and design.
A conveyor is described by its rated capacity Q in m3/h or t/h, which is
a function of:
Q = f (W, , dyn)
Where: W (belt width), (lamda,troughing angle of the idlers), dyn
(the surcharge angle of the carried material) and
v the belt speed and the bulk density of the material (t/m3) if they
are different from 1 (m/s or t/m3)
Any change of these factors, affects the capacity of the conveyor.
Physical properties and features of solid bulk

materials affecting their handling :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Bulk Density
Lump-Size
Particle size (mean, max, min)
Particle size distribution (PSD) of the conveyed material
Particle shape
Moisture content
Flowability
Temperature
Coefficient of friction on solid surfaces
Abrasiveness
Corrosiveness
Miscellaneous Characteristics
Particle size distribution (PSD) of the conveyed material
10
Inclined conveyor belt fully loaded
Boddington Gold Mine (Australia) 11.5 kilometres conveyor belt , after FLSmidth
11
Angle of repose (a) and angle of surcharge (b)
st = angle of repose (static angle) of a material or angle of

natural friction
dyn = angle of surcharge or dynamic angle of a moving
material
Approximately dyn = (0.5 - 0.9)st
12
During material transport

1. Settling of the material (range 10-15%)
2. Material rearrangement on the moving belt
3. Increase of the bulk density of the conveyed material,
due to external forces
4. Changes in the cross-sectional area (profile) of the
conveyed load
13
Material properties affecting material flowability

and conveyor belt capacity after CEMA
Thus, for capacity and equipment calculations necessary to
know
1. The angles of repose and surcharge of the conveyed
material related to belt configuration (number of
idlers, belt width W, usable belt width b, troughing
angle/-s )
2. The variation in bulk density in loose and packed states
3. The particle size distribution (PSD) of the material and
4. The moisture content of the material greatly influencing
the above factors
14
Cross Sectional Area S / Comparison for Various Forms of

Troughing configurations
The number of
idler rolls in a
carrying idler set
and the troughing
angle (-s)
determine the
cross sectional
area of the load
stream and thus
the conveying
capacity
15
(Cross-sectional area, S)
Material moving on a conveyor belt supported on
three equal-length roll idlers
The area of the section S may be calculated

geometrically adding the area of a circle segment A1 to
that of the trapezoid A2 or mathematically
16
Geometrical calculation of the cross-sectional area

(profile) of a conveyed load
17
Equation for capacity factor CF in three roll equal-length

trough idlers belt designation
Applying multiple linear regression analysis to the 30 sets of data

(surcharge angle dyn, idler troughing angle lamda, Table) yields:
CF = (-0,0002*+0,0219)*dyn + 0,0408*0,7903
18
Capacity factor CF
Data given compared to computed values
1,4
Compared values (data vs computed)
1,2
0,8
0,6
0,4
0,2
0
1
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Number of pairs compared (data vs computed values)
19
Relationship of the cross-sectional area S

and the belt width W
0,7
Cross-sectional area S of the load, m2
0,6
0,5
0,4
S = 0,1084W2,1473
R = 0,9997
0,3
0,2
0,1
0
0
0,5
1,5
2,5
Conveyor belt width W, m

20
Assessment of the cross sectional area S model

2
1
0
-1
9 10 11 12 13 14 15 16 17 18
-2
-3
-4
All % differences (except

one), between the given
and the computed S values,
vary from about -3 to 2 %
-5
-6
Number of data values used for model derivation
Comparison of the given

and the computed S values
for 18 pairs
Number of data values (pairs) compared
% difference between given and

computed S values
17
15
13
11
9
7
5
3
1
0
0,1
0,2
0,3
0,4
0,5
0,6
Cross sectional area S (data vs computed), m2

21
0,7
Integrated model for the calculation of the

conveyor belt capacity Q (m3/h)
But, since Q = Sv (m2m/s) = 3600 Sv (m3/h)
Multiplying the two models, derived previously, yields:
= , ,
, + , + , ,
The model gives the conveyor belt capacity Q

Q = f(W, , dyn)
( )as
a function of:
Where: W Belt width (m), the troughing angle and dyn the angle
of surcharge (thus, taking into account the capacity factor CF for
different conveyor configuration)
22
Remarks-suggestions referred to the model

= ,
, + , + ,
Q values refer to horizontal conveyor belts,
moving at speed v = 1 m/s and

loaded with a material of bulk density = 1000 kg/m3 (1 tonne/m3)
Under different operating conditions
(belt speed, material bulk density, belt inclination)
Use correction factors !!!
given in the technical literature by the belt conveyor manufacturers

23
Assessment of the proposed model using CEMA data

Only belt conveyors wider
than 84 inches (2.1 m)
present differences greater
than 4%, all other from
-2 to 4%
90000
Conveyor capacity Q (ft3/h)
80000
70000
60000
50000
40000
30000
20000
10000
0
1
10
11
12
13
Number of pairs compared (data given vs computed values)
Conveyor Equipment Manufacturers

Association (CEMA)
Percent difference in capacity, %

published vs predicted values
14
12
10
8
6
4
2
0
-2
-4
20
40
60
80
100
120
Conveyor belt width W, inches
24
RESULTS
A new polyparametric empirical model, predicting the
horizontal conveyor belt capacity as a function of:
1.
2.
3.
4.
5.
The idler troughing angle

The surcharge angle dyn of the carried material
The belt width W
The belt speed v
The material bulk density,
25
CONCLUSIONS
With the help of the proposed model:
not only accurate prediction of the conveyor
belt capacity Q under various operating
conditions, but
use it for design purposes of belt conveyor
systems
26
Acknowledgement
This work was supported by the LIFE+ financial instrument of the
European Community in the context of LIFE RECLAIM Landfill
mining pilot application for recovery of invaluable metals, materials,
land and energy (www.reclaim.gr), Grant: LIFE12 ENV/GR/ 000427.
The coordinating beneficiary is ENVECO S.A. and the associated
beneficiaries are the Municipality of Polygyros, School of Mining &
Metallurgical Engineering NTUA and HELECTOR S..
27

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Belt Conveyors - Capacity of Belt Conveyors

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Formate disponibile

athematical modeling of the

conveyor belt capacity

Objective of the work

Outline of the presentation

Belt conveyor applications

Outline of the presentation

Belt conveyor applications

Aggregates processing plant - layout

After Pathak K., Belt Conveyors

Belt Conveyor Advantages

Conveyor belt design

Physical properties and features of solid bulk

Particle size distribution (PSD) of the conveyed material

Inclined conveyor belt fully loaded

Angle of repose (a) and angle of surcharge (b)

st = angle of repose (static angle) of a material or angle of

During material transport

Material properties affecting material flowability

Cross Sectional Area S / Comparison for Various Forms of

The area of the section S may be calculated

Geometrical calculation of the cross-sectional area

Equation for capacity factor CF in three roll equal-length

Applying multiple linear regression analysis to the 30 sets of data

Compared values (data vs computed)

Relationship of the cross-sectional area S

Cross-sectional area S of the load, m2

Conveyor belt width W, m

Assessment of the cross sectional area S model

All % differences (except

Number of data values used for model derivation

Comparison of the given

Number of data values (pairs) compared

% difference between given and

Cross sectional area S (data vs computed), m2

Integrated model for the calculation of the

The model gives the conveyor belt capacity Q

Remarks-suggestions referred to the model

Q values refer to horizontal conveyor belts,

moving at speed v = 1 m/s and

Use correction factors !!!

given in the technical literature by the belt conveyor manufacturers

Assessment of the proposed model using CEMA data

Conveyor capacity Q (ft3/h)

Number of pairs compared (data given vs computed values)

Conveyor Equipment Manufacturers

Percent difference in capacity, %

Conveyor belt width W, inches

The idler troughing angle

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