HGRS MASTER - Maintenance

Type of Skill: Specific Technical Skills

Category : Transport Equipment
Module: Belt conveyors
Unit: Material characteristics and 03 of 18
behaviors
Version: 1.0 06-02-03
Reference: Belt conveyors MTC Training.ppt - Page 26

Material characteristics and behaviors

Purpose: To understand the impact of characteristics of the materials on belt conveyor design

Description: Specific weight:

Mass per volume unit in kg/m3 or lbs/ft3:
For design consideration, different values are used for determination of the belt transport
capacity and for the power calculation (see table 1)

Angle of repose:
The angle the material pile will make to horizontal in a freely formed pile (in degrees). This
characteristic depends on the material and also the lump size and the shape of the lumps or
particles.

Angle of surcharge:
The angle to the horizontal the material pile will make on the belt (in degrees). This angle is
lower (5 to 15) than the angle of repose, due to the movement of the belt. This
characteristic is important to calculate the loaded area on the belt and hence the capacity.

Recommended maximum inclination:

From practice the following maximum angles are recommended for the belt inclination to the
horizontal. (see table 2)
Rock 18
Clinker 18
Cement/Raw Meal 6

Material Size:
The material size is rated in the belt conveying design from A to E:
All materials in the industry can be transported from very fine A (cement), fine B (coarse
returns from separator), granular C (reject from vertical roller mill), lumpy D (clinker, raw
material after crusher), and irregular E (lumpy + some oversize material)
Abrasiveness:
Non abrasive (raw meal), abrasive (cement), very abrasive (rock, clinker), sharp (granulated
blast furnace slag) all can be transported by belt if properly loaded.

Miscellaneous:
Some characteristics need to be taken into account in design of individual parts or auxiliary
devices:
Standards: Respect of the material characteristics in the initial design or rectification works
Impact if not Improper working condition
correct: Reduced capacity
High maintenance cost
High housekeeping cost due to spillage and overflow
High environmental emissions
Actions: Review of design and rectification to fit the application

Unit Trainees to describe the characteristics of three main material transported in the plant
Completion:
See site specific unit for additional information, respective actions and applicable safety instructions.

Training in Maintenance Page 1 of 3

Table1 Characteristics of Selected Cement Materials

Material Specific weights Angle of repose

Angle of Friction
surcharge angle
A B C For size of For civil (For (discharge
silos & design conveyor angle)
For conveyor size For conveyor H.P. For material loads stockpiles
design and size of silos & on building size design)
stockpiles structures
3 3 3 3 3 3
[kg/m ] [lbs/ft ] [kg/m ] [lbs/ft ] [kg/m ] [lbs/ft ] [] [] [] []
Cement (40% Puzzolan) 950 59 1300 81 1600 100 10 - 0-5 -
Cement (40% Slag) 950 59 1300 81 1600 100 10 - 0-5 -
Cement (Portland) 1000 62 1400 87 1600 100 10 20 0-5 20
Clay: Fine (dry) 1000 62 1200 75 1600 100 25 30 5 - 10 -
Clay: Loose (dry) 1600 100 1800 112 2000 125 40 - 25 - 30 -
Clay: Loose (wet) 1800 112 2000 125 2000 125 50 15 25 - 30 -
Clinker 1200 75 1400 87 1600 100 35 30 20 - 25 30
Coal: Anthracite (as
800 50 900 56 1000 62 40 30 25 - 30 30
received)
Coal: Bituminous 700 44 800 50 900 56 40 35 25 - 30 35
Coal: Pulverized/Meal 600 37 700 44 800 50 15 15 0-5 15
Gypsum (raw) 1280 80 1440 90 1600 100 40 35 25 - 30 -
Iron ore 2000 125 2400 150 2800 175 40 - 25 - 30 -
Kiln dust 600 37 800 50 1000 62 10 10 0-5 -
Limestone (crushed) 1400 87 1500 94 1700 106 40 35 25 - 30 35
Petcock (as received) 600 37 700 44 800 50 40 20 25 - 30 -
Petcock (meal) 400 25 550 34 750 47 - - - -
Puzzolan: course (wet) 1200 75 1360 85 1520 95 30 - 15 - 20 -
Puzzolan: ground (dry) 950 59 1200 75 1360 85 20 - 5 - 10 -
Pyrite (pellets) 2100 131 - - - - 35 - 20 - 25 -
Raw meal 900 56 1200 75 1500 94 15 15 0-5 15
Raw meal: blend. silo 900 56 1200 75 1500 94 15 15 0-5 15
Raw meal: cont. blend 900 56 1200 75 1500 94 15 15 0-5 15
Sand: dry (as received) 1400 87 1600 100 1680 105 40 35 25 - 30 35
Shale (crushed) 1300 81 1500 94 1680 105 40 35 25 - 30 35
Slag: blast furnace
1100 69 1200 75 1300 81 30 - 15 - 20 -
granular, (wet)
Slag: blast furnace,
900 56 1000 62 1200 75 20 - 5 - 10 -
ground, (dry)
Slag (pulverized 5600 Bl) 750 47 - - - - 15 - 0-5 -

Training in Maintenance Page 2 of 3

Table 2 Maximum recommended angle of conveying (upward)

Mate rial Bulk De ns ity Appro xim ate Ang le Max. Re c o m m e nde d
o f Re po s e Co nve ying Ang le
kg / dm 3 % De g re e %
Ce m e nt P ortla nd Bulk 1.20 - 1.36 10 12 21.5
Ae ra te d 0.80 - 1.20 -- 6 10.5
Clinke r 1.20 - 1.52 33 18 32.5
Cla y Crus he d 0.96 - 1.20 35 18 32.5
Coa l Crus he d 0.72 - 0.88 38 18 32.5
P ulve rize d 0.48 - 0.64 15 14 24.5
Ae ra te d 0.30 - 0.50 -- 8 14.0
G yps u m Crus
Crushehedd <50mm 1.28 - 1.44 40 18 32.5
Kiln Dus t 0.64 - 0.96 10 12 21.5
Lime s tone Crus he d 1.36 - 1.52 40 18 32.5
P yrite 2.00 - 2.40 40 18 32.5
Ra w Me a l 0.72 - 1.28 15 14 24.5
S a nd Dry 1.36 - 1.60 40 18 32.5
S ha le Crus he d 1.36 - 1.52 40 18 32.5
S la g Gra nula r 1.12 - 1.28 40 18 32.5

Training in Maintenance Page 3 of 3