Professional Documents
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2
4
R= 40 m
3
7
6
5
10 m
CONVEYOR PROFILE
500 m
20 m
Coal Ash
Bottom
Lump Type
Lump Size Type
Uniform Size
Average Flowing
300 mm
960 TPH
0.800 t/m3
:
:
:
:
1200 mm
B
KL
KAB
Abrasiveness Factor
KAS
Speed Factor
Where, KV = ( KL + KAB + KAS )
KV
Belt Speed
Angle of Inclination
Angle of Surcharge
:
:
:
Angle of Repose
Slope Factor
Maximum Capacity of a Belt
(for =1.0 t/m3, V=1.0 m/s, K=1.00)
Corresponding Values:
Maximum Belt Capacity
Trough Angle
Belt Width
Cross Sectional Area
K
C
:
:
B
A
:
:
:
:
B
V
:
:
:
Over 35
and up to
40
3 m/s
14
25
0.91
439.56 t/h
464
20
1200
0.129
t/h
mm
m2
1.2 meter
2.84 m/s
Fabric Carcass Belt
17822 N
2717 N
f
L
mc
:
:
0.02
100 m
15 kg/m
mr
15 kg/m
mB
mG
:
:
7.7285 kg/m
93.912 kg/m
14
RS
2164 N
Ra
757.21 N
Volumetric Capacity
Q=
A.V.K
0.3333 m3/s
V0
Rska
258.38 N
b1
0.8 m
la
0.7648 m
0.6
0.5
Rw
610.47 N
Secondary Resistance
RS = Ra + Rska + Rw + Rb
Inertial and frictional resistance at the loading
point and in the acceleration area between the
Handled material and the belt
Ra = Q . 1000 . . ( V - V0 )
0 m/s
2.Q2.1000.g.la
(V+V0) 2
.b12
2
V -V
2
la =
2
0
2.g.1
Rw = 9B 140+0.01.
Rw = 12B 200+0.01.
Tav
Tav
Tav
t
:
:
17115 N
0.1 m
3E-005
Rb
d
Rb=0.005
Rv
D
d
:
Shaft diameter inside diameter
D
:
Pulley diameter
R
:
Vectorial sum of the two belt tensions
v
acting on the pulley and of the forces
due to the mass of the revolving parts of the pulley
Rsp
Special Resitance
:
Rsp = (Rsp1+Rsp2) = (Ri + Rsk + Rbc + Rp )
Resistance due to idler tilting
Ri = g.Ci.0.Li (mB+mG) cos . sin i
Ri
537.53 N
0.15 m
0.5 m
35835 N
1E-010
1886 N
1.5099 N
A constant
Ci
0.5
0.35
Li
0.5 m
Rsk
84.491 N
lsk
1m
Rbc
0.048 N
Al
0.1 m2
0.6
Rp
1800 N
Ka
RSL
:
:
Rsk =
2.Q2.1000.g.lsk
V2 b 1 2
Rp = B . K a
Scraping factor
Slope Resistance
RSL = mG.H.g
Lift of conveyor between loading end and
dicharge end
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
1500 N/m
11055 N
12 m
:
:
T1
T2
30
TE
TE
17822 N
T2min
8204.12 N
TE max
21386.38 N
:
:
:
Tmin
5191.077 N
Pc
1m
Tmin
592.0756 N
1
e - 1
1.2
0.35
3.67 radian
Pr
Pitch of return idler or idler spacing on return
:
1.5
side of conveyor
Maximum Allowable Belt Sag
S
:
0.024
h
S=
a
adm
Minimum Force required in slack side
T2
:
8204.12
Tension of Tight Side
T1
:
26026.11
Average Belt Tension at the pulley
Tavg
:
17115.11
Vectorial sum of the two belt tensions acting on the
Rv
:
35835
pulley and of the force due to the mass of the
revolving parts of the pulley
={ (T1 * cos() + T2 * Cos () )2 +(T1 * sin() + T2 * sin () + W p )2 }1/2
Weight of Pulley
-1
e - 1
N
N
N
N
Wp
:
:
:
14
30
5000 N
Tmax
-9617.87 N
Belt Width
300
400
450
500
600
650
750
800
900
1000
1050
1200
1350
1400
1500
1600
1800
2000
Unsized
100
100
125
150
200
230
300
330
380
430
460
530
660
680
750
800
900
1020
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Lump Size
Lump Size
Factor
Air Bone
Factor
<10 mm
<25mm
<20 percent
of maximum
permissible
lump size
Quantity of
Sized,
largest Lump
<60% in is <60 percent
permissible of maximum
Range
permissible
lump size
1
2
Largest lump
does not
exceed
maximum
permissible
lump size
Largest lump
does not
Sized, in
exceed
permissible
maximum
Range
permissible
lump size
Unsized
0
5
0
6
Type of
Abrasivenes
Material
s Factor
Cereal
Grains
Wood
Chips
Wood Pulp
Fullers Earth
Non Abrasiv Flue Dust
1
Soda Lime
Char
Loam
Sand
Ground
Gravel
Run of bank
sand and
gravel
Mildly
Slate
2
Abrasive
Coal
Salt
Sand stone
Slag
Spar
Abrasive
3
Limestone
Concentrates
Pellet
Iron Ores
Tacontie
Jaspar
Heavey
Mineral
Flint Rock
Very
4
Abrasive
Glass cullet
Granite
Traprock
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Very
Abrasive
31
32
33
Pyrites
Sinter
Coke
IS 8730 : 1997
Table 1: Class based on Flowability, Angle of Sucharge and angle of repose
22
4
25
Over 35 and up to 40
Class
Surchage
Angle
Angle of
Repose
(degree)
Flowability
Over 0 and
up to 20
Very free
flowing
10
Over 20 and
up to 30
Free
Flowing
20
Over 30 and
up to 35
Average
Flowing
25
Over 35 and
up to 40
Average
Flowing
30
Over 40
Sluggish
Material Characteristic
Very Free Flowing
-uniform size
-Very small round particle
-very wet
-or very dry
-like silica sand
-cement
-wet concrete, etc.
Free Flowing
-rounded
-dry polished
-medium wight
-like whole grain
-beans
Average Flowing
-irregular
-granular or lumpy
-medium weight
-anthracite coal
-cotton-seed meal
-clay, etc.
Average Flowing
-bituminous coal
-stone
-most ores, etc
Sluggish
-irregular
-stringy
-fibrous
-interlocking
-like, wood chips
-bagasse
-tempered foundry sand, etc.
Speed
Factor
1
2
3
4
5
6
7
8
Belt Width in mm
up to 500 600 to 650 750 to 800 950 to 1050 1200 to 2000
2.5
3
3.5
4
4.5
2.3
2.75
3.2
3.65
4.12
2
2.38
2.75
3.15
3.55
2
2.38
2.75
3.15
3.55
1.65
2
2.35
2.65
3
1.65
2
2.35
2.65
3
1.45
1.75
2.05
2.35
2.62
1.45
1.75
2.05
2.35
2.62
Lump Size
300
11
1
300
7
Lump Type
Uniform Size
Unsized
Belt Width
Speed Factor:
Velocity
Belt Type
Fabric Carcass Belt
Steel Cord Belt
1200
6
3
280
1050
300
750
0.93
1200
1.0
800
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Table 7: Maximum Section of the Handled Maaterial in M2 for Triple Roller Troughed Belt
1200
25
20
0.129
Trough Angle in Degree
Belt Width
(in mm)
Surcharge
Angle
500
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
20
0.009
0.014
0.018
0.023
0.018
0.026
0.034
0.042
0.027
0.04
0.053
0.067
0.047
0.067
0.087
0.109
0.07
0.098
0.129
0.16
0.098
0.138
0.179
0.221
0.13
25
0.012
0.016
0.02
0.025
0.022
0.029
0.037
0.045
0.034
0.046
0.059
0.072
0.058
0.077
0.096
0.117
0.085
0.113
0.142
0.172
0.12
0.158
0.197
0.238
0.159
30
0.013
0.18
0.022
0.026
0.026
0.033
0.04
0.048
0.04
0.051
0.063
0.076
0.067
0.085
0.104
0.134
0.099
0.126
0.153
0.182
0.139
0.175
0.213
0.253
0.185
35
0.015
0.019
0.023
0.027
0.029
0.036
0.043
0.05
0.045
0.056
0.067
0.079
0.076
0.093
0.111
0.129
0.112
0.137
0.163
0.19
0.157
0.191
0.22
0.264
0.208
40
0.017
0.021
0.024
0.028
0.032
0.038
0.045
0.052
0.05
0.06
0.071
0.082
0.083
0.099
0.116
0.134
0.123
0.146
0.171
0.196
0.171
0.204
0.237
0.272
0.228
45
0.018
0.022
0.025
0.029
0.034
0.04
0.046
0.053
0.054
0.063
0.073
0.084
0.089
0.105
0.12
0.136
0.132
0.154
0.176
0.2
0.184
0.214
0.245
0.277
0.244
10
20
0.182
0.236
0.209
0.261
0.233
0.282
0.253
0.3
0.27
0.314
0.283
0.324
30
0.293
0.315
0.334
0.349
0.36
0.366
0.167
0.203
0.237
0.266
0.292
0.313
650
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
10
0.233
0.268
0.298
0.324
0.346
0.363
20
30
0
10
20
30
0.302
0.374
0.207
0.29
0.376
0.465
0.334
0.403
0.253
0.332
0.415
0.501
0.361
0.427
0.294
0.37
0.448
0.53
0.384
0.446
0.331
0.403
0.476
0.554
0.401
0.46
0.362
0.429
0.49
0.571
0.414
0.468
0.388
0.45
0.514
0.581
0
10
20
30
0
10
20
30
0
10
20
30
0
10
0.257
0.357
0.461
0.569
0.303
0.423
0.547
0.677
0.36
0.502
0.648
0.801
0.413
0.578
0.311
0.408
0.508
0.613
0.368
0.484
0.604
0.729
0.439
0.575
0.716
0.863
0.505
0.663
0.363
0.455
0.549
0.649
0.428
0.539
0.653
0.772
0.51
0.64
0.774
0.914
0.585
0.727
0.408
0.494
0.584
0.677
0.482
0.586
0.694
0.806
0.573
0.695
0.822
0.953
0.66
0.803
0.446
0.527
0.61
0.697
0.528
0.625
0.725
0.83
0.628
0.741
0.859
0.982
0.721
0.885
0.478
0.552
0.629
0.71
0.566
0.656
0.748
0.845
0.672
0.777
0.885
0.999
0.774
0.897
20
30
0.749
0.928
0.827
0.998
0.894
1.063
0.95
1.104
0.993
1.137
1.025
1.158
500
650
0.018
0.034
800
1000
1200
1400
1600
0.053
0.087
0.129
0.179
0.236
1800
2000
2200
2400
2600
0.302
0.376
0.461
0.547
0.648
2800
0.749
400
500
650
800
1000
1200
1400
20
Flat Belt
25
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
0.005
0.008
0.01
0.014
0.01
0.014
0.018
0.023
0.017
0.025
0.033
0.042
0.027
0.039
0.052
0.065
0.044
0.064
0.084
0.106
0.066
0.007
0.01
0.012
0.015
0.012
0.017
0.021
0.025
0.023
0.03
0.038
0.045
0.036
0.047
0.059
0.071
0.057
0.076
0.095
0.116
0.085
0.009
0.011
0.013
0.016
0.015
0.019
0.023
0.027
0.027
0.037
0.041
0.048
0.042
0.053
0.064
0.076
0.069
0.86
0.104
0.123
0.102
10
0.095
0.112
0.127
0.03
20
0.125
0.14
0.153
0.062
30
0.156
0.17
0.181
0.095
0.001
0.002
0.004
0.002
0.005
0.008
0.004
0.009
0.014
0.008
0.016
0.025
0.013
0.026
0.04
0.021
0.042
0.065
1600
10
0.042
20
0.086
30
0
10
20
30
0.132
0.56
0.114
0.175
Slope
Factor K
1
0.99
0.98
0.97
0.95
0.93
0.91
0.89
0.85
0.81
0.78
0.76
0.73
0.71
0.68
0.66
0.64
0.61
0.59
0.56
650
800
1000
1200
1400
1600
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
20
35
51
67
84
56
94
123
153
100
145
192
241
172
242
315
392
252
355
464
576
352
497
644
795
468
25
43
58
74
90
80
107
135
165
123
168
212
260
209
277
348
421
307
407
511
619
432
569
709
857
572
10
20
655
849
752
939
30
1054
1134
601
731
1800
839
965
1087
1202
1346
745
1044
1359
1674
1451
911
1195
1494
1803
67
123
192
315
464
644
849
1087
#N/A
74
135
212
348
511
709
939
1202
#N/A
10
2000
500
650
800
1000
1200
1400
1600
1800
2000
20
30
0
10
20
30
0
0
0
0
1
1
1
1
#N/A
35
56
70
85
100
106
130
156
182
163
203
244
287
274
336
339
464
403
493
587
684
565
687
792
950
749
40
62
75
89
103
116
139
163
188
180
217
255
296
301
359
417
482
443
525
615
705
615
734
853
979
820
45
67
79
92
105
125
146
169
192
194
229
265
302
323
378
432
489
475
554
633
720
662
770
882
997
878
839
1015
911
1080
972
1130
1019
1166
1202
1256
1296
1317
853
957
1051
1127
Belt Width
(mm)
Surchage
Angle
300
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
10
20
30
0
21
30
40
50
36
53
67
84
64
96
121
151
99
143
188
236
161
232
304
381
238
10
342
20
450
30
561
400
500
650
800
1000
1200
1400
1073
1166
1245
1307
10
1299
1382
1443
1490
20
1537
1058
1332
1613
1908
1605
1191
1451
1713
1994
1656
1303
1544
1793
2055
1685
1397
1620
1850
2091
80
146
229
374
551
767
1015
1299
#N/A
85
156
244
339
587
792
1080
1382
#N/A
89
163
255
417
615
853
1130
1443
#N/A
92
169
265
432
633
882
1166
1490
#N/A
1600
30
0
10
20
30
Flat Belt
5
10.5
15.8
27
36
45
55
46
61
76
92
83
109
137
165
129
171
214
258
208
275
344
417
306
33
41
49
58
55
69
83
98
98
123
148
175
154
193
233
274
248
310
374
443
367
403
457
111
504
551
225
612
651
345
10
20.5
31
17
34
52
30
60
93
47
95
146
75
154
235
153
311
475
201
410
630
TE
17822 N
PDP
50.606 kW
Absorbed Power
TE . V
PA =
1000
PA
53.866 kW
Rwd
610.47 N
Rbd
537.5 N
PM
56.701 kW
( Rwd + Rbd )V
1000
0.95
Pa
79.169 kW
nt
:
:
5
0.1
( Rwd + Rbd )V
1000
Number of trippers
Factor for extra power for each tripper
Transition Distance
x = 0.707y
E
T
1200 mm
Tmin
N
Selected Idler Spacing is Safe
1/2
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
500 N/mm
N/mm See IS:11592, Table 18
Factor of Safety:
Selectecd Belt
Belt Thickness
:
:
10
-96178.6626 N
:
:
Belt Type
m
:
:
:
:
:
:
:
:
:
:
N17
2.5
1.0
1.5
2.5
:
:
:
:
:
:
:
:
:
:
mm
mm
mm
mm
mm
mm
mm
See IS-1891
(Part-1) Annex A
See IS-1891(Part-1)
Table 8 and IS
3181 for PVC Belt
Factor of Safety:
Textile Belt
Steel Cord Belt
Belt Type
Textile Rubber Belt
PVC Belt
Steel Cord Belt
M24
N17
N17 Synthetic
B G
b
c
m
f
r
j
D
TYPICAL CONVEYOR CROSS-SECTION
a = angle of surcharge , degrees
= angle which the surface of the material
assumes with the horizontal while the
material is at rest on a moving conveyor belt
= 25 O for bituminous coal or lignite
b = angle of the idler roll , degrees
b = width of belt , inches
Standard edge distance , c =0.055b + 0.9 , inches
b = l + 2m + 2c
m = 0.2595 x b -1.025
l = 0.371 x b + 0.25
Cross-sectional area of material on conveyor , sq. in
A = [ 0.371b + 0.25 + (0.2595b - 1.025) cos b ] x
[ ( 0.2595 b -1.025 ) sin b ]
+ ( a/180 - sin 2a / 2 ) X [ { 0.1855 b + 0.125 + (0.2595 b - 1.025 ) cos b}/ sin a ] 2
BELT WIDTH
mm
800
450
500
600
750
900
1000
1050
1200
1350
1500
1800
2100
2400
in
32
18
20
24
30
36
40
42
48
54
60
72
84
96
a
deg.
25
25
25
25
25
25
25
25
25
25
25
25
25
25
b
deg.
20
20
20
20
20
20
20
20
20
20
20
20
20
20
A
sq. ft
0.6728
0.1881
0.2391
0.3593
0.5853
0.8661
1.0838
1.2017
1.5921
2.0373
2.5373
3.7017
5.0852
6.688
Belt
Bulk. Dnst.
Kg/m
800
800
800
800
800
800
800
800
800
800
800
800
800
800
Capacity
Te/Hr.
151.2151
100.6383
76.7525
192.2602
313.2048
463.4721
530.6457
643.0621
532.4842
1090.21
1357.768
1980.852
2721.226
3578.892
in
12.12
6.93
7.67
9.15
11.38
13.61
15.09
15.83
18.06
20.28
22.51
26.96
31.41
35.87
mm
307.90
175.97
194.82
232.51
289.05
345.59
383.29
402.13
458.67
515.21
571.75
684.83
797.92
911.00
Detail Proof
As = area of surcharge , sq. in ( area ABC )
Ab = base trapezoidal area , sq. in (area AFGC)
l = length , smaller edge of trapezoidal area , inch
l1 = length , larger edge of trapezoidal area , inch
j = height of trapezoidal area , inch
m = slant length of trapezoidal area , inch
r = radius of surcharge angle, inch
f = horizontal projection of slant side of trapezoid , inch
c = edge distance , edge of material to edge of belt ,inch
b = width of belt , inch
Standard edge distance c = 0.055 b + 0.9 inch
Ab = 0.5 (l + l1) x j
b=l+2xm+2Xc
l1 = l + 2 x f
f = m x cos b
l = 0.371 x b +0.25
c = 0.055 x b + 0.9
Solving , m = 0.2595 x b -1.025
j = m x sin b
Area of whole sector (ABCD) = x r2 x 2 x a /360
Area of triangle (AECD) = r2 x 0.5 x sin ( 2 a)
Surcharge area , As = r2 x { x a / 180 - 0.5 x sin ( 2 a) }
r = 0.5 x l1 / sin a
Total area in sq. ft. , At = ( Ab + As ) / 144