SELLER/CONTRACTOR DECAL FORM

Organic Growth Project 1 (OGP1)

Execution Phase

SELLER/CONTRACTOR NAME: ThyssenKrupp Frdertechnik GmbH

DOCUMENT TITLE: Belt calculation 1220-CV-239

SELLER/CONTRACTOR REVISION NO: 02

BECHTEL DOC NO: 25713-220-V1A-MHCB-0088
 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239
Drawing number 4492452
Prepared by Walther
Date of calculation Friday, September 28, 2012 ____________________
(Signature)

Pulleys, belt forces and tensions for conveyors acc. to scheme 202

Pulley 1 Pulley 3
T1 To3 To2 To1 T4

Pulley 4
T2
Tu0 T3

Pulley 2 F2 Pulley 5
Tu1 Tu2

Take-up device with movable counterweight

Belt loop upper strand

Dimensions in [m] B = 2200 mm v = 4,7 m/sec Q = 12550 t/h
Belt load 100 50 0%

0,0
Section 1
269,4

Remarks: Mass of inertia increased to enable coasting time of approx. 28sec.

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Input data

Basic data

Material Copper ore

Density 2100 kg/m
Abrasion heavy
Surcharge angle 15
Particle size 380 mm

Conveying capacity 12550 t/h

Volumetric capacity 5976 m/h
Theor.conveying cap. @ 100% belt load 23016 t/h

Belt speed 4,7 m/s

Feeding speed in horiz.dir. 0,0 m/s

Belt width 2200 mm

Troughing type upper strand 3-roll
Idler length upper strand 800 mm
Troughing angle upp.strand 40
Troughing type lower strand 2-roll
Roller length low.strand 1250 mm
Troughing angle low.strand 10

Friction values

Reasons for deviating from standard

Range
idler/belt 0,30 Bechtel comment
scraper/belt 0,70
sealing/belt 0,70
material/belt 0,50
material/chute 0,60
Pressure force chute-sealing 0,30 N/mm
Pressure force scraper upp.strand 0,80 N/mm
Pressure force scraper low.strand 0,80 N/mm

Operation conditions favorable

min. operation temperature - 10

Proposed resistance coefficient f 0,023

Selected resistance coefficient f 0,02

Conveyor scheme

Selected scheme 202

Tension device Const.take-up at head area
Belt tripper without tripper car
Sections in upper strand 4
Sections in lower strand 3

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Upper strand

Section Length Lift Loadfactor Additional Chute Chute Number of

resistance length width scrapers
m m % kN m m

1 19,4 0,0 0 0,0 0,00 0,00 0

2 5,0 0,0 100 0,0 5,00 1,39 0
3 59,6 0,0 100 0,0 0,00 0,00 0
4 185,4 0,0 100 0,0 0,00 0,00 0

Lower strand

Section Length LiftAdditional Number of

resistance scrapers
m m kN

1 158,2 0,0 0,0 3

2 2,6 0,0 0,0 0
3 108,6 0,0 0,0 1
Length and height of sections = projected length, chute length = effective length

Summary of conveyor details

Total length 269,4 m

thereof loaded 250,0 m
Total lift 0,0 m
thereof loaded 0,0 m
Total lift inclined 0,0 m
thereof loaded 0,0 m
Total lift declined 0,0 m
thereof loaded 0,0 m

max. rel. height 0,0 m

min rel. height 0,0 m
Sum of special resistance 0,0 kN
Number of chutes 1
Total length of chutes 5,0 m

Calculated minimum chute length in section

Belt section 2 2,3 m

Height of material against chute walls

loading area
Belt section 2 0,313 m

at material guiding
Belt section 2 0,059 m

Number of scrapers 4

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Belt

Typ of belt ST 1800

Rated belt strength (splice) 1800 N/mm
Manufacturer ContiTech
Belt weight 45,4 kg/m
Belt weight 99,9 kg/m
Thickn. cover plates carrying side 22 mm
Thickn. cover plates running side 8 mm
Requ. safety factor during start-up 5,8
Requ. safety factor during steady operation 6,7

Idlers/Garlands Upper strand

Permissible belt sag for all conveyor sections 1,0 %

Section Idler Type of Idler Mass of Tilting calc. tilting

spacing idlers diameter rot.idlers angle angle
m mm kg

1 1,0 G 178,0 75,00 -0,74

2 0,4 IG 178,0 75,00 -0,74
3 1,5 ID 178,0 75,00 -0,7 -0,74
4 1,5 ID 178,0 75,00 -0,7 -0,74

ID = Idler, II = ImpactIdler, G = Garland, IG = Impact Garland

Idlers/Garlands Lower strand

Section Idler Type of Idler Mass of Tilting calc. tilting

spacing idlers diameter rot.idlers angle angle
m mm kg

1 6,0 SI 180,0 41,20 0,0

2 6,0 SI 180,0 41,20 0,0
3 6,0 G 180,0 41,20 -0,20

ID = Idler, SI = Supportring-Idler, G = Garland, SG = Supportring-Garland

Conveyor drive

Drive design Squirrel cage motor with frequency control

Motor speed 1000 min-1
requ. gear box ratio 11,7
max. starting torque 1,0 x P ref
max. starting time 90,0 s
max. braking torque(empty) 0,1 x P ref
max. braking torque (loaded) 0,1 x P ref
max. braking time (empty) 26,4 s
max. braking time (loaded) 24,2 s

Drive efficiency 0,98

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Pulleys

Drive pulley lagging Rubber coated

Conveying conditions wet, proper
drive pulley/belt in oper. 0,25
drive pulley/belt starting up 0,3

Pulley 1 2 3 4 5
Power [%] due to
Zero speed 0 100 0
Start-up 0 100 0
Steady operation 0 100 0
Stopping 0 100 0

Angle of belt wrap [] 180 180 180 180 180

Pulley diameter [mm] 1040 1050 1040 840 840
Pulley speed [RPM] 86,3 85,5 86,3 106,9 106,9
Linear mass of inertia [kg] 1339 94948 1339 2052 2052

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Results of Calculation

Total resistance upper strand (without pulleys)

Belt section empty loaded

1 0,7 0,7 kN
2 2,4 22,4 kN
3 1,9 11,3 kN
4 5,9 35,2 kN

Total resistance lower strand (without pulleys)

Belt section empty loaded

1 7,0 7,0 kN
2 0,5 0,5 kN
3 4,1 4,1 kN

Total secondary resistance 26,5 kN

Total special resistance 6,0 kN
Total additional special resistance 0,0 kN

Total resistance
empty 23,7 kN
loaded 82,7 kN

Power due to
loaded empty
Main resistance 235,83 64,83 kW
Slope resistance 0,00 kW
Accelerating material 77,01 kW

Friction res. chute (feeding point) 12,83 kW

Friction res. chute (outside feeding point) 0,33 kW
Friction res. chute sealings (feeding point) 9,87 9,87 kW
Friction resistance belt scraper 23,16 23,16 kW

Pulley resistance 11,66 9,98 kW

Camber resistance 18,23 3,40 kW
Add. special resistance 0,00 kW

total at pulley shaft 388,92 111,24 kW

Loss in efficiency 7,94 2,84 kW

Required motor power 397 114 kW

Reference power for starting P ref 400 kW

C - factor 1,53 -

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Starting and stopping

Total mass
empty 170389 kg
loaded 355820 kg

Moment of inertia at motor shaft

empty 337 kgm
loaded 703 kgm

Starting time
empty 90,0 s
loaded 90,0 s
Stopping time
empty 26,4 s
loaded 24,2 s
Coasting time
empty 33,7 s
from total resistance # 26,4 s
from total resistance 20,3 s

Start-up factor at motor

empty 0,39 -
loaded 0,99
Start-up factor at pulley -
empty 0,33 -
loaded 0,93 -
Stopping factor
empty 0,08 -
loaded 0,07 -

Stopping distance
empty 62,0 m
loaded 56,8 m

req. chute volume at emergency stop and 100% belt load

20,1 m

Coasting distance
empty 79,2 m
from total resistance # 62,0 m
from total resistance 47,6 m

Holding force of brakes 0,0 kN

# without acceleration of material and friction of chutes

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Peripheral force

Zero speed Starting Steady op. Stopping

Belt conveyor empty

F 0,0 26,2 22,4 9,4 kN
F1 0,0 -0,6 -0,5 -0,2 kN
F2 0,0 27,3 23,4 9,9 kN
F3 0,0 -0,5 -0,5 -0,2 kN
Belt conveyor loaded

F 0,0 75,5 81,1 11,8 kN

F1 0,0 -0,8 -0,8 -0,2 kN
F2 0,0 76,9 82,4 12,2 kN
F3 0,0 -0,5 -0,5 -0,2 kN

Belt traction force

Zero speed Starting Steady op. Stopping

Belt conveyor empty

To1 150,0 156,2 155,2 152,0 kN
To2 150,0 158,6 157,6 154,1 kN
To3 150,0 161,0 159,5 154,5 kN
T1 150,0 168,2 165,4 155,6 kN
Tu0 150,0 168,8 165,9 155,8 kN
Tu1 150,0 176,7 172,9 159,8 kN
T2 150,0 149,4 149,5 149,9 kN
Tu2 150,0 150,0 150,0 150,0 kN
T3 150,0 154,8 154,1 151,6 kN
T4 150,0 155,3 154,5 151,8 kN

Zero speed Starting Steady op. Stopping

Belt conveyor loaded

To1 150,0 156,2 155,2 151,7 kN
To2 150,0 159,7 177,6 153,9 kN
To3 150,0 173,8 188,9 155,0 kN
T1 150,0 217,5 224,1 158,2 kN
Tu0 150,0 218,4 224,9 158,4 kN
Tu1 150,0 226,3 231,9 162,2 kN
T2 150,0 149,4 149,5 150,0 kN
Tu2 150,0 150,0 150,0 150,0 kN
T3 150,0 154,8 154,1 151,4 kN
T4 150,0 155,3 154,5 151,6 kN

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Required friction coefficient at drive pulley considering full utilization of the angle of wrap

Zero speed Starting Steady op. Stopping

Belt conveyor empty

Pulley 2 0,00 0,05 0,05 0,02

Belt conveyor loaded

Pulley 2 0,00 0,13 0,14 0,02

Pulley load considering the angle of belt wrap

Zero speed Starting Steady op. Stopping

Belt conveyor empty

Pulley 1 300 337 331 311 kN

Pulley 2 300 326 322 310 kN
Pulley 3 300 310 309 303 kN
Pulley 4 300 299 299 300 kN
Pulley 5 300 300 300 300 kN

Belt conveyor loaded

Pulley 1 300 436 449 317 kN

Pulley 2 300 376 381 312 kN
Pulley 3 300 310 309 303 kN
Pulley 4 300 299 299 300 kN
Pulley 5 300 300 300 300 kN

Belt sag

Zero speed Starting Steady op. Stopping

Upper strand loaded

Belt section 1 0,08 0,08 0,08 0,08 %

Belt section 2 0,28 0,26 0,27 0,27 %
Belt section 3 1,03 0,97 0,87 1,01 %
Belt section 4 1,03 0,89 0,82 1,00 %

Lower strand

Belt section 1 0,49 0,49 0,49 0,49 %

Belt section 2 0,49 0,49 0,49 0,49 %
Belt section 3 0,49 0,49 0,49 0,49 %

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 Calculation of Belt Conveyors - FTB001
(Version: 4.2.3.9; Update: 09/2011 )

Project data

Order/Project Escondida OGP1

Order-/Project number N-010-00090
Conveyor 1220-CV-239

Belt tension

Belt conveyor empty 68 80 79 73 N/mm

Belt conveyor loaded 68 103 105 74 N/mm

Safety factors belt

Belt conveyor empty 26,4 22,4 22,9 24,8

Belt conveyor loaded 26,4 17,5 17,1 24,4
requ. safety factor 0,0 5,8 6,7 5,8

Tensile Force

Tensile force : 150,0 kN

Take-up force 300,0 kN
Requ. tensile path acc. to DIN : 0,16 m
Variation of take-up weight location:
0,04 m

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