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AbstractThe model for energy calculation of the belt con- and FDA are inaccurately determined, which inevitably results
veyor is much needed for the optimisation of its operating in energy calculation errors [7], [8].
efficiency. There are two categories of models in the literature, The main purpose of this paper is to propose a practicable
one relying on resistance force calculation, and the other one on
energy conversion through a compensation length. In the paper, new energy calculation model for belt conveyor. We begin with
we propose a new model. Our proposed model is evolved by the the analysis of the existing energy calculation models which
interlinkage of the two categories. This modified model is char- are divided into two categories. The first category is based on
acterized by two compensation length variables. It is evidenced resistance calculation methodology, and the other one is based
by comparative studies in terms of the better accuracy and on energy conversion methodology. Then a modified energy
applicability. Further, the elaborative procedure for calibrating
this model by field experiment is also proposed. calculation model is proposed by interlinking the previously
mentioned categories. This model is characterized by two
I. I NTRODUCTION compensation length variables. A belt conveyor, conveying
Belt conveyor is believed to be the most effective among coal in a harbour, is used for a comparative study of all of the
all means for handling the bulk material over short to medium above mentioned energy calculation models. The influences
conveying distances. Energy cost forms a large part of the on these models from conveying distance, transfer rate and
operating cost of belt conveyor system which is estimated up belt speed are illustrated. For the sake of minimizing the
to 40%. The improvements of the efficiency of equipment or errors between the newly proposed model and the actual
that of the operating mode lower the energy cost definitely. energy consumption, a practicable method and its procedure
The majority of the literatures on energy savings on the belt for calibration this model are also proposed.
conveyors focus on the improvement of the equipments effi- The layout of the paper is as follows: In Section II, two
ciency [1],[2],[3],[9],[10]. That was done either by introducing categories of existing energy models for belt conveyor are
highly efficient equipment or improving the efficiency of the reviewed. In Section III, a new energy model is proposed.
existing equipment. The energy saving on belt conveyor can Section IV presents the comparative study results. Section V
also be achieved by optimizing the operating parameters, for proposes the applications and the calibration method of the
example, the transfer rate and belt speed [11]. new model. The last section is conclusion.
In the current scenarios, the existing belt conveyors are
focusing on feasibility and reliability and their operating points II. T WO C ATEGORIES OF E NERGY C ALCULATION M ODEL
always deviate from the optimal ones. In order to save energy The aforementioned energy calculation models are divided
of the belt conveyor by optimizing the operating parameters into two categories. ISO 5048, DIN 22101 and CEMA belong
the practicable energy calculation models are needed. There to the first category which is based on resistance calculation
are several energy calculation models to design the drive sys- methodology. While JIS B 8805, FDA and Goodyears model
tem for belt conveyors. These models derive from well-known [8] belong to another category which is based on energy
standards or specifications, such as ISO 5048, DIN 22101, conversion methodology. There are still some other meth-
JIS B 8805, CEMA (Conveyor Equipment Manufacturers ods to calculate the energy consumption of belt conveyors.
Association) and FDA (Fenner Dunlop Australia) [4],[5],[7]. For instance, reference [14] summarizes a single resistance
They incorporate design parameters and operation parameters method. Since they also use resistances to calculate the power
together to calculate the power which is needed to drive of belt conveyor, they are similar to ISO 5048, DIN 22101 and
the belt conveyor under certain operating conditions. Since CEMA. Therefore, detailed comparison with them will not be
operating parameters are involved, these models can also be carried out.
used to estimate the operating power of existing belt conveyor.
Among these models, ISO 5048, DIN 22101 and CEMA A. Energy Model Based on Resistance Calculation
require many parameters, which make their applications in- A typical belt conveyor is shown in Fig.1. Under stationary
convenient. However, JIS B 8805 and FDA require relatively operating conditions, the energy consumption of belt conveyor
less parameters by lumping other parameters together and is mainly determined by the motion resistance in the loaded
compensating it with a length parameter, hence they are easy section of the belt and the return belt. The accessories, such
to use. But the compensation length constants in JIS B 8805 as belt cleaners, plows and skirt boards outside the feeder
Carrying Idler
Drive pulley
or
L FU = CFH + Ff r + Fsb + Fc + Fp +Fst . (3)
TABLE I
T HE PARAMETERS OF THE BELT CONVEYOR FOR COMPARATIVE STUDY
Parameter description Symbol Value Unit Parameter description Symbol Value Unit
Transfer rate T 2000 t/h Centre-to-centre distance of the belt L 313.25 m
Density of the material 900 kg/m3 The net change in elevation H 9.98 m
Inclination angle 1.825 Width of the belt B 1400 mm
Belt speed V 3.15 m/s Average spacing of the carrying idlers a0 1.2 m
Troughing angle 35 Average spacing of the return idlers au 3 m
Forwards tiling angle of idlers 2 Length of skirt boards outside feeder station lsb 4.5 m
Diameter of carrying idlers 133 mm Diameter of return idlers 133 mm
Length of carrying idlers La0 530 mm Mass of the moving parts of each carrying idler qr0 6.3 kg
Length of return idlers Lau 800 mm Mass of the moving parts of each return idler qru 11.64 kg
Unit mass of the belt QB 18.73 kg/m Unit mass of rotating parts of carrying idlers QR0 15.75 kg/m
Unit mass of the load QG 176.37 kg/m Unit mass of rotating parts of return idlers QRU 7.76 kg/m
Surcharge angle 30 Friction factor between belt and idlers 0 0.3 0.30.4
Length for forwards tiling idlers lr 313.25 m Fiction factor between material and belt 1 0.6 0.50.7
Diameter of the pulley D 0.8 m Fiction factor between material and skirt board 2 0.6 0.50.7
Inclination coefficient k 1.0 Fiction factor between belt and its cleaners 3 0.6
Interval of the skirt boards b1 0.85 m Maximum sectional area A 0.253 m2
Thickness of the belt d 0.01 m Pressure exerted on belt by belt cleaner P 100000 N/m2
Friction factor f 0.024 Coefficient of the troughing shape Ce 0.45
Coefficient of the scraping board Ks 1500 N/m
energy calculation by introducing the empirical compensation calculation formulae of FbA , Ff and Fw from [4] with (11),
length constants L0 s into the models, so they are easy to L02 is expressed as
use. However, since they use just one or few compensation V T 3.6CF t
length constants to satisfy all cases, there must be some energy L02 = (V + + ), (12)
gf 1.8b21 T
calculation errors.
This paper proposes a modified energy calculation model where b1 is the interval of the skirt boards. Then the modified
for belt conveyor by interlinking aforementioned two cate- energy calculation model is expressed as follows.
gories. It follows the basic structure of the models based on T T
the methodology of energy conversion, and characterized by PT = gf (Lh + L01 )QV + gf (Lh + L02 ) + gH + PAcs .
3.6 3.6
two compensation length variables, L01 and L02 . L01 is the (13)
compensation length variable for Pec and L02 is for Pl . When It is obvious that the modified energy calculation model is
the belt is empty (T=0), FN and Fst equal zero. Under this easier to use than ISO 5048 and DIN 22101 because of
condition, the total resistance becomes FU |T =0 = FH + FS the relatively less parameter requirements. Furthermore, this
and (5) becomes PT |T =0 = Pec + PAcs . FU |T =0 and PT |T =0 model is more accurate than JIS B 8805 or FDA because the
are obtained under the same condition, so compensation length variables vary with the parameters the
belt conveyor to fit different cases.
PT |T =0
FU |T =0 = . (9)
V IV. T HE C OMPARATIVE S TUDY
Combining (1), (6) and (9), L01 is obtained by An inclined belt conveyor for conveying coal in a harbour
2QB is used for a comparative study of these energy calculation
L01 = L(1 cos )(1 ). (10) models. Its parameters are shown in Tab.I.
Q
Using the same method, L02 is obtained as follows A. Calculation Results for the Specific Case
Seven energy calculation models are used to calculate the
FN FbA + Ff + Fw + Ft
L02 = = . (11) power of the belt conveyor under the specific condition as
gf QG gf QG shown in Tab.I. The special resistance is calculated using
In (11), Ft is comparatively small and omitted [5]. Fw is also ISO 5048. For simplicity, we make the convention in the
small and does not vary much, so it is taken as a constant rest of the paper that ISO denotes the accurate calculation
CF t . Ordinarily, the friction factor between material and belt method of ISO 5048, ISO C denotes C coefficient method of
equals that between material and skirt boards [4]. In many ISO 5048, DIN denotes accurate calculation method of DIN
cases, the input speed of the material in the belt direction 22101, DIN C denotes C coefficient method of DIN 22101,
equal zero (V0 =0). Under all these conditions, combining the JIS denotes calculation method of JIS B 8805 standard, FDA
TABLE II 110
C ALCULATION RESULTS FOR THE SPECIFIC CASE 100 ISO
ISO_C
90 DIN
Symbol Description Value (KW) DIN_C
80
FDA
ISO Accurate calculation method of ISO 5048 141.58 JIS
70
ISO C C coefficient method of ISO 5048 151.46 TwoL0
P(KW)
60
DIN Accurate calculation method of DIN 22101 141.45
50
DIN C C coefficient method of DIN 22101 139.17
40
JIS JIS B 8805 standard 144.55
30
FDA FDAs calculation handbook 140.11
20
TwoL0 Modified energy calculation model 142.77
10
0 20 40 60 80 100 120 140 160 180 200
L(m)
denotes calculation method in FDAs handbook and TwoL0 Fig. 2. Power curves for L=10-200 with V=3.15 m/s and T=2000 t/h
denotes the modified energy calculation model we propose
in this paper. The calculation results are shown in Tab.II. 1600
The seven energy calculation models draw similar results with 1400
ISO
ISO_C
small differences except ISO C. 1200
DIN
DIN_C
The ultimate purpose of these energy calculation models FDA
1000 JIS
discussed here is operating optimisation or scheduling for belt TwoL0
P(KW)
conveyors. So, it is necessary to analyze and evaluate the 800
0
B. Variable Conveying Distance 0 500 1000 1500 2000
L(m)
2500 3000 3500 4000
ISO_C
errors of the other models are obtained as shown in Fig.4. By 5 DIN
analyzing calculation results of diffident combinations of belt DIN_C
FDA
speeds transfer rates and conveying distances, the following 10
JIS
conclusions are drawn. TwoL0
500 1000 1500 2000 2500 3000 3500 4000
1) The accurate calculation method of ISO 5048 and that of L(m)
330
to other models. With very high belt speed, they yield
320 ISO
ISO_C the largest values comparing to other models.
DIN
310
DIN_C
2) When belt speed is relatively high, DIN C and FDA re-
300 FDA sult in large values. so, they can just be used within low
JIS
290 TwoL0 to medium belt speed where the secondary resistances
P(KW)
ISO_C
2 DIN model results in smaller errors relative to other models except
DIN_C
FDA DIN. Hence, the new model shows quite good accuracy within
4 JIS
TwoL0
the domain of transfer rate.
6
1.5 2 2.5 3 3.5 4 4.5 5 5.5 6
V(m/s)
V. A PPLICATION A ND C ALIBRATION
A. Applications of The Modified Energy Calculation Model
Fig. 6. Relative errors for V=1.5-6 m/s with L=1000m and T=1200 t/h
The modified energy calculation model is formulated into
420 three integrated analytic equations. While the resistance based
400
ISO models consist of many equations for all kinds of resistances.
ISO_C
380 DIN Moreover, the empirical compensation lengths within the mod-
DIN_C
360 FDA els based on energy conversion methodology are determined
340
JIS
TwoL0
mainly by experiences. All these issues make the modified
model more suitable for the operational optimisation of the
P(KW)
320
300
belt conveyors than other models. The ultimate purpose is to
280
use this model for the optimisation of energy efficiency of belt
260
conveyor. The goal is achieved by using this energy calculation
240
model for the belt conveyor design or for the improvement of
220
the efficiency of the existing belt conveyors. During the design
1000 1100 1200 1300 1400 1500
T(t/h)
1600 1700 1800 1900 2000
phase of a belt conveyor, the modified energy model is built
using the design parameters. Then it will be used to verify
Fig. 7. Power curves for T=100-2000 t/h with L=1000 m and V=3.15 m/s the design of the drive system. For existing belt conveyors,
this model will be used to improve their energy efficiency by
4
ISO_C
optimizing the transfer rates and belt speeds, and it will also
DIN be used for load shifting or operation scheduling.
3 DIN_C
FDA
JIS
TwoL0
B. Calibration of The Modified Energy Calculation Model
2
existing belt conveyor, including Ff r , Fsb , Fc and Fp , has the model and the actual energy consumption of the corre-
following relation with T and V sponding belt conveyor.
T2 T For belt conveyors with permanent instruments for PT , T
FS = k1 + k2 + k3 , (14) and V , an adaptive parameter identification scheme can be
V2 V
where k1 , k2 and k3 are constant coefficients which relate to developed to adjust the model automatically to guarantee the
the structure parameters of the belt conveyor. Combining (12) accuracy of this energy calculation model.
(13) and (14), and denoting VI. C ONCLUSION
1 This paper proposes a modified energy calculation model for
1 = ,
6.48b21 belt conveyors. It is expected to be useful in the optimisation
2 = gf (Lh + L01 )Q + k3 + CF t , of operating efficiency, load shifting and operation scheduling
3 = k1 , of belt conveyors. This model is proposed by interlinking two
gH + gf Lh existing categories of the energy calculation models. The first
4 = + k2 , (15) category is complicated because it needs many parameters of
3.6
the total power PT is expressed as follows the belt conveyor. The second one introduces the compensation
length constants into the models to make itself easy to use.
V 2T T2
PT = + T 2 V 1 + V 2 + 3 + T 4 , (16) The modified energy calculation model employs two compen-
3.6 V sation length variables L01 and L02 , which vary with design
where 1 , 2 , 3 and 4 are constant coefficients for a certain parameters and operation parameters to adapt all the cases. Its
belt conveyor, but they cannot keep constant all through for a applicability and validity are proven by the comparative study
long time span. In (15), L01 is related to the structure parame- of all these energy models. This model will be used either
ters of the belt conveyor, which guarantees the invariability of for belt conveyor design or for the improvement of operating
2 . Then, 1 , 2 , 3 and 4 in (16) can be calibrated by field efficiency of existing belt conveyor. A calibration method and
experiment. Some measurement instruments must be installed its procedure are also proposed to guarantee the applicability
to measure PT , V and T during the experiment. For the belt of the newly proposed energy calculation model.
conveyor with fixed speed, the transfer rate is controlled to
operate it at different operating points to get different equations R EFERENCES
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