BELT CONVEYOR

Presented ByALOK VARDHAN

ADMISSION NO- 2013MT0078

MINING MACHINERY ENGINEERING ISM DHANBAD

Content
Introduction Types of Belt Conveyor Typical Example of Belt Conveyor in a Mine Components of Belt Conveyor Different arrangement of Belt Conveyor Calculations in Belt Conveyor Advantages of Belt Conveyor Limitations of Belt Conveyor Conclusion References

Introduction
The belt conveyor is basically an endless belt moving over two end pulleys at fixed positions and used for transporting material horizontally or at an incline up or down.

Types of Belt Conveyors

Permanent: This type of conveyors is installed for the life of the mine. They are used
in main line, slope, long overland installation, preparation plants and stockpiles.

Portable: These are characterised by relative ease of assembling and disassembling to facilitate advances and recovery in development and retreat operations in underground
mining.

Shiftable: Used in continuous surface mining this type of conveyor is mounted on skid
or supporting structures aligned together and the whole can be shifted transversely to follow the advancing working face.

High Angle Conveyor: These are special type of conveyor belt arrangement used for
negotiating steeper angle of inclination. Such belts can work in slope up to 70-800. Sandwich belt conveyor is a type of such belt conveyor.

Cable Belt Conveyor: Where the belt is carried on moving wire ropes and the tractive
force is applied through the rope to the belt is known as cable belt conveyor..

Pipe Belt Conveyor: The belt is made to form a pipe while running the main length of
the conveyor. At the receiving and discharge end the belt is like troughed belt conveyor. They are suitable for having spillage free transportation and free from risk of polluting the environment.

Cont
Mobile Transfer Conveyor: Mobile Transfer Conveyors are installed between Bucket
Wheel/Chain Excavators and the shiftable bench conveyor allowing multi block and multi bench operations to increase the block width and the block height. Thus, increasing the time between two shifting operations of the bench conveyor results in a higher utilization of the mining system.

Grasshopper style Mobile Transfer Conveyors: Installed as a chain like one

connected to the other are part of waste dumping. This can eliminate dump trucks from mines. Mobile transfer conveyor

TYPICAL EXAMPLE OF BELT CONVEYOR IN A MINE

Mining industry deploys conveyor belt for transport of materials in many ways

Apron Feeder Scalping grizzly feeder

(Fines ) Gyratory crusher Vibrating screen

(Primary Crusher Discharge)

To Tert. conv

Middlings

Line diagram of belt conveyor

DISCHARGE HOOD

TRIPPER

SKIRT BOARD END PULLEY SCRAPER DRIVE PULLEY

IMPACT IDLERS BEND PULLEY SNUB PULLEY CARRYING IDLERS RETURN IDLERS BELT CLEANER

GRAVITY TAKE-UP

Components of belt conveyor

Belt

Idlers
Pulley Tensioning device

Drive
Loading point Discharging point

BELT
End Cover

Top Cover (Carrying Side)

End Cover

Carcass Bottom Cover (Non-Carrying Side)

Construction of conveyor belt.

Essential Belt Properties

The belt works as a tractive element as well as load-carrying element. It may be used for different kind of material transportation at a higher speed ( 6-8 m/s). For this purpose the belt need to have the following essential properties:

Flexibility Transverse rigidity Low mass per unit length High strength Simplicity and inexpensive Longer life Should not stretch under normal working stresses ,i.e., low relative elongation. Wear resistant Fire resistant

Recommended maximum belt speeds

Speed (m/sec) Coal, damp clay, soft ore, fine crushed stone, Over burden and earth Heavy, hard, sharp edged ore. Coarse crushed stone 2.032 3.048 4.064 5.08 1.778 2.54 3.048 Speed (fpm) 400 600 800 1000 350 500 600 Width (mm) 457.2 609.6-914.4 1066.8-1524 1828.8-2413 457.2 609.6-914.4 over 914.4 Width (inches) 18 24-36 42-60 72-95 18 24-36 over 36

Top C over

Bottom Cover

Rubber Interply

Cross section of a multi ply conveyor belt.

Belt Joining Processes

Vulcanising process Belt joining Mechanical joining Plate fasteners Hook type fasteners

Hot vulcanising Cold vulcanising

Belt Fastener

Idlers
Seamless pipe of cast-steel moving on its own axle and ball bearings filled with grease is attached. 1. Carrying idler 2. Return idler 3. Self aligned idler 4. Impact idler 5. Wing idler

Advantages of troughed shape of Belt Conveyor

Deal with large outputs(10-15% more than flat belt). Reduce spillage. Lower power consumption. Assure higher life. Silent in running.

pulley
Drive pulley

Bend pulley
Snub pulley Tandem pulley Crowned shape pulley
TANDEM PULLEY DRIVE

Lagged pulley
Return pulley Discharge pulley
SNUB PULLEY DRIVE

CROWNED SHAPE PULLEY

LAGGED PULLEY DRIVE

Tensioning Arrangement
The purposes of take-up are:

To allow for stretch and shrinkage of the belt. To ensure that the minimum tension in the belt is sufficient to prevent undue sag between idlers. To ensure that the tension in the belt in the rear of the drive pulley is sufficient to permit such pulley to transmit the load.

Types 1. Screw Take-up system 2. Loop Take-up system 3. Gravity Take-up system

Screw take-up

Gravity Take up

Various Gravity Take up Arrangement

Drives
motor

Fluid coupling

Gearbox

Mechanical coupling

pulley

Squirrel cage induction motor is used (for lighter conveyor). Slip-ring induction motor is used(for longer and heavier conveyor). worm and worm gear box is used.

DIFFERENT ARRANGEMENT OF CONVEYOR

Level Conveyor receiving material at tail end and discharging at head end

Level Conveyor receiving material at any point through travelling Hopper and discharging at head end.

Level and inclined Conveyor receiving material at and near tail end, having vertical curve to incline, and discharging at head end.

Level and inclined Conveyor with chute. Material received from bins too close to elevated head end to permit use of vertical curve.

Belt conveyor calculation

Capacity calculation

T=3600abv
T=capacity of the belt(tph) a= cross sectional area of material on the belt(m2) b=bulk density of the material(tonne/m3) v=belt speed(m/s) 2/10 to W2/12 a=W Empirical equation: W=width of the belt(m)

 Power calculation
Pe=power required to run the belt in empty condition Pm= power required to convey the material at loading condition Pr=power required to raised the material PT=Total system power

PT=Pe+PmPr

MOTOR POWER

 Belt Strength

Advantages
A wider range of material can be handled which pause problems in other transportation means. Belt conveyor can be used for abrasive, wet, dry, sticky or dirty material. The lump size of the transported material is limited by the width of the belt. Belts up to 3000 mm wide are used in mining industry. Higher capacity can be handled than any other form of conveyor at a considerably lower cost per tonne kilometer. Conveyor belts with capacity of 11000t/h and even higher can be deployed to match with higher capacity mining machinery. Longer distances can be covered more economically than any other transportation system. A single belt conveyor or a series of belt conveyors can do this. Belt conveyors can be adopted for cross-country laying.

Cont
It carries materials continuously and silently.

It can operate up or down on all but the steepest gradient.

Highly reliable. Specific power consumption is very less. It is much safer. By the use of many forms of ancillary equipment such as

mobile trippers or spreaders bulk material can be distributed and deposited wherever required. It can be horizontal, incline or decline or combination of all. Minimum labor is required for the operation and maintenance of belt conveyor system.

Limitations
The loading and transfer points need to be properly designed. Numbers of protective devices have to be incorporated to save the belt from getting

damaged by operational problems.

The belt needs higher initial tension (40-200% of useful pull). The use of belt is restricted by the lump size. If the maximum diagonal of a irregular

lump is X then the belt width (B) is approximately given by: B>=Xa+200 Where, B: Belt width, mm X: Longest diagonal of irregular lump, mm a: Factor to account for grading. a is taken as 2.5 for graded material and 3 for ungraded material. However, for particular material these values must be properly estimated.
Conveying of sticky material is associated with problems of cleaning and discharge

causing poor productivity.

Higher elongation of the belt (4% elongation may take place at the working load).

Conclusion
Conveyor belts are widely used in mineral industry.

Underground mine transport, opencast mine transport and processing plants deploy conveyor belts of different kinds to adopt the specific job requirements. The capacity of belt conveyor is near about 1100 tph and it is also used for abrasive, wet, dry, sticky or dirty material. Longer distances can be covered more economically than any other transportation system. So Belt Conveyor system is more useful in mining industry.

References
"Conveyor". Webb Conveyor. Retrieved 27 October 2011. Alspaugh, Mark, Bulk Material Handling By Conveyor Belt 7, p 83 id = ISBN 087335-260-2 "Stoppage of limestone supply to Lafarge Surma Indian SC issues showcause notice on central, Meghala". Mines and Communities. 2007-06-20. Retrieved 2013-03-27. Rines, George Edwin, ed. (1920). "year=1920". Encyclopedia Americana.

Hounshell, David A. (1984), From the American System to Mass Production, 18001932: The Development of Manufacturing Technology in the United States, Baltimore, Maryland: Johns Hopkins University Press, ISBN 978-0-8018-29758, LCCN 83016269
"Mobius band". Daviddarling.info. 2007-02-01. Retrieved 2013-03-27.