Industrial Processes

Module no. 2

Methods, processes and

equipment involved in
handling of solids
(Conveyors and Conveying
systems)

Engr. Augusto A. Avanceña

Instructor

Alba, Edgar Luigi T.

BSME-5B
LEARNING OBJECTIVES:
At the end of this module, you should be able to;
1. Know what is Conveyors and Conveying systems.
2. Understand the application of Conveyors and Conveying systems in
industrial plant
3. Understand the manufacturing process of Conveyors.
4. Know the equipment involved in the manufacturing process of
Conveyors.
5. Understand the design concept of Conveyors and Conveying systems.

ACTIVITY:
1. Research Work: Write your discussion about the Methods, processes and
equipment involved in handling of solids (Conveyors and Conveying systems). Follow the
following outline.
a. Introduction
b. Processes involved in handling of solids (Conveyors and Conveying systems).
c. Equipment involved in handling of solids (Conveyors and Conveying systems).
d. Application of Conveyors and Conveying systems
e. Safety protocols
f. References
Conveyors
A conveyor system is a common piece of mechanical handling equipment that moves materials from one
location to another. Conveyors are especially useful in applications involving the transportation of heavy
or bulky materials.

Conveyors are usually fixed into positions with ancillary equipment and add on’s being available
for them so they can connect to an existing or non-conveyor system. You can get portable
conveyors which can be moved around with ease. This way you can put the conveyor into a
different floor plan and move depending on the volume of products.
MAIN ELEMENTS OF A CONVEYOR
Conveyor drive

• Conveyor drives may account for from 10 to 30 percent of the total cost of the conveyor
system, depending on specific job requirements. They may be of either fixed-speed or
adjustable-speed type.
• Fixed-speed drives are used when the initially chosen conveyor speed does not require
change during the course of normal operation. Simple sheave or sprocket changes suffice
should minor speed alterations be needed. However, for major adjustments motor or
speed-reducer changes are required. In any event, the conveyor must be shut down while
the speed change is made.
• Adjustable-speed drives are designed for changing speed either manually or
automatically while the conveyor is in operation, to meet variations in processing
requirements.
Conveyor motor

• Conveyor Motors for conveyor drives are generally of 240- and 480-V ratings.
• The squirrel-cage motor is most commonly used with belt conveyors and with drives up
to 7.457 kW (10 hp)
Auxiliary Equipment

• They are the addition support equipment.

• For example: Elevating conveyors must be equipped with some form of holdback or brake
to prevent reversal of travel and subsequent jamming when power is unexpectedly cut
off
Control of Conveyors

• Control has been enhanced considerably with the introduction of process-control

computers and programmable controllers, which can be used to maintain rated capacities
to close tolerances. This ability is especially useful if feed to the conveyor tends to be
 erratic. Through variable-speed drives, outputs can be adjusted automatically for changes
in processing conditions

Processes involved in handling of solids (Conveyors and Conveying systems).

How do conveyor systems work?
Typically, conveyor systems consist of a belt stretched across two or more
pulleys. The belt forms a closed loop around the pulleys so it can continually
rotate. One pulley, known as the drive pulley, drives or tows the belt, moving
items from one location to another.

The most common conveyor system designs use a rotor to power the drive
pulley and belt. The belt remains attached to the rotor through the friction
between the two surfaces. For the belt to move effectively, both the drive pulley
and idler must run in the same direction, either clockwise or counterclockwise.

While conventional conveyor systems such as moving walkways and grocery

store conveyors are straight, sometimes, the unit needs to turn to deliver the
items to the proper location. For the turns, there are unique cone-shaped wheels
or rotors which allow the belt to follow a bend or twist without getting tangled.

Types of conveyors
Wheel conveyor
Skate wheel conveyors consist of small skate wheels mounted on a series of axles attached to
rigid or flexible frames. The wheels let boxes, totes, and other loads with firm, flat bottoms roll
along the conveyor from one place to another, reducing the effort it takes to move the loads.
These unpowered (gravity-flow) conveyors use a downward slope or a manual push to move
loads down the line.
Compared to roller conveyors, skate wheel conveyors need less force or slope to move loads and
are better at maintaining the orientation of loads as they move around curves. The conveyors'
wheel density impacts the size of the loads that can be conveyed on them. The smallest item on
the conveyors should be supported by at least five wheels on three axles at all times. Gate kits
and transition sections can be used to customize the conveyors.
Skate wheel conveyors can be reconfigured for temporary applications and are often used in
warehousing, manufacturing, package handing, and distribution tasks.

Roller conveyor

• Gravity rollers are considerably heavier than the wheels on wheel conveyors
• Non-powered roller conveyors or Gravity Conveyors are the most economical and
common method of conveying unit loads. The conveyors are typically mounted on a slight
decline angle, therefore using gravity to assist product movement, especially for long
distances. They can also be used in applications where the conveyor is level and operators
can push the product along to its final destination, allowing for multiple workstations, if
needed.
• As with gravity wheel conveyors, roller
units are highly standardized and auxiliary
equipment is available for supporting the
line from ceiling or floor. Many special
rollers are available for retarding
containers if speed becomes too great for
safe handling.
Gravity roller conveyor
• These can be used as pusher units set horizontally or inclined for gravity flow.
• They are highly standardized and are usually sold in 1.5- or 3-m (5- or 10-ft)
sections; special lengths are available at extra charge
• Gravity skate wheel will convey lightweight loads that have firm flat bottoms such
as cartons, totes, cases, etc. Skate wheel conveyor “rolls” more easily than roller
conveyor allowing for lighter packages and
less slope.
• Since wheel units are relatively light, they
have relatively low inertia, and loads may be
started and stopped quite easily
• Metal plates or projecting hardwood slats
are commonly used as stops on conveyor
lines.

Flight Conveyor

• An enclosed, rectangular cross - section, made of steel casing is furnished with an endless
chain equipped with flights.
Flight chain

• Flight conveyors have scrapers, or flights, mounted at intervals perpendicular to the

direction of travel on endless power-driven chains operating within a trough.
• Bulk materials such as sawdust, sand, gravel, coal, and chemicals may be pushed along
the trough.
ADVANTAGESLow installation cost.

• Suitable for transportation at steep places.

DISADVANTAGES

• High power consumption.

Apron Chain Conveyor
Apron conveyors consist of endless chains with
attached overlapping and interlocking plates to provide
a continuous-carrying surface that forms a leakproof
bed suitable for bulk materials without containers.
Their main application is the feeding of material at
controlled rates, with lump sizes that are large enough
to minimize dribble.

Characteristics of apron chain conveyors

Exclusively used for transportation of heavy loads. Apron conveyor speeds are typically 50-75
ft/min. They have high load-carrying capacity. The number of branches can be selected
depending on the nature of the material being moved. Possibility of managing special
requirements of the customers, such as the use of a different chain type, chain with carriers, etc.

Slat conveyor

• Uses discretely spaced slats connected to a

chain.
• The slats are either of wood or flanged metal.
• Unit being transported retains its position (like
a belt conveyor).
• Orientation and placement of the load is
controlled.
• Slat Conveyors are conveyors employing one or
more endless chains to which non-overlapping,
non-interlocking, spaced slats are attached.
• Slat conveyors consist of endless chains, driven by electric motors operating through
reduction gears and sprockets, with attached spaced slats to carry objects that would
damage a belt because of sharp edges or heavy weights.
Bucket conveyor

• Bucket elevators are the simplest and most dependable units for making vertical lifts.
• They are available in a wide range of capacities and may operate entirely in the open or
be totally enclosed.

Working Principle
The product is fed into the moving bucket belt at a controlled rate in a similar manner to feeding
a normal belt conveyor. At the end of the conveyor, the buckets are emptied by gravity into the
discharge section.
Types of Bucket conveyors
Centrifugal discharge

• These elevators are the most common mounted on a belt or a chain, the buckets are
spaced to prevent interference in loading or discharging. This type of elevator will handle
almost any free flowing fine or small-lump material such as grain, coal, or dry chemicals.
• Speeds can be relatively high for fairly dense materials but must be lowered considerably
for aerated or low-bulk-density materials [under 641 kg/m3 (40 lb./ft3)] to prevent
fanning action.
Positive discharge

• Elevators of this type are essentially the same as centrifugal-discharge units except that
the buckets are mounted on two strands of chain and are snubbed back under the head
sprocket to invert them for positive discharge.
• These units are designed especially for materials which are sticky or tend to pack, and the
slight impact of the chain seating on the snub sprocket combined with complete bucket
inversion is generally sufficient to empty the buckets completely.
 • The speed of these units is relatively slow, and buckets must be larger or more closely
spaced to reach capacity levels of the centrifugal style.
Continuous bucket

• These elevators are generally used for larger-lump materials or for materials too difficult
to handle with centrifugal-discharge units.
• Buckets are closely spaced, with the back of the preceding bucket serving as a discharge
chute for the bucket which is dumping as it rounds the head pulley.
• Close bucket spacing reduces the speed at which the elevator must run to maintain
capacities comparable with the spaced-bucket elevator

Vibrating conveyor

• Most vibrating conveyors are essentially directional-throw units which consist of a spring-
supported horizontal pan vibrated by a direct connected eccentric arm, rotating eccentric
weights, an electromagnet, or a pneumatic or hydraulic cylinder. The motion imparted to
the material particles may vary, but its purpose is to throw the material upward and
forward so that it will travel along the conveyor path in a series of short hops.
• Capacity of directional-throw vibrating conveyors-- is determined by the magnitude of
trough displacement, frequency of this displacement, angle of throw, slope of trough, and
ability of the material to receive and transmit through its mass the directional throw of
the trough.
• The material itself is the most important factor. To be conveyed properly it should have a
high friction factor on steel as well as a high internal friction factor so that conveying
action is transmitted through its entire depth. Thus, deep loads tend to move more slowly
than thin ones. Material must also be dense enough to minimize the effect of air
resistance on its trajectory, and it should not aerate.
Screw conveyor

• One of the most widely used conveyors in the processing industry.

• Consists of a tube or U-shaped stationary trough through which a shaft-mounted helix
revolves to push loose material forward in a horizontal or inclined direction
Screw-conveyor abilities
CAPACITY - generally limited to around 4.72 m3 /min (10,000 ft3 /h).
PROCESSING OPERATIONS - Screw conveyors operate using a continuous shaftless helicoid screw
that moves almost any type of solid material through it. They typically operate on an incline and
can transport up to 80 feet. It can convey up to 1,800 cfh (cubic feet per hour).
MATERIAL DESIGN - In addition to a wide variety of designs for components, screw conveyors
may be fabricated in materials ranging from cast iron to stainless steel.
SIZE - Standard sizes range from 2 in. to 8 in. diameter.

• Screw conveyors are capable of handling a great variety of bulk materials from sluggish
to free-flowing. Screw conveyors can have multiple inlet and discharge points. Bulk
materials can be conveyed and distributed to various locations as required. Slide gates or
valves can be added to control the flow into and out of a screw conveyor.
• Screw conveyors are totally enclosed to
contain the product and prevent spillage.
Screw conveyors can be utilized in the
horizontal, vertical or any inclined
position depending upon the
characteristics of the product being
conveyed.
• Screw conveyors can be used to cool,
heat or dry products in transit.
Depending on the heat transfer
requirements, a screw conveyor can be
jacketed, or a hollow-flight design utilized
to provide the necessary heat transfer for
the application Screw conveyors can be
designed to be vapor-tight or hold an
internal pressure. This is very important
when conveying toxic or hazardous products such as those in the chemical industry.
Pneumatic conveyor
Principle

• When High velocity is passed through a bed of solid particles, individual particles are
dragged by the air and suspended in the air... Fluidized bed
• Suspension behave like dense fluid and can be transported
• Solid can be recovered at discharge end.
Construction

• Fans or cycloid blower are

connected to conveying system
• Air passes through porous base
• Feed is connected to air slide
through valve
• The other end is connected to
cyclone separator.

Belt conveyor

• One of the basic tools in material handling

industry
• Belt conveyors are most commonly used in
transportation of bulk materials (grain, salt, coal,
ore, sand, etc.).
• Capacity and ability-- It can travel for miles at
speeds up to 5.08 m/s (1000 ft/min) and handle
up to 4539 metric tons/h (5000 tons/h).

Working principle of Belt Conveyor

Belt conveyor is composed by two pulleys and a closed conveyor belt. The pulley that drives
conveyor belt is called drive pulley; the other one–only used to change conveyor belt movement
direction–is called bend pulley. Drive pulley is driven by the motor. The drive pulleys are generally
installed at the discharge end. Material is fed on the feed-side and landed on the rotating
conveyor belt.
Types of Belt Conveyor

• Flat belt conveyor

A type of belt conveyor in which the carrying run of the conveyor belt is supported by flat
belt or by a flat surface. They are suitable for low speed and low capacity.
• Magnetic belt conveyor
A type of conveyor in which either is a magnetic slider bed or magnetic pulley is used to
transport materials.

• Trough belt conveyor

Troughed belt conveyor is that in which the belt forms a trough on the carrying side while
running over the rollers which are either in set of 5 rolls, 3 rolls or 2 rolls. They are suitable
for bulk quantity materials.
Application of Conveyors and Conveying Systems
Ranging from discrete product transport to bulk-material carriage, conveyor functions are as
varied as the places in which they work. Engineers make conveyors meet specific applications by
tailoring about a dozen conveyor design elements: belt or chain size, morphology and material;
bases and support frames; controller, drive, and motor or motors; mode of belt or chain
engagement with the drive; encoder, vision, and switch feedback; tracks, bumpers, and gates;
and HMIs and plant-level IT integration.
WHY DO PEOPLE USE CONVEYORS?
Manufacturing engineers include conveyor systems in their production facilities for many
reasons:

• Moving products from point A to B (to avoid wasted time walking, or to reduce
movements of forklifts, etc)
• To carry products that are too heavy to for team members to lift
• To move a product while operators are working on it (or adding to it). Like a final assembly
conveyor at an auto plant
• To deliver products to a robot for processing. Or to receive products from a robot that are
ready for the next step
• To store products between processes or at the final process step
• To create a buffer or accumulation bank. This is a flexible storage system. Use it where
the quantity of products in storage can be lower or higher as required to balance process
flow
• To avoid injury to workers from repetitive movement. Or to prevent damage to products
caused by movement
• To sequence or re-sequence products between processes. Conveyor types like power and
free conveyors can provide this

Safety Protocols on Conveyors

Conveyors are very helpful in moving material and supplies within a facility. However, they are a
common cause of injury in a plant. We’ve compiled this list of safety practices that will help keep
you and your coworkers safe.
1. Don't sit, stand, or walk on conveyors
Conveyors are never meant to be occupied by a person.
✓ Conveyors have many features, including pinch points that
can catch clothing or people and cause serious injuries.
✓ A limb stuck in a pinch point can be severely damaged or
even torn off.
 • Industrial conveyors are not designed for people so you should never ride on
conveyors.
2. Make sure conveyor controls are operating correctly
Controls that don’t work properly can cause serious problems.

✓ Inspect your conveyor controls to make sure no employee has

misused, modified, or disconnected them.
✓ Controls should be easy to read and use, as well as easily accessible.
✓ Place emergency stops in highly visible and accessible locations.

3. Keep hair, clothing, jewelry, and other loose items away

Conveyors can catch loose clothes or long hair, resulting in severe injuries.

✓ Make sure long hair is tied back or tucked under a cap.

✓ Don't wear bracelets, rings, watches, or other jewelry.
✓ Avoid wearing baggy clothing; remove ties or tuck them into your shirt.

4. Check that all conveyor guards are in place

Don’t operate a conveyor if guards are not securely mounted.

✓ Conveyors contain gears, chains, belts, and other moving parts that can be
hazardous if exposed.
✓ Employees should not be able to bypass, remove, or alter conveyor guards.
✓ Guard openings should be small enough to keep workers from entering
danger zones.

5. Be watchful of pinch points

Conveyors are filled with pinch points by their very nature.
✓ Conveyors contain gears, chains, belts, and other moving parts that
can be hazardous if exposed.
✓ Employees should not be able to bypass, remove, or alter conveyor
guards.
✓ Guard openings should be small enough to keep workers from
entering danger zones.
6. Alert management of any potential safety or operational concerns
If you see something, say something.
✓ The best way to correct an unsafe situation (e.g. loose guards, a person
riding the conveyor) is to alert the person responsible for the area.
✓ Make sure it is clear who the point of contact is and how to reach that
person.
✓ Training about safety issues and when to report them should be made
available to all employees.

7. Follow lock-out/tag-out procedures

Failure to do so exposes employees to life-threatening injuries.
✓ Secure conveyor systems before maintenance or repair by following
proper lock-out/tag-out procedures.
✓ Lock-out/tag-out procedures prevent equipment from being powered up
while maintenance or repairs are being done.
✓ Conveyor operators must be properly trained to perform lock-out/tag-out
procedures.

8. Allow only authorized personnel to operate or maintain the conveyor

This ensures technician safety and optimal conveyor performance.
✓ Material handling equipment can be dangerous to those who do not
understand how to safely work on it.
✓ When something needs to be fixed, contact your trained maintenance
person.
✓ Only those employees who are trained to operate and perform
maintenance on conveyors should do so.
References
Introduction to Conveyors and Conveying systems
Murtaza, A. (2017). Conveyors and types. Retrieved from
https://www.slideshare.net/alym96/conveyors-and-types
Baig, M.S. (2017). Conveyor. Retrieved from
https://www.slideshare.net/SalmanBaig6/conveyor-82353196
Processes and Equipment involved in handling of solids (Conveyors and Conveying systems)
Murtaza, A. (2017). Conveyors and types. Retrieved from
https://www.slideshare.net/alym96/conveyors-and-types
Carolina Monroy, 6 River Systems, Inc. (2020). How do conveyors work.
Retrieved from: https://6river.com/what-is-a-conveyor-system/
Wheel Conveyor
https://www.grainger.com/category/material-handling/transporting/conveyors-
components/skate-wheel-conveyors-components/skate-wheel-conveyors
Application of Conveyors and Conveying systems
Conveyor types and uses. Retrieved from https://www.ultimationinc.com/conveyor-
technologies/conveyor-
types/?__cf_chl_captcha_tk__=794a8faebffe8444f913c179e8994563249379df-1601196090-0-
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Safety Protocols on Conveyors
Harrington, B. (2018). 8 Conveyor Safety Tips. Retrieved from https://www.cc-efi.com/blog/8-
conveyor-safety-tips/