PDHonline Course M360 (1 PDH)

Chain Conveyors
Practical Calculations
Jurandir Primo, P.E.

2009

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Chain Conveyors - Practical Calculations

1. INTRODUCTION:

Roller Chain Conveyors or Apron Chain Conveyors are used to transfer heavy bulk materials from one point to
another. This manual for practical application indicates the chain conveyor basic calculations for Bulk Materials in the
metric and imperial system.

The main function is informative for both experienced professionals and beginners interested in knowing the
dynamics of this segment of Material Handling.

Arrangement:

Drive chains are ideally installed with the shaft in the horizontal position, as shown below:

Position of Sprockets:

The sprockets should be "key-wayed” and matched in pairs. Since the tail shaft is an idling shaft, key it to only one
sprocket. In this way the sprocket can position itself if uneven wear takes place in the chain strands.

The two shafts should be parallel and the sprockets should be firmly installed. Use a straight edge to check that the
two sprockets are installed along the same horizontal level. This is illustrated in Figure 1 and 2 below:

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Chain Conveyor Speed:

Commonly the Chain Conveyor speed is dictated by how it is loaded and unloaded and what is done to the load
during conveying. The table below shows the basic conveyors and their typical operating speeds.

CONVEYOR
SPEED (fpm)
Continuous Bucket Elevator 75 to150
Centrifugal Bucket Eleva or 200 to 300
Slat or flat top Conveyor 50 to 150
Assembly line Conveyor 5 to 15
Drag and Scraper Conveyors 50 to 100
Apron Conveyors 10 to 60

2. APRON CHAIN CONVEYORS

Apron feeders are used in the mining industry for the transportation of heavy and lumpy materials. They are designed
for the most hard conditions of exploatation to feed the crushers at quarry and storage bins.

These types of conveyors have capacities up to 6000 t/h and are able to transport materials with maximum lump size
up to 2000 mm. The large size of material lumps is the cause for the increase of the width of the aprons and the height
of the skirts. The presence of fixed skirts cause additional resistances due to skirt friction.

The presence of receiving hopper causes additional resistance due to the pressure of the material in it. The hard
conditions of exploatation and the great starting resistances are the cause for the introduction of a coefficient of
reserve of motor power.

The basic formulae for Apron Chain Feeders calculation are given for references, since that each company
manufacturing has it’s own methodology for calculation.

Velocity, Width an Height of Skirts

As the transported material is lumpy, it’s maximum lump size will determine the apron width B [m]:

Considering the following data:

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The formula for the determination of the height of the skirts h, is given h for apron conveyors, as:

(1 m = 3.28 ft)

When width B and height of the skirts h are determined, the apron speed v is determined by the known formula for
the capacity:

(1 m/s = 3.28 ft/s)

where:

Qh = capacity in t/h
ρ = density of the transported material in t/m³ (t/ft³)
ψ = 0,75 – extraction efficiency factor
c = 100 – β - inclination factor (β – angle of inclination).
100

The coefficient “c”, as indicated above, must be taken into account, when feeding are inclined (usually β = 15° - 25°).
The reason for the inclination is the facilitation of truck discharge and the protection of the equipment when the
material will fall directly on it.

Speed is limited to 0.25 m/s (0.82 ft/s), and in some cases to 0,4 m/s (1.3 ft/s). The reasons for the limitation are the
great dynamic loads in the track chains and the high abrasion wear of the aprons.

If the calculated speed is greater than limited, the skirt height “h” must be increased. The contemporary drives allow
variation of the speed in the work diapason v = 0.03 – 0.16 m/s (0.1 – 0.5 ft/s) for different capacities, realized with
the use of variable speed DC, AC and hydraulic motors.

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Apron Chain and Rollers:

Apron feeders use heavy duty crawler tractor chains (Caterpillar tractor type), commonly sized to suit the
application. The chain links are forged for increased load capacity. Pins and bushes are hardened on the wearing
surface.

The carrying rollers are spaced to eliminate the sag, mounted on support frames to permit easy removal for
maintenance and replacement. The apron plates are bolted on flat top of the chain links, as shown below:

Special design and exclusive metal to metal allows continuous pan contact through articulation minimizes spillage
and leakage, as indicated below:

Drag and Flight Conveyors

Drag conveyors are used where multiple loading or discharge points are required and a totally enclosed conveyor is
needed for dust containment, capable of handling fine materials ranging from dust to 6 inch (150 mm) lumps, where
capacity requirements are high, 200 - 400 TPH.

They are used and when the material is somewhat fluid. The typical materials conveyed are TSP (fertilizer), raw meal,
and finish cement.

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3. FORMULAS FOR EASY CALCULATIONS:

1) Chain conveyor or apron chain conveyor calculation system. The load tensions are calculated as indicated below:

T = Fs + Fi + Fk (Kgf) (lbf)

 Fs = (Qt x L) + (Pch x L) x f =

 Fi = Pch x L x f1 =
2

 Fk = (Qt + Pch) x L1 x sen α x f2

2) To calculate the driving power (CV or HP), use the following formulas:

N = T x v (m/s) (metric) and T x v (fpm) (imperial).

75 33000

Where:

T = Total chain force or total work chain tension – (kgf) (lbf);

Fs = Upper chain tension – (kgf) (lbf)
Fi = Under chain tension – (kgf) (lbf)
Fk = Lift chain tension – (kgf) (lbf)
Q = Conveyor total load - (t/h) (tph)
Qt = Conveyed material weight – (kg/m) (lb/ft)
L = Total conveyor direct length (including inclined/declined) - (m) (ft)
L1 = Conveyor horizontal direct length – (m) (ft)
L2 = Conveyor slope (inclined / declined) extension direct length – (m) (ft)
Pch = Total chain weight (see manufacturers tables according to chain
types); N = Driving power (kW) - (HP)

f = Upper chain friction factor – 0.25 ~ 0.35;

f1 = Down chain friction factor – 0.10 ~ 0.15;
f2 = Lift chain friction factor – 0.25 ~ 0.35;
v = Chain conveyor speed – (m/s) - (fpm)
φ = Driving sprocket diameter – (mm) - (in)
α = Conveyor slope angle;
δ = Bulk density of conveyed material – (kg/m³) - (lb/ft³)

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4. PRACTICAL EXAMPLE:

Calculate the driving power of a Drag Roller Chain Conveyor, commonly used in Sugar Plants considering the
following sketch below:

CONVEYOR CAPACITY = 90 tph PESO DO MATERIAL = 300 kg/m

DRIVING PULLEY DIA = 270 mm SPROCKETS DIAMETER = 270 mm CONVEYOR SPEED = 6 m/min
TOTAL CHAIN WEIGHT = 160 kg/m

2500 (8,2 ft)

Where:

Q - Chain conveyor capacity = 90 tph

δ - Sugar cane bulk density = 900 kg/m³ - (56 lb/ft³)
v – Conveyor speed = 5 m/min (0.083 m/s) – (16.3 fpm)
φ - Driving sprocket diameter = 270 mm – (10.6 in)
φ1 – Driving pulley on driving shaft = 290 mm – (11.4 in)
Pch -Total drag chain weight = 160 kg/m (both sides) – (107.5 lb/ft)
L1 - Conveyor horizontal direct length = 2.5 m – (8.2 ft)
L2 = Conveyor slope (inclined) direct length = 14.5 m – (47,5 ft)
α = Conveyor slope angle = 28º

Solution:

1). CALCULATION ACCORDING TO MATERIAL FLOW:

kg/h = kg/mor m/h lb/h = lb/ft

ft/h

Q - 90 tph = 90,000 kg/h – (198,450 lb/h)

v – 5 m/min = 5 x 60 = 300 m/h – (984 ft/h)

Qt = 90,000 kg/h = – Qt = 198,450 lb/h = 202

300 m/h 300
984 ft/h

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L = L1 + L2 = 17.0 (55.7 ft)

a) Fs = (Qt x L) + (Pch x L) x f =

Fs = (300 x 17.0) + (160 x 17.0) x 0.25 = 1955 (4310 lbf)

b) Fi = Pch x L x f1 = 160 x 17.0 x 0.15 =

2 2

Fi = 2720 x 0.15 =
2 204 (450 lbf)

c) Fk = (Qt + Pch) x L2 x sin 28º x f2 =

Fk = (300 + 160) x 14.5 x sin 28º x 0.35 = 1096 (2416 lbf)

d) T = Fs + Fi + Fk = 1955 + 204 + 1096 =

T = 3255 (7177 lb.ft)

N = T x v = 3255 x 0.083 = 3.6 ~ 5.0 CV

75 75

Or:

N = T x v = 7177 x 16.3 = 3.5 ~ 5.0 HP

33000 33000

2). CALCULATION ACCORDING TO TSUBAKI FORMULA:

T = [(Qt + 2.1.Pch) x f1 x L1] + [(Qt + Pch) x (f1 x L2 x cos α + L2 x sin α) + [1.1.Pch (f1 x L2 x cos α – L2 x sin α)]
= (kgf) (lbf)

Using the data above, calculate the tension using the Tsubaki formula:

T = [(300 + 2.1x 160) x 0.15 x 2,5] + [(300 +160) x (0.15 x 14.5 x cos 28º + 14.5 x sin 28º)]+ [1.1 x 160 (0.15 x 14,5
x cos 28º - 14.5 x sin 28º)] =

T = 4254 (9380 lbf)

N = T x v = 4254 x 0.083 = 4.7 ~ 5.0 CV

75 75

N = T x v = 9380 x 16.3 = 4.6 ~ 5,0 HP

33000 33000

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3) CALCULATION ACCORDING TO THE WINDLASS TORQUE:

According to applied mechanics the torque calculation to revolve the driving chain conveyor pulley just like the
windlass arm to pull the bucket is:

F x R1 = P x R

Where:

P = Conveyor chain force to pull the load, kgf;

R = Driving sprocket radius, m;

F = Pulley peripheral force on driving shaft, m

R1 = Driving pulley radius, m

Calculate the driving chain conveyor power, using the data above.

F x R1 = P x R

a) P is the force to carry up the sugar cane plus the chain weight, as we calculated before:

P = Fs + Fi + Fk = 1955 + 204 +1096 =

P = 3255 (7177 lbf)

Or,

P = 42 (9380 lbf) according to Tsubaki formula.

b) The conveyor data above indicate the sprockets diameters, φ = 270 mm, then: R = 0,135 (5.3 in).

c) The diameter of the driving pulley on driving shaft is, φ1 = 290 mm, then: R1 = 0,145 (5.7 in).

We need to find the force F to move the driving shaft, so:

P = R1 = 3255 = 0,145 = F = 3030 and, 7177 = 5.7 = 6673

F R F 0, 135 F 5.3

N = F x v = 3030 x 0,083 = 3,35 ~ 5.0 CV

75 75

N = F x v = 6673 x 16.3 = 3.3 ~ 5.0 HP

33000 33000

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SUMMARY:

Chain Conveyors:

Chain conveyors are commonly used in siderurgy and mining industries to transport heavy minerals The
manufacturing industry also use widely chain conveyors to carry unit loads, pallets, grid boxes and general industrial
containers. These conveyors can be single or double chain strand or Catterpillar type chains. Single chain conveyors
are generally easy to install and have very minimun maintenance for users.

Many industry sectors use chain conveyor technology in their production lines.The automotive industry commonly
use chain conveyor systems to convey car parts through paint plants. Chain conveyors also have widespread use in the
white and brown goods, metal finishing and distribution industries.

Chain conveyors are also used in the painting and coating industry, ceramics, thermal treatment of metals, feed and
discharge systems of boilers. In automatic painting systems the products are attached to an above head chain
conveyor, keeping products off of the floor allows for higher productivity levels.

References:

Sugar Cane Handling and Process Equipment, Dedini, 1st Edition, 1975
Tsubaki Manufacturer, Chain Conveyor Calculations
Grinding Manual, Technical Publication, Faço/Allis-Chalmers, 4th Edition, 1985

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