CONVEYOR SYSTEMS

INTRODUCTION
In lifting and conveyance of material, the machines are based on two principles;
i. Intermittent motion-the periodic supply of loads carried in individual portions according to the
load carrying capacity of the machine e.g. crane, elevator, trucks etc.

ii. Continuous motion-characterised by non-stop motion of the bulk unit loads along a given path
without halts (stops) for loading and unloading.
CONVEYOR SYSTEMS
A mechanical apparatus consisting of a moving belt that transports material from
one-unit process to the other or from one location to the other.
It is especially useful in applications involving the transportation of heavy or bulk
materials for distances up to 30km.
Conveyor systems allow the quick and efficient transportation for a wide variety of
materials.
A conveyor belt is the carrying medium of a belt conveyor system ( often shortened
to belt conveyor).
TYPES OF CONVEYOR
SYSTEMS
1. Troughed belt conveyor

2. Flat belt conveyor

3. Pipe belt conveyor

 TROUGHED BELT CONVEYOR
Belt forms a trough on the carrying side while running over idler rollers
Idler rollers can be in a set of 5 rolls, 3 rolls or 2 rolls
Return idlers are usually flat
The usually adopted troughing angles are 15˚,20˚,25˚,30˚,35˚,40˚,45˚
TROUGHED BELT CONVEYOR
Troughed belt conveyors are used for higher capacity, higher speed requirement and
for handling bulk materials of a large lump size. It is suitable for inclined or declined
type conveyor.

Transition distance is the distance from the centerline of the first fully troughed idler
roll to the centerline of either the head or tail pulley.

If the transition distance is too short, the edge of the belt can be overstretched . This
will adversely affect the load support and belt life.
TRANSITION DISTANCE, TROUGHING
ANGLE & SURCHARGE ANGLE
FLAT BELT CONVEYOR

Belt runs flat on carrying side over

straight roller type idler or just a set of
idlers
Suitable for lower capacity and low
speed requirement
PIPE BELTS
Used where bulk materials must be
conveyed along horizontal or vertical
curves in confined spaces.
Used mostly where spillage must be
avoided.
The belt can negotiate horizontal or
vertical curves and confined spaces.
TYPES OF CONVEYORS
Belt conveyor system
Flexible gravity conveyors
Roller conveyor system
Screw conveyors
Trolley conveyors
Reciprocating vertical conveyors
Vertical lift conveyors
Pneumatic conveyors
Vibrating conveyors
Bucket conveyors
Conveyor belts find their application in:

Highly productive transport machines for the transfer of goods from one point to
another on liners in a plant

Transfer of devices in an automatic process flow lines for the manufacture and
treatment of parts e.g. assembly components

The movement of ore for subsequent crushing and screening which is best performed
by belt conveyors
The main requirements are:-

A conveyor must be reliable, have appropriate strength and service life.

Should satisfy the whole of the complex plant and engineering requirements including
reliability in given conditions.

Should be efficient

Should be economic
COMPONENTS
 IDLERS
Carrying idlers
These support the loaded belt. May be
single rolls supported by the outer edge
of the conveyor table which cause the
belt to form a trough.
CARRYING IDLERS VARIETIES
Troughing idlers normally consists of three (3) rollers in a
single frame
The outer rollers are inclined towards the edge of the belt at
an angle of 20˚, 30˚ or 40˚.
Shallow angle troughing idlers are used in sorting and
packing applications to prevent spillage
High angle troughing idlers are used in maximum load
carrying applications
RETURN IDLERS

These carry the unloaded portion of the

belt underneath the table.
RETURN IDLER VARIETIES
Normal return idlers-these are long single idlers supported at either end by a
mounting bracket
Return troughing idlers-single rollers supported in pivoted guide idlers
Rubber disk return idlers-these are self cleaning idlers which combat the problem
of sticky material adhering to the empty belt building up on return idlers.
IMPACT IDLERS
oThese are heavy duty , closely spaced
idlers which absorb impact and down
thrust on the belt.
oUsually constructed of solid rubber
disks supported by a central shaft.
 TRAINING IDLERS
These idlers help to keep a belt tracking properly by lateral motion. They pivot
around a vertical axis located at the centre of the idler. Small guide idlers that are
fitted at either end on a vertical axis to pivot and automatically correct the belts side
motion.
TRAINING IDLERS Training Idlers
BELT CAPACITY
Belt capacity is calculated assuming that the peak level is maintained continuously.
When choosing belt width and speed, it is useful to consider:-
oWear on the conveyor idlers and drums is directly proportional to the speed

oFor a given belt power, belt tension increases with increasing speed hence ventilation air should be
considered to keep dust to a minimum

oHigh belt tension require stronger and more costly belts

BELT CAPACITY…
The capacity of the belt is dependant on the speed of the belt, bulk density of the
material and the cross-sectional area of the conveyed materials.
This cross-sectional area is in turn dependant on the belt width, angle of troughing ,
method of loading and the surcharge angle of the material.
A quick estimation of the belt capacity

T=belt capacity (t/s)

a=cross sectional area (
b=bulk density ()
v=belt velocity (m/s)
 BELT CAPACITY…
Approximately
1) (blocky materials)

2) (fine materials)

w is the belt width

The choice of the belt speed must take into consideration the type of the material and
the actual spillage on the mine.
ADVANTAGES
(i) large manpower saving on mineral movement;
(ii) ability to handle pick loads without delay;
(iii) remote monitoring and control possible;
(iv) safer from the point of view of haulage accidents;
(v) ability to operate safely on steep gradients;
(vi) minimum excavation required for drives and
(vii) low maintenance costs
LIMITATIONS
(i) fire risk due to frictional heating;
(ii) initial installation cost high;
(iii) not convenient for transporting material in both directions;
(iv) wet conditions result in lowered efficiencies;
(v) a straight-line path is required;
(vi) maximum lumpy size is limited to about half of the belt width;
(vii) high belt speeds can cause dust problems and
(viii) segregation of different qualities of ore is difficult.
BELT MATERIALS
 BELT
The belt consists of one or more layers of material

 An under layer: to provide liner strength and shape called the carcass (poly ester, nylon, cotton etc.)
 An over layer: called the cover ( rubber or plastic materials)
 BELT MATERIAL
Belts are typically made from cotton, canvas, Kevlar, nitrite, nylon, polyester,
polyurethane/urethane, PVC, rubber, silicone, steel cord, Teflon, mesh wire or weave.
 BELT MATERIAL
MATERIAL ADVANTAGES LIMITATIONS
Poly amide • Elastic • Hygroscopic
• Can easily handle shock
• Easy to bond
Polyester • Non hygroscopic • Not elastic
• Shock loads can cause problems
• Not chemically bondable
Teflon • High temperature resilience • Medium abrasion resistance
• Very expensive
Aramid (Kevlar) • Very strong • Not elastic
• Non hygroscopic
PVC • Inexpensive • Low oil resistance
• Acid resistant • Low abrasion resistance
TPU (thermo plastic polyurethane) • Oil resistance • Expensive
• Abrasion resistant • Yellows on exposure to light
Cotton • Good heat insulator • No strength (will continue to
• Absorbent stretch)
• Will easily rot
CONVEYOR BELTS
Usually categorized into:
1. Steel cord belts
2. Textile belts
CONVEYOR BELTS
Steel cord belt Textile belts

The ensure maximum conveyor Low price and easy maintenance

performance under grueling stress Temperature resistance belts
conditions
Oil and grease resistance belts
High tensile strength
Dirt repellant cover belts
Excellent impact resistance
 BELT NOMENCLATURE
STEEL CORD BELT CONVEYOR
2000 m DIN 22131 AB 1200 St 1600 7T/5X
2000m Length
DIN 22131 Applicable Standard/Norm
AB Manufacturer’s acronym
1200 Belt width in mm
St Carcass material (steel cords)
1600 Belt’s minimum breaking strength in N/mm
7 Top cover thickness in mm
T Textile reinforcement in top cover
5 Bottom cover thickness in mm
X Rubber Cover grade
TEXTILE BELT CONVEYOR

1000m DIN 22102 AB 1000 EP 630/4 6/2 Y

1000m Length
DIN 22102 Applicable Standard/Norm
AB Manufacturer’s acronym
1000 Belt width in mm
EP Carcass material (steel cords)
630 Belt’s minimum breaking strength in N/mm
4 Number of plies
6 Top cover thickness in mm
2 Bottom cover thickness in mm
Y Rubber Cover grade
FAILURES IN BELT CONVEYOR
SYSTEMS

 Drive unit failure

 Pulley failure
 Idlers and belt failure
DRIVE UNIT
FAILURE

Drive unit consists of the

motor, damping coupling, two
or three stage gear box and the
coupling that connects output
shaft with the pulley.
Failure occurs mainly in
pulleys and gear box
IDLER AND BELT FAILURE

 Due to overload side idler may fail

Due to foreign pointed bodies belt may cut along its length

Bearings in the idlers may fail

 BELT CONVEYOR
TROUBLESHOOTING
 PROBLEM CAUSE SOLUTION

One or more idlers not at Advance the end of the

right angles to the idler to which the belt has
longitudinal centre line of shifted in the direction of
1.Conveyor belt runs to the belt the belt travel
one side at a particular
point on the conveyor belt Sticking idlers Replace or free idlers

Built up of material on Improve maintenance

idlers Install scrappers
 PROBLEM CAUSE SOLUTION

Slippage between belt and Lag drive pulleys

drive pulley or pulleys Renew worn out lagging

2.Excessive wear on Sticking troughing idlersReplace or free sticking

bottom side of the belt idlers
Increase arc of contact
between drive pulley with
snub idlers or use tandem
drive
Material grounded Install scrappers in front
between pulley and belt of tail pulley or return belt
 PROBLEM CAUSE SOLUTION

Dirt, frozen or misaligned Install belt cleaning plows

return idlers at head end and tail end of
the belt
3.Excessive wear on
carrying side of the belt
Excessive sag between Clean, repair and align
troughing idlers causing return idlers
load to move and shift on Increase belt tension if too
belt as it passes over idlers low
Reduce idler spacing
Use rubber skirt material
Avoid use of old belting
 PROBLEM CAUSE SOLUTION

Impact of lumps falling on Use impact idlers

belt at loading station

4. Short breaks in carcass Material trapped between Install plows/ scrappers

of belt parallel to edge and belt and pulley ahead of the pulley
star breaks in carcass
 PROBLEM CAUSE SOLUTION

5. Belt running of at tail Build up of material on Remove material, provide

pulley return idlers better house keeping

Return rollers out of line Adjust at right angles to

the frame

Unequal loading Adjust loading chute to

properly centre the load
BELT DESIGN
The actual belt of a system is determined on what the conveyor is going to be used
for. Items to consider when choosing a conveyor belt;
oSize of items being moved
oWeight of materials
oShape of materials particles
oMaterials properties

This will help decide what belt to use so coefficients of friction can stay as low as
possible so the electric motors will not overload.
 DESIGN CONSIDERATIONS
Designing the system for continuous flow of material (idle time should be zero)

Going in for standard equipment which ensures low investment and flexibility

Incorporating gravity flow in material flow system.

 ESSENTIAL PROPERTIES OF
THE BELT
Flexibility
Transverse rigidity
Low mass per unit length
High strength
Simplicity and inexpensive
Longer lifespan
Wear resistant
Fire resistant
Acid resistant
Should not stretch under normal working stresses i.e. low relative elongation
 PARAMETERS
Belt speed
OF DESIGN
Belt dimensions and capacity
Gear box selection
Drive pulley shaft
Roller diameter
Idler spacing
Pulley diameter
Belt control
Belt power and tensions
Electric motor selection
 BELT DIMENSION, CAPACITY
AND
The diameter SPEED
of the drive
conveyor belting,
and driven pulley is determined by the type and dimensions of the

The diameter of the pulley must be designed such that it does not place undue stress on the belt,
The length of the belt conveyor (m) is the length from the center of the pulley parallel to the
belt line to the center of the other pulley.
Capacity is the product of belt speed and its cross-sectional area:

T=belt capacity (t/s)

a=cross sectional area (
b=bulk density ()
v=belt velocity (m/s)
ROLLER DIAMETER
The rollers support the belt and facilitates easy as well as free rotation of the
conveyor belt in all directions.
The correct choice of roller diameter must take into consideration the belt width
The relationship between the maximum belt speed, roller diameter and the relative
revolution per minute is given by

Where, n=number of revolutions per minute

D=roller diameter (mm)
V=belt speed (m/s)
BELT POWER AND TENSION
The longer the length of the belt, the more the power required for the conveyor.
The higher the vertical lift of the conveyor, the higher the magnitude of the power
required.
The power at the drive pulley drum is;

F= total tangential force at the periphery of the drive pulley (N)

V= belt speed
BELT POWER AND TENSION…
Power required for the conveyor to produce lift can be calculated as;

P=power required for lift (kW)

C=Conveyor capacity (t/hr.)
L=lift (m)
BELT TENSION
Belt tension at steady state is given as;

= Steady state belt tension (N)

f= coefficient of friction
L=conveyor length (conveyor belt is approximately half of the total belt length)
=acceleration due to gravity (9.81m/
=load due to idlers (kg/m)
=Load due to belt (kg/m)
=Load due to conveyed material (kg/m)
α= inclination angle of the conveyor
H=vertical height of the conveyor
 PULLEY DIAMETER

Pulleys are manufactured in a wide range of sizes. The selection of pulley

diameter takes into account the belt speed, the method of belt strain, belt tension,
belt width and the type of splice of the conveyor belt.
 MOTOR
The minimum motor power for sizing the electric motor is;

-min motor power (kW)

-power at drive pulley (kW)
=efficiency of the reduction gear
To determine the motor horse power

=horse power to drive empty belt

=horse power to move the materials horizontally
=horse power to elevate materials
SHAFT DESIGN
Shaft design consists primarily the determination of the correct shaft diameter that will
ensure rigidity and strength when the shaft is transmitting motion under different operating
and loading conditions.
The values of the belt width and pulley diameter helps in selecting the size of the shaft
diameter from different conveyor handbook
Control
Compact Programmable Controllers also known as Application Controllers can be used for
the control of the conveyor system
These controllers can be used for time control and supervisory functions such as :
conveyor speed control, speed control of individual drives, load equilibration between two
driving drums and speed difference control between two motors on one driving drum.
FURTHER STUDY
1. Conveyor belt components characteristics and functions
2. Enumerate advantages and disadvantages of conveyor belt system in the mineral processing
industry

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