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February 1st, 2012
BELT CONVEYORS
Vincent GUILLEMOT
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RBL-REI is active in the field of
RBL-REI
more than a century through its branch LaStphanoise.
more than 50 years through REI.
more than 30 years through RBL.
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The main activities of our company are:
Handling by belt conveyor
Storage and extraction of materials
Loading and unloading of trucks and wagons
Preparation of materials
Conditioning
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RBL-REI activities are made in the followingindustries:
Mines Quarries
Port infrastructures
Processing industries (cement factories,
fertilizers, mineralurgy, etc)
Food industry
Environment (biomass )
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CESECO Presentation
1) Belt conveyors / principle
2) Belt Conveyors applications
3) Why choosing a belt conveyor transportation instead of road or railmode ?
4) Types of belt conveyors
5) Equipments
6) Calculation and design of a belt conveyor
7) Global procedure for a project
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Subject :Handling of bulk or conditioned materials from A to B.
Belt conveyors / principle
Belt conveyors technology has been existing since1870s. At this time, the first tests had been made with
coton belts without coating and wooden idlers.
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Belt conveyors / principle
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Belt conveyors / principle
PRINCIPLE
Feeding
Driving unit
Tail
Head
Tensioning system
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Belt conveyors / principle
Composants :Belt
Feeding skirts
Driving unit
PulleysScraper
Idlers support /
idlers
COMPONENTS
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Mines and quarriesBelt Conveyors Applications
unne s
Ports
Food/fertilizers
Mobile equipments
Airports, automatism
Industries
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Quarries
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VICAT ENIEU
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VICAT ENIEU
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Mines
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Tunnels
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Tunnels
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Tunnels
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TUNNEL
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TUNNEL
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Tunnels
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TUNNEL
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PORTS
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Ports
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Portuaire
Ports
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Portuaire
Ports
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Ports
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FOOD / FERTILIZERS
Fertilizers
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Portuaire
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Portuaire
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3. WHY CHOOSING A BELT CONVEYORTRANSPORTATION INSTEAD OF A ROAD OR
RAIL MODE ?
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Compared to the road transportation
Limitation of pollution
Cost price by transported ton very low
Very low power consumption
Limitation of transshipments (setting/taking back )
Very high reliability of the process
Infrastructure in design and maintenance less expensive
Reduced staff
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Compared to the rail transportion
Limitation of transshipments (setting/taking back)
Infrastructure in design and maintenance less expensive
Installation adapted to short and average distances
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SOME FIGURES
More than 1000 conveyors of which 35 of more than 5000 m et 50integrating vertical curves and especial range of horizontal curves
Range of capacities: from a few tph to 20 000 tph Speed of the belts: between 0.5 m/s to 8 m/s for the fastest.
Power: from a few hundred watts to 10 500 kW.
Length: from a few meters to more than 16 kms.
Rays of horizontal curves : from 150 m to several kms.
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Case studyCase study
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Rights, concave or convex conveyors
Curves conveyors Raising conveyors
Descending conveyors
Belt conveyor with two loading strands Conveyors going through natural obstacles
Extensible conveyors
Change of angle
Stackers
Tripper
Reserve of belt
Belt extractors
Belt with side
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On the ground
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P.R.S (Reconstitued welded beams)
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Gallery
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Ground / P.R.S/ Gallery
T b
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Tube
C b lt
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Concave belt conveyors
C b lt
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Concave belt conveyors
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Convex belt conveyors
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Curved belt conveyors
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Curved belt conveyors
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TURNING RADIUS
Conveyors with horizontal curves are called : CURVODUC
Curved belt conveyors
(mark deposited ).
The first we achieved was commissioned in 1963.
95 % of very long conveyors are conveyors which havehorizontal curves due to the facts of natural obstacles or
agrarian constraints.
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CurvoducTM
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Curved belt conveyors
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Curved belt conveyors
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Raising conveyor
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Descending conveyor
Generator conveyor
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Generator conveyor
Supply of power to the network
Belt conveyor with two loaded strands
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Belt conveyor with two loaded strands
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Belt conveyor with two loaded strands
Conveyor going through natural
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Conveyor going through natural
obstacles
GOING THROUGH NATURAL OBSTACLES
eren so u ons:
PRS structure or gallery for a crossing span up to 80 m
Between 80 and 200 m, suspended bridge
Beyond, we start a particular study
Conveyor going through natural
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y g g g
obstacles
Transporteurs passant des obstaclesnaturels
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Conveyor going through natural
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obstacles
Conveyor going through naturalobstacles
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Conveyor going through natural
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obstacles
Change of angle
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g g
Change of angle
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g g
Stacker
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Extensible conveyor
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Diaporama 1
Belt Storage
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g
Belt extractor
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Edges Belt
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Equipments
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Belt Feeding Skirts
Driving unit
PulleysScraper
Idlers support /
idlers
COMPONENTS
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B l
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BeltsBelts are characterizes by :-The type of carcass.
-The type of coating-The elements of the structure
The type of carcass:
Three types of carcass exist:
- The SteelCord belt.Made of steel cables.
-The textile belt multipliEquipped with several fabric folds (coton,polyester, polyamide, aramide)
-The belt textile monopliA monopli carcass made of polyester
Polyamide.
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- Type of coatings :
The coating is the part of the belt in contact with the product, it can be:
- Abrasive Resistant- Heat Resistant- Cold Resistant
- rease es s an
- Anti-static- Flame Resistant- Impact Resistant- Anti-clogging- Food products dedicated
- The elements of the structure :
The belt can also be equipped with elements of the structure such as:- Plate- Chevrons,
- Side-..
Belt Conveyor Driving
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It exists many ways to drive a conveyor:
Thanks to one driving unit or several, connected to one or several pulleys
1 single driving unit connected to a single driving pulley
5 driving unit shared on 4 driving pulleys
Belt Conveyor Driving
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Generally, a driving unit is composed of :
-Motor 4 poles 1500 tr/mn with legs.
- -
-Parallel or perpendicular reducer
- Low Speed coupling (semi-rigid) orReducer with hollow shaft
Note : For inclined conveyors, a back stop system is recommanded
2 Driving Units with Hollow Shafts
Booster
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Booster function is to reduce the belt tension
Booster
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Cleaning
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scraper
The cleaning of the belts is an important
element in designing conveyors. Il isgenerally done by Scapers with blade
type underlying or tangential.
Cleaning :
Underlying scraper
On long conveyors, systems of belt returnsare generally employed.
Tensioning system
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Tensioning systems:
Every conveyor is equipped with a tension system to:
- Permit the power transmission by friction between the driving .
- Absorb the differences of belt length due to belt extension.
Three main systems of belt tension exist:
1/ Screw tension for conveyors with low Axis Distance Center
2/ Gravity counterweight
3/ Tension with electric winch.
Tensioning system
Gravity Counterweight through take-up pulley
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Gravity Counterweight through take-up pulley
Tensioning system
Gravity Counterweight through horizontal trolley
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Gravity Counterweight through horizontal trolley
Tensioning system
Electric Winch
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Electric Winch
Covers
Hooding
Complete hooding
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Complete hooding
Covers
Hooding
Protection of upper strand only
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Protection of upper strand only
Safety
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Safety
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Emergency wires along the belt conveyor
Clogging detector
Speed switch
Belt Deviation switch
Control Box
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Supervision screens
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Calculation and desi n of a belt
conveyor
Product :
Parameters to calculate and design
a belt conveyor
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Chimical charcterisrics :
Corrosive
Explosive
Dangerous
..
Product :
Physical characteristics :
Density
Pulverulent (cement)
Round (fertilizer)
a be t co eyo
Abrasive (clinker, granite )
Liquid (muds) Granulometry ( 0-1000 mm)
Sticking (clay)
Cutting (glass, slate) ..
The type of the product will determine the length, the speed and
the belt coating.
Parameters to calculate and design
a belt conveyor
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Implantation:y
The implantation of a conveyor is necessary for:- The power calculation- The implantation of the elements of the conveyor and in particular, the tensioningsystem.
The environnement of the conveyor is also important (interior, exterior, wet, dusty,
wind, seism, snow, etc. ..)
Parameters to calculate and design
a belt conveyor
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Capacity : The capacity of a belt conveyor is reached thanks to the trough capacityFormed by the belt on the idler supports.
y
For example, the sectional capacity of this type of through is 0, 39 m.With a belt speed of 1 m/s, the flow is: 0,39 m3 x 3600 s = 1404 m3/h.For a product with a density of 2 at a speed of 2,5 m/s and an angle of dynamic slope angle of 10
The calculated flow of the conveyor will be of: 1404 x 2 x 2,5 = 7020 tph
Capacity (usual table) :
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Idlers/Idler supports:
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Idlers are the rolling metal supportA Idler support can be equipped with 2,3 or 5 idlers according to
conveying needs.Generally, they are with 3 idlers for the superior parts. For inferiorparts, conveyors can be equipped with plate or V idlers at 10.
The transition of the trough is the necessary length to put the belt on trough, itis determined in function of the type of the belt and the angle of the trough.In a usual way, we consider that the transition must not be inferior to 8 timesthe depth of the trough.
Transitions :
Pinching
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The idlers pinching is important for the belt tobe well-held on the track. The upholding of the
belt is done by the friction belt / idlers.
Idlers are greased for life and generallyhave standard diameters (89, 133, 159 mmor more).The idlers are determined in function of theproduct load, the idlers supports span, and
the belt speed.
Idlers:
Functioning timetable:
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The idlers can be equipped with special coatings:
- Rubber for shock absorber idlers.
- Rubber rings for the anti-plug
Special idlers :
Calculation and design of a belt conveyor
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A conveyor is determined by 2 phases:
- The choice of the belt and the trough angle of the conveyor.
- The calculation of the power of the conveyor.
Example of calculation :
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Example for a conveyor having the hereafter characteristics:
Axis distance center: 100 m, rectilinear.Slope: 5,7 Product: scories (scoria)
ow requ re : pDensity of the product: 1,3 t/m3
Dynamic slope angle: 10Maxi speed of the belt: 2 m/sMaxi loading rate: 70%
Determination of the belt width:
The researched flow in m3/H is of 615 m3/h
The maxi speed being of 2 m/s, the flow at 1 m/s will so be of 308
m3/h.
With a maxi filling rate of 70 %, the belt flow has to be of 440 m3/h
Selection
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Filling rate with a belt of 1200 mm , trough 30 : 61%
Calculation of the conveyor :
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In our case :
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P3 = 1,5 * 1,2 * 2 = 3,6 KW
PT = 13,14 + 21 + 3,6 = 37,7 KW
PM = 37,7 /0,9 = 42 KW soit : 45KW
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Choice of the belt:
s erea er ca cu a on a ow o
make a approach of the type of the
belt for a conveyor with simplegeometry and one motorization.
- Angle denroulement :
200,
- FS between 8 and 10.(security factor)
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K = CR * PT K = 17 * 37,7 K = 320 N/mm
In our case, with the use of a belt with a security coefficient to junction 1:
CV V 1 2
The belt will be of Trioflex 400 type or more
CHARACTERISTICS OF PRODUCTS -1-
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CHARACTERISTICS OF PRODUCTS -2-
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CHARACTERISTICS OF PRODUCTS -3-
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CHARACTERISTICS OF PRODUCTS -4-
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CHARACTERISTICS OF PRODUCTS -5-
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CHARACTERISTICS OF PRODUCTS -6-
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Global procedure of a project
GLOBAL PROCEDURE OF A PROJECT
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Analysis of the customers needs
Seeking solutions
Calculation
Phase of achievement
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CUSTOMERS NEED
Lifespan of the equipment
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Lifespan of the equipment
Annual flow and time to reach Daily, monthly and annual mode of use
Characteristics of the product (density, granulometry,
moisture, abrasion etc.) Geographical considerations between the feeding point and
the discharging point
Obstacles to be taken into account
Constraints of environment (pollution, dust and noise)
Safety constraints
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Elements to be taken into
account
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Altimetry of the ground
, , .
Obstacles of infrastructures such as roads, railways,powerlines, etc .
Predimensioning of the conveyor with an approach of the
possible horizontal radii by sections according to the
various efforts in the belt
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FIGURING
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In tartin
In steady state operation
In normal deceleration, emergency stop
In the event of electrical supply network shutdown
CALCULATION OF BELT STABILITY
IN HORIZONTAL CURVE
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DYNAMIC CALCULATION
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PHASE OF ACHIEVEMENT
V lid ti f th li t d f i
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Validation of the alignment and of rise
Validation of the means of self-supporting quality
on the ground and dimensioning of the bridges
or tunnels
Phase of construction
Phase of assembly
Phase of tests
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Validation of belt conveyor route and profile
ground and in elevation)Fabrication and procurement
Erection and commissioning phase
Tests phase
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THANK YOU FOR YOUR