Power plant conveyor belt

1. Bulk Material
Handling
Part-1
Dated 01-06-2020

2. Capability Development

3. Belt Conveyor

5. Manual
Loading

6. Loader
Loading

7. Rope Loading

8. Engine on
Load
Latest in
World

9. Wagon Unloading
Twin WAGON Tipler
IN
Kalinga Nagar

10. Material Being Conveyed in Conveyor Belt

11. BELT CONVEYOR - History
• 17 th and 18 th Century
Belt (leather, canvas or rubber) traveled over wooden
bed.
• 1908
Patented by Hymle Goddard of LOGAN company.
• 1920
Long belt ( 8Km, cotton and rubber layers) for coal
handling
• 1940-1960
Synthetic belt
• 1970
Nylon, neoprene, polyester, silicon and steel belts

12. BELT CONVEYOR - History
WORLD LONGEST CONVEYOR BELT ON
EARTH
100 Km long, phosphate mines of Bu Craa in Western Sahara

13. BELT CONVEYOR - History
* Meghalaya to Chatta
* Single Flight of 17 Km
* 960 tph / 1.2 mtpa
* Specification 800 / 2500 – 6/6
X
* 89 reel of 500m each

14. These basic objectives that a material handling system should fulfill are:
1. Quick and precise pick-up of loads.
2. Quick and efficient transfer of load with planned time interval.
3. Transport of loads in planned quantity.
4. Safe transport without any damage.
5. Accuracy in delivering at the destination.
6. Automation with minimum human element.
7. Low initial and operational costs.
8. Simple and easy to maintain.
9.Safe operation.
BASIC OBJECTIVES

15. Rubber belting constitutes a major outlet for rubber in industrial application. Rubber belts can be
generally divided into flat belt and 'V' belts. The flat belts further split into conveyor and transmission
belts.
Conveyor belts: It carries material at low speeds and operates over relatively large pulleys.
Transmission: It is used to transfer power and operate over relatively large pulleys.
‘V’ belts: It transmits power between 'V' grooved pulleys
BELTING SYSTEM

16. A) High strength
B) Low self-weight
C) High wear resistance
D) Low elastic and permanent elongation
REQUIREMENT OF BELT WHICH IS TO BE USED IN BELT CONVEYOR
E) Flexibility
F) High resistance to ply separation
G) Low water absorption capability
H) Suitable working environmental conditions

17. Belt is power transmission device.
Power transmission depends upon following factors:
1.The velocity of the belt.
2.The tension under which the belt is placed on the pulley.
3.The arc of contact between the belt and smaller pulley.
4. The conditions under which the belt is used.

18. Selection of Belt Drive:
Following are the various important factors upon which selection of
belt drive depends:
1.Speed of driving and driven shaft.
2.Speed reduction ratio.
3.Power to be transmitted.
4. Center distance between two shaft.
5. Positive drive requirement.
6. Shaft layout.
7.Space Available.
8. Service Conditions.

19. DESIGN OF BELT:
Important factors are to be considered:
a) Angle of repose and angle of surcharge.
b) Flow ability.
c) Effective belt width for material.
d) Volume capacity of belt .
e) Mass capacity of belt.
f) Belt speed.

20. a) Can be operated over long distances over any kind of terrain.
b) Having high load carrying capacity and carry all kinds of loads.
c) Noiseless as compared to chain conveyors.
d) Much simpler to maintain and don’t require any major lubrication system like
chain conveyors.
e) Their reliability has been proved over a long period by its use in the industry.
f) Environmentally more acceptable.
g) Low labor and low energy requirements.
h) Unlike screw conveyors, belt conveyors can be easily used for performing
processes functions in a production line.
ADVANTAGES OF BELT CONVEYOR.

21. BELTING SYSTEM
FLAT BELTING V-BELTING
CONVEYOR TRANSMISSION
TROUGHED
FLAT

22. Conveyor belt
Textile Fabric
Conveyor Belts
Steel Cord
Conveyor Belts
Depending on the Carcass

23. Textile Conveyor belt
•Carcass Reinforcement
1) Nylon-Nylon.
2) Polyester-Nylon.
3) Cotton-Cotton.
4) Cotton-Nylon.
•Cover Grades
1) Super Abrasion Resistant
2) Heat Resistant
3) Fire Resistant
4) Oil Resistant
5) Chemical Resistant

24. Material used for Belts:
1.Leather belts
2.Cotton or fabric belts
3.Rubber belts
4.Balata belts

26. Conveyor belts generally are composed of three main components:
1) Carcass
2) Skims
3) Covers
CONVEYOR BELT CONSTRUCTIONAL DETAILS.

27. A) Carcass:
The reinforcement usually found on the inside of a conveyor belt is referred to as the carcass. The functions
of a carcass include the following:
• Provide the tensile strength necessary to move the loaded belt.
• Absorbs the impact of the impinging material being loaded on to the conveyor
belt.
• Provide the bulk and lateral stiffness required for the load support.
• Belts are connected at the ends by splicing them with belt fasteners. The
Carcass should provide the necessary strength to hold fasteners.
The carcass is normally rated by the manufacturer in terms of maximum permissible operating tension. The
carcass can of two major types:
1. Fabric ply type 2. Steel cord type
CONVEYOR BELT CONSTRUCTIONAL DETAILS.

28. B) Skims:
The rubber, PVC or urethane between the plies is called as skim. Skims are important contributors to internal
belt adhesions, impact resistance and play a significant role in determining the belt load support and trough
ability. Improper skims can give reverse effect too. It can lead to ply separation failure.
C) Covers:
They are used in conveyor belt construction to protect the conveyor belt carcass and also to extend its
service life. Therefore, the top cover normally will be greater in thickness than the bottom cover to take care
of wear of conveying side of belt.
Its desirable properties such as:
1) Textures
2) Clean ability
3) A specific co-efficient of friction
4) A specific color
5) Cut resistance.
6) Enhanced impact resistance.
7) Hardness. 8) Fire, oil and chemical resistance.
CONVEYOR BELT CONSTRUCTIONAL DETAILS.

29. Cross Section of a Textile Belt:
Textile Belting:
 Multiple- ply is made up of two or more plies of specially woven cotton , Rayon or synthetic
fibers bonded together by an elastomer compound.
 Belt strength and load carrying characteristics carry according to the number of plies and the
fabric used.
 Depending on the application, textile conveyor belts feature various cover stock properties like
HR, SHR, UHR, FR, Oil resistance etc. and a single- or multi-ply textile tensile member.
3 Ply Belt
Top Cover
Carcass(Woven
Fibers
Bottom Cover

30. Cross Section of a Textile Belts:
The Cover Rubber:
 The purpose is to protect the underneath
carcass from damage.
 Cover qualities is designed to contain
specific properties which determine the
ability of belt to withstand abrasion,
ripping earing, heat, cold, fire, moisture,
oil and other chemical reaction.
 E.g.- M24, SAR, HR, SHR, UHR,OR & etc.
Carcass:
 Layers of specially woven fabric with rubber
inner plies. Absorb the impact of the
material being loaded
 Provides inherent characteristics like tensile
strength & elongation( Elasticity under
tension)
 E.g.- NN( Polyamide-Polyamaide), EP(
PloyEster-Poly Amide)
 May be to provide adequate strength for
holding mechanical fasteners.
Intermediate Rubber/Skim:
 Layers of Rubber in between plies for ply to Ply bonding.
Skims are important contributors to internal belt
adhesion.
 Significant role in determining “Load Support” &
Troughability”

31. SL. No GRADE TEMPERATURE DUTY MATERIAL USE
1
N-17
M-24
S.A.R(super
abrasion
resistance)
500
640
900
General Duty
Abrasive material (Coal, Dust,
Scrap etc.)
2 H.R 90-1200 Heavy Duty Coke, Sinter, Lime Stone etc.
3 S.H.R 120-1500 Extra Heavy Duty
Coke, Hot Sinter, Lime Stone
etc.
4 U.H.R 150-1800 Extra Heavy Duty
Coke, Hot Sinter, Lime Stone
etc.
5
OIL RESISTANCE
OR-51
OR-62
750-900 For Transporting Fine coal, oily sheet metal.
DIFFERENT GRADES OF BELTS

32. The most common carcass construction in general use is the multiply type, which is made up of two or
more plies of weaver belt fabric previously impregnated with an elastomer.
CONVEYOR BELT CONSTRUCTIONAL DETAILS.

33. Cross Section of a Steel Cord Belt:
Steel Cord Belting:
 Steel Cord-type constructions utilize a single layer of uniformly tensioned steel cords as strength
members; encased in rubber.
 Steel cord belts are generally found in high tension applications and low % elongation.
We at KLNR
having 23 No's of
steel cord Belts
covering 23.1
Km.
(i.e. 26% of Total
Conveyor belt
population)

34. EP 2000 4 10+6 M- 24
Cover Grade
Top cover 10 mm
Bottom cover 6 mm
No. of ply = 4
Tensile Strength of 2000 N/mm
BELT DESIGNATION/SPECIFICATIONS
Carcass Material
(polyester warp/polyamide weft)
1000
Width of Belt

35. • Belt Width
• Type of Ply
• Ply Rating
• Number of Plies
• Top Cover Thickness
• Bottom Cover Thickness
• Cover Rubber Grade
• Total Thickness of the Belt
Belt Specification:

36. Belt Specification:
● Belt Width
● ST Rating
● Top Cover Thickness
● Bottom Cover Thickness
● Cover grades
● Cord Diameter (d)
● Cord Pitch (P)
● No. of Cords

37. Types of Belts:
1.Flat Belt
2.V-belt
3.Circular Belt

38. Basic Layout of Conveyor Belt System:

39. Basic Layout of Conveyor Belt System:

40. BELT CONVEYORS
A belt conveyor consists of an endless belt of a resilient material connected between two pulleys
and moved by rotating one of the pulleys through a drive unit gearbox, which is connected to an
electric motor. The driving pulley end is called as head end, and the pulley is called as head pulley.
Conversely, the other pulley is at the tail end and is referred to as the tail pulley.

42. A)HEAD PULLEY: - Normally the discharge end of the conveyor where the material is transferred to another
conveyor is called as the Head end and the pulley in this end is called the head pulley.
B) TAIL PULLEY: - The pulley which is situated in the receiving end of the conveyor is called as tail pulley.
Sometimes Screw take-up will be situated in this pulley.
GENERAL ARRANGEMENTS OF BELT CONVEYOR

43. E) IDLERS: - The needs for Idlers are to give proper support to conveyor and also to the Material
to conveyor. An endless conveyor belt in a conveyor structure is dragged from the tail pulley
where material is loaded onto the conveyor, to the head pulley or drive pulley where the material
is discharged. Between a conveyor' tail and head pulleys, whether the distance is a number of
kilometers or merely a few meters, the carrying and return strand belting is supported on idler
sets.
a) TROUGHING IDLER
b) TRAINING IDLER
c) IMPACT IDLER
d) RETURN IDLER
e) GUIDE IDLER
The most commonly used troughing idler has three rolls of equal length with inclined rolls usually
of troughing angles of 20 deg. 35 deg & 45 deg. 20 deg are standard in most application.

44. C) SNUB PULLEY: - Snub pulleys are incorporated into the design of a conveyor in order to increase the angle
of wrap of the belt on the drive pulley.
D) SCRAPERS: - The function of the Conveyor Belt is to carry material and during this process material sticks
to the Belt for which Belt Scrapers are used to clean the Belt.

45. TROUGHING IDLER
TRAINING IDLER
IMPACT IDLER
RETURN IDLER
GUIDE IDLER

46. Carrying Idlers

47. G) TAKE UP: -Take up devices, the name from the fact that it takes up changes in belt length. In taking up
length they maintain tension. Often the critical point lies immediately following the drive since it is
necessary to maintain tensions at the point to prevent slippage on the drive pulley.
F) Manual (Screw type):- The screw type (manual type) providing enough movement to establish initial
tension in the belt and to provide periodic readjustment as the belt stretches.
G) Gravity (VGTU) - Vertical Gravity Take UpAn automatic take-up (counter weight) must provide sufficient
travel to handle any elastic length changes due to load variation or temperature changes and inelastic
changes likely to occur between refastening and replacing.
H) SKIRT BOARD: - The chute having delivered material the succeeding belt; has no further control of the
material. To control on loading turbulence, the skirt board are necessary.
TYPES OF TAKE UP

48. I) CHUTES: - Chutes are generally of two types feed chute and discharge chute; feed chute are used for
feeding the materials in the belt and it is situated near the tail pulley and discharge chute is used for
discharge the materials and it is situated near the head pulley.

49. J)Lagging:
Enhances coefficient of friction between belt and the drum/pulley to
reduce
required equivalent tension for belt operation
– Rubber lagged pulley
• Plain rubber sheet
• Diamond sheet
• Herringbone pattern
– Ceramic lagged pulley (very high wear
life) Ceramic shapes embedded in
rubber matrix
• Straight ceramic bars
• Custom built ceramic shape
• Small ceramic squares/honeycomb or other shapes
BELT CONVEYOR SYSTEM

50. BELT CONVEYORSYSTEM
Ceramic lagged
pulley

51. BELT CONVEYOR SYSTEM
Rubber lagged
pulley

52. Types of Flat Belt Drives:
1. Open belt drive
2. Crossed belt drive
3. Quarter turn belt drive
4. Compound belt drive
5. Belt drive with idler pulleys
6. Stepped or cone pulley drive
7. Fast and loose pulley drive

53. QUESTION: If drive diameter is 800 mm and tail diameter
is also 800 mm and both pulley is separated
by 6 meter . Find total length of belt for this system?

54. Velocity Ratio of a Belt Drive:
𝝅d1N1= 𝝅𝐝𝟐𝐍𝟐 , 𝐝𝟏 = 𝐝𝐢𝐚, 𝐍𝟏 = 𝐑. 𝐏. 𝐌 of 1st pulley.
N2/N1=d1/d2
N2/N1= d1+t/d2+t ,where t is thickness of belt
In case of compound belt drive velocity ration
is given by
N4/N1=(d1xd3)/(d2xd4)
Speed of last driven/Speed of first driver=
Product of diameters of drivers/Product diameters of driven

55. Length of Open Belt Drive:
Length of belt = 𝜋(r1+r2)+2x + (r1-r2)^2 /x
Work done per sec =(T1-T2)Xv N-m/s
Power transmitted = (T1-T2)Xv Watt (1N-m/s= 1W)

56. Ratio of driving tensions of flat belts:
T1= Tension in the belt on the tight side.
T2= Tension in the belt on the slack side.
Loge (T1/T2)= µ.Ө
T1/T2= e^µ.Ө
2.3 log10 (T1/T2) = µ.Ө

57. When thickness of the belt is known:
L = ((D*D)-(C*C)) / (15.3*t)
L = Length; D = Outside Diameter (inches); C = Inside
Diameter (inches); t = belt thickness (inches)
When wraps are known:
L = ((D+C)*3.14*n) / 24
n = Number of wraps in roll
Capacity (Tones per hour)= 3.6 XLoad cross section
area (m^2)XBelt speed (m/s)XMaterial Density
(kg/m^3).

58. Question :Two pulleys ,one 450 mm diameter
and the other 200 mm diameter on parallel
shaft 1.95 m apart are connected by a crossed
belt .Find the length of the belt required and the
angle of contact belt and each pulley.
What power can be transmitted by the belt
when the larger pulley rotates at 200 rev/min ,if
the maximum permissible tension in the belt is 1
KN , and the coefficient of friction between belt
and pulley is 0.25 ?

59. Angle of contact between the belt and each
pulley
Sin alfa= r1+r2/x=.225+.1/1.95=.1667
Alfa=9.6
Theta=180 degree +2 alfa= 180+ 2x9.6=199.2 degree

60. Power Transmitted:
2.3 log(T1/T2)= MuX THETA
Log(T1/T2)= .8693/2.3=.378
ANTILOG Of .378= 2.378
T2= T1/2.387= 1000/2.387= 419 N
We know velocity of belt v= PIEXd1xN1/60
= piex.45x200/60= 4.713 m/s
Power transmitted = P= (T1-T2)XV=(1000-419)X4.713=2738W
= 2.738 kW

61. Ans:
Length of belt= 4.974 m
Angle of contact =199.2 degree
T2=419 N
V= 4.713 m/s
P=2.738 kW

62. Conveyor Belts used can be categorised into Bucket Conveyor, Chevron Conveyor &
Troughing Conveyor.
Belts can come with features
With Breaker:-Fabric Breaker, Steel Breaker
Without Breaker
With Rip Detection loops
With RFID
Edge Construction
Moulded Edge-Steel Cord(will rust if left open), Fabric belts where Oil & Chemicals can
react with fabric.
In moulded Edge - First damage happens to the edge rubber & saves the internal
construction.ME belts are Costly in comparison to same spec CE fabric belt
Cut Edge- Fabric Belts used in normal operating condition belt. Synthetic fibres used these
days are less susceptible to environmental conditions.

63. Hardness
Usual approach is to check with Shore A durometer. 60-70 Shore A when new,
unused, stored well.
Pulley Diameter
Minimum Pulley Diameter
The smallest pulley diameter that the belt will encounter in the
conveyor system is a primary consideration in selecting the
proper conveyor belt.
It is important that as the belt wraps around that pulley,
under tension, the stress in the belt is below the fatigue limit
of the bond between the belt components.
Due to system limitations, smaller than recommended pulleys
may be used. This will affect the service life of the belt and will
result in more frequent splice replacements.

64. When transitions are shorter than
suggested minimum, belt damage
can occur.
At the high tension area, such as
the head pulley or tripper discharge,
excessive edge tensions will cause
adhesions to break along the edge of
the belt, and can also rupture the
carcass in severe cases.
At a low tension terminal, such as the
tail, short transitions will cause a
belt to buckle at the bottom of the
trough, resulting in splice failure and
cover adhesion breakdown in the
center of the belt.