04 pipe conveyors
TRANSCRIPT
The Pipe Conveyor ®
The Pipe Conveyor ®
The convincing Transport System
for every type of bulk material
2
3
4
Coal and Lignite Power Plants
Cement Plants
Steel Works
Chemical Plants
Wood And Paper Industry
Mines
Processing Plants
Costumers
5
6
Market
Wet and fly ash, slag, REA gypsum, FGD, filter cake.
Limestone, lime, gypsum, chalk, cement, clinker, clay, pozzolan.
Woodchips, wood pellets, straw pellets, bark chips, paper pulp, sewage sludge, wood waste,
saw dust, biomass, garbage, dried sewage, substitute fuel.
Coal, coal dust, lignite, tailings, muck.
Bauxite ore, bauxite, alumina, petcoke.
Iron ore, sinter, chromite, slag sand, gold ore, copper concentrate, zinc and lead
concentrate, nickel,
Kieserite, dolomite, crushed hard rock, slate
Raw phosphate, phosphate, urea, fertilizer, sulphur,
Plastic granulate,
For almost all bulk materials Long reference list capacity up to 8000 T/H length up to 8200 M built diameter up to 650 mm built
Strength
7
No spillage on return sector of conveyor Simultaneous conveying in upper and
lower conveyor strand Optimal adaption to extreme field
conditions ddue to horizontal, vertical and 3-dimensional curves
Safe and technologically perfect adaption to existing industrial facilities
Special applications Maximum protection of the transported
material and the surrounding environment
Long distance transport Low space requirement 50 % higher inclination compared to
conventional conveying systems Safe downhill transportation with high
percent of slope
8
Pipe Conveyor References > 2300 m length
Client Country Pipe Ø mm
Length m
Capacity t/h Material Industry Year of
comm. Pingyuan China 350 2274 1000 clinker, coal 2004
Petrozuata Venezuela 500 2301 1500 petrol coke, sulfur port handling
1999
DMW - Shaw / Cleco USA 500 2458 1361 petrol coke, limestone
power 2008
JPMC Eshidia Mine Jordan 400 2834 1250 phosphate raw material
1995
SAIL - Bhilai, Chhattisgarh. India 200 2912 100 lime steel 2012
EVN AG - KW Dürnrohr Austria 300 3160 550 coal power 2010
Birla Copper, Dahej India 450 3200 1760 1540 1100
copper concentrate, rock phosphate,
coal
mining 1999
VINACOMIN Vietnam 350 3600 600 coal mining 2009
DMW - First Energy Sammis USA 300 3870 453 gypsum FGD power 2009
Penna Cement, Tandur, Andhra Pradesh
India 350 4050 1100 limestone cement 2012
Vedanta Alumina Ltd, Lanjigarh Orissa
India 400 4334 alumina fines alumina 2009
Taiyuan China 250 4350 200 limestone burnt steel 2006
NTPC - Vallur, Tamil Nadu India 650 4353 4000 coal power 2012
Vedanta Alumina Ltd., Lanjigarh Orissa
India 400 4875 1150 bauxite ore alumina 2007
Ausenco Services Pty Ltd Papua New Guinea
300 5420 800 gold ore mining 2009
Holcim Shurova Russia 350 6200 1400 limestone cement 2009
Cementos Lima Peru 300 8200 690 515
cement or clinker ; coal or limestone
cement 2008
9
Weaknesses
Sensitive to overfilling and oversize material
Higher power consumption
Higher investment costs.
11
Conveyor Belt
Main Components
Special edge structure
Fabric insert for curve-going ability
Rigidity to stabilize
All common properties available
Diam.(150) 200 to 650 (800) mm
Tensile strength up to 5000 N/mm
Different suppliers
EP or ST type possible
molded edge
carrying side
running side
ply: steel or fabric
12
Conveyor Pulleys
Bigger pulley diameter
Wider pulley face
The ceramic pulley lagging ensures a high coefficient of friction
13
Idlers
permanent lubrication
multiple labyrinth seal
Low friction factor
Exposed to rain water
Site conditions to consider
Usage of different bearings
Axial forces to consider
Gaps in placing possible
Drive Unit
14
Fluid couplings
Gear motors
Back stop devices
Creeping speed by additional gear motor
Forced lubrication can be required due to
lower speed, Forced cooling
Full torque required
Load distribution to reduce forces
Load combinations to consider
.
Bevel helical design reduces space
hollow shaft for low size
Bigger sized gear boxes connect by coupling
Multiple drives are possible
Intermediates drives are possible
VFD controlled, torque controlled
.
15
Drive Unit
At high speed side
At low speed side
Consider throttle valves
Controlled brake – torque over time ramp
With power back-up
For downhill applications
To manage full and empty conditions
Brakes
16
screw-type tail take-up
gravity tail take-up
gravity head take-up vertical
gravity head take-up horizontal
winch type take-up
Take-up systems
Cap stan brake to increases take-up
tension while braking
17
Take-up systems
Tower with drive unit and take-up
Take-up with controlled winch
18
Belt Cleaning System
19
integration in the standard cross
section
for weighing and control of the
transported material
Conventional scales possible in
transition area
Pipe Conveyor Belt Scale
Feeding area
20
Design of Pipe Conveyor
Skirt board
Width = 1,6 to 2 x PC diam.
Shorter length due to transition area
Variable idler stations necessary
Finger rollers to close the belt
21
Feeding spoon to accelerate material and avoid dust
22
Transport in upper strand
Transport in upper strand and lower strand
23
Intermediate feeding
24
Multiple feeding
25
Double Transport Patented “Pretzel”
26
Double Transport
27
Safety devices feeding area
Overfill Paddle at Skirtboard
Overfill Paddle to avoid Belt Overloading
28
Safety Flap Panel
flap panel opens automatically if the belt is
overfilled with either the product or with
foreign material
29
Conveyor is stopped when foreign material penetrates the belt
Mechanical Belt Rip Detection
Feeding Table
30
Electronical Belt Rip Detection
BELT RIP SCANNER
BELT
COMPUTER
COIL COIL COIL CHARGE CHARGE
~25
S1
~350S1
Loop marks
loop cords
PHOENIX-STEEL-CORD-BELT
with sensor loop
P H O E N I X
C-Sheet: CL Date: 06.05.97 Name:060597 labus
belt width
BELT WIDTH
LOOP MARKS LOOP CORDS
31
Discharging area
• Belt opens automatically at the discharge area
• After material discharge the belt is closed again
• Idler stations in front of discharge
pulley to prevent belt turnovers caused by belt twisting
How to design the PC
32
“PC inquiry data sheet” General data
Regarding Location
Climatic conditions
Material properties
General design data
Electric, control
Standards and regulations
Scope of supply; Interfaces
Time schedule
Etc.
No Data - no Offer
33
Diameter of Pipe Conveyor Consider lowest density for volumetric flow
Max. 50 to 75 % filling ratio, depend on lump size
Diameter = 3x max.lumps
Consider additional max. lump
Job NTPC outer diameter 685 mm Belt width 2400 mm belt thickness 22,4 mm neutrale layer 13,5 mm R0 336,5 mm R1 329,0 mm R2 314,1 mm R3 306,6 mm L1 12,9326 mm overlapping 63,0 ° cross section.100% 30,763 dm² Capacity 4000 t/h Density 0,8 t/m³ Volumetric flow 5000,00 m³/h Velocity 6,00 m/s Reduction due Curve 80% % Cross section 0,23148 dm² Filling ratio 75,2% % Straight Filling ratio 94,1% % Curve
PC is very specific
No standards in Europe
Free to offer acc. Own standards
Safety to consider
CEMA 6`th – design recommendations
34
Recommendations done by “CEMA 6th edition” to give thumb values
PC is very sensitive against overfilling due to oversized lumps.
For critical material measurements have to be taken – crusher, screen
35
Maximal transport capacity of Pipe Conveyors
Coal Iron ore
Density [t/m³] 0,8 2,4
Density [lb/ft³] 50 150
Diam Pipe Conveyor Velocity Capacity Capacity Capacity
in mm in inch in m/s in ft/min in m³/h in
ft³/min in t/h in t/h
150 6 2,1 421 94 55 75 224 200 8 2,1 421 165 97 132 396 250 10 3,0 594 366 215 292 877 300 12 3,0 594 520 306 416 1248 350 14 3,0 594 716 421 573 1718 400 16 3,7 722 1131 665 904 2713 450 18 3,7 722 1430 841 1144 3432 500 20 3,7 722 1761 1036 1409 4227 550 22 4,5 890 2630 1547 2104 6312 600 24 4,5 890 3152 1854 2521 7564 650 26 4,5 890 3675 2162 2940 8820 700 28 5,4 1065 5103 3002 4083 12248
To be competitive –
Low diameter and high velocity
Attention to be paid to
Lump size
Pre-acceleration of material
36
Recommendations done by “CEMA 6th edition” to give thumb values
Power consumption and Belt Type
37
Capacity
Density
Grain size
Velocity
angle of deviation
PC diameter
Panel distance
Idler diameter
Pulley diameter
Temperature / F-value
Number Transition areas
Wrap angle pulley
Friction factor
Drive power head/tail
Time start/stop
Take-up force
Belt data
Strength/weight
PC calculation P r o j e c t Number : K2.0395 dazugehörige Z e i c h n u n g: Route A-I_in Arbeit_RevB für Berechnung Datum 05.09.2011
C l i e n t :
Ausenco PNG Papa New Guinea Morobe Hidden Valley 07MP092
0 stph 1 pcf 0,000 m3/h 0,000 t/h 16,018 kg/m3
173,91304 10434,78 cfph 615,4 m³ / h Gold ore resistance factor in curves 0,03075 Fc
Conveying Capacity : 1300 kg/m³ ====> ergibt 800,0 t/h am OG resistance factor : 0,02446 Fw
bulk density : 100 mm 0 t/h am UG additional resistance length 36,08 m lo
grain size : 4,00 m/sec ====> erf. Pipe∅ 319,2 Pipe shape keeping force : 10297 N F1
conveying speed-v : 90 necessary min. radius R 289 m Pipe shape force total : 2502 N F2
max. angle deviation in° : 300 effective filling rate in % 92,1 4 curve resistance total : 207515 N F3
selected PipeØ : 1200 mm
calculation area 66% vom Nenn- durchmesser curve resistance total empty : 207515 N LF3
belt width : 1,80 m
chosen Panel dist. 1,50 m motor power empty operation : 1390,04 kW N1
max distance betw. Idlers : 1,50 m
chosen Panel dist.Curve 1,50 m necessary motor power hor. : 284,40 kW N2
idlerØ / length : 133,0 mm /
290 mm Gew. 4,31 kg necessary motor power vert. : -772,70 kW N3
idler speed : 574,4 UpM =OK min. Anzahl 43080 Quantity 28,92
Panel: height / width : 1252 mm / 626 mm Anzahl 3588 Quantity C1 = 63598 N R1= 63598 N
drive pulley Ø min. : 800 mm Pulley diam ∅ = 1030 mm C2 = -191063 N R2= 0 N
drive pulley speed : 74,2 UpM inkl. Reibb. C3 = -152406 N R3= 152406 N
D I S T A N C E L O A D S 1865 UpM Motor-rpm C4 = 5148 N R4= 5148 N
material 55,6 kg / m total load belt + rollers / m = w 99,0658 C5 = 834 N R5= 1668 N
belt per cord : 32,3 kg / m C6 beladen = 111386 N R6= 96129 N
rollers per cord : 17,2 kg / m C6 leer = 111386 N R6= 96129 N
ambient temperature : 30 ° C
T1= 265 kN T2= 113 kN
average friction value - 'f' : 0,02430 T4= 319 kN T3= 391 kN
amount belt closing upper belt : 1 Belt
T1= 326 kN T2= 113 kN
amount belt closing lower belt : 2 EP oder ST ST T4= 258 kN T3= 391 kN
material on return strand : 0,0 kg / m deflection angle in ° : 710,73
: input see system sketch
Part Sec length / m
+ / - height / m
incl
inat
ion
radius / m vertikal
o,u, so, su, sou a in ° radius / m horizontal α ιν °
+ / - height / m
horiz. resp vertical curve length / m
actual horiz. curve radius actual length in m
actual inclination in °
lifting height in m
1 67,40 0,000 0,0 0,00 0,00 67,40 0,00 0,00
2 0,000 0,0 300,00 u 9,13 0,00 47,80 0,00 47,80 -9,13 -3,80
3 0,000 -9,1 320,00 5,04 -4,52 28,15 324,11 28,51 -9,13 -8,32
4 155,80 -25,039 -9,1 0,00 0,00 0,00 157,80 -9,13 -33,36
5 0,000 300,00 suu 22,86 0,00 119,69 0,00 119,69 13,73 -28,59
6 0,000 300,00 sou 11,06 0,00 57,91 0,00 57,91 2,67 -20,34
47 0,000 300,00 sou 2,19 0,00 11,47 0,00 11,47 3,00 -370,80
48 0,000 3,0 230,00 8,37 1,76 33,60 230,32 33,65 3,00 -369,04
49 0,000 3,0 260,00 25,47 6,06 115,58 260,36 115,74 3,00 -362,98
50 196,68 8,515 2,5 0,00 0,00 0,00 196,86 2,48 -354,47 0
total length : 5399,20 m horizontale Länge ====> 5332,79
conveying height : -354,47 m
average inclination : -3,80 ° Power inclined loaded 2051 kW
max. height : -481,03 m Art des Anlaufes ==> h Power declined loaded 487 kW
theor. drive power empty : 1.390,1 kW 1387,0 h = sanft
theor. drive power full : 901,8 kW 896,7 s = starr
mech. efficience : 0,9000
min. nec. drive power : 1002,0 kW 996,4 1544,5556 leer 2520 kW bei +30° C
installed drive power : 2520,0 kW = Head kW Tail kW
1260 1260
friction factor Belt/Drive pulley : 0,55 <<=== ========= 0,10-0,15= plain and wet å kW 0
wrap angle : 200 ° 197,1 0,30-0,40= checkered rubber but dirty
calculated by : Dr. Wiedenroth 0,45-0,60= checkered rubber dirty until dry
38
P r o j e c t Number : K2.0395 dazugehörige Z e i c h n u n g: Route A-I_in Arbeit_RevB für Berechnung
Datum 05.09.2011
C l i e n t : Ausenco 0 stph 1 pcf 0,000 m3/h 0,000 t/h 16,018 kg/m3 173,91304 10434,78 cfph 615,4 m³ / h Gold ore resistance factor in curves 0,03075 Fc Conveying Capacity : 1300 kg/m³ ====> ergibt 800,0 t/h am OG resistance factor : 0,02446 Fw bulk density : 100 mm 0 t/h am UG additional resistance length 36,08 m lo
grain size : 4,00 m/sec ====> erf. Pipe∅ 319,2 Pipe shape keeping force : 10297 N F1
conveying speed-v : 90 necessary min. radius R 289 m Pipe shape force total : 2502 N F2 max. angle deviation in° : 300 effective filling rate in % 92,1 4 curve resistance total : 207515 N F3
selected PipeØ : 1200 mm
calculation area 66% vom Nenn- durchmesser
curve resistance total empty : 207515 N LF3
belt width : 1,80 m chosen Panel dist. 1,50 m motor power empty operation : 1390,04 kW N1
max distance betw. Idlers : 1,50 m chosen Panel dist.Curve 1,50 m necessary motor power
hor. : 284,40 kW N2
idlerØ / length : 133,0 mm / 290 mm Gew. 4,31 kg necessary motor power vert. : -772,70 kW N3
idler speed : 574,4 UpM =OK min. Anzahl 43080 Quantity 28,92 Panel: height / width : 1252 mm / 626 mm Anzahl 3588 Quantity C1 = 63598 N R1= 63598 N drive pulley Ø min. : 800 mm Pulley diam ∅ = 1030 mm C2 = -191063 N R2= 0 N
drive pulley speed : 74,2 UpM inkl. Reibb. C3 = -152406 N R3= 152406 N
D I S T A N C E L O A D S 1865 UpM Motor-rpm C4 = 5148 N R4= 5148 N
material 55,6 kg / m total load belt + rollers / m = w 99,0658 C5 = 834 N R5= 1668 N
belt per cord : 32,3 kg / m C6 beladen = 111386 N R6= 96129 N
rollers per cord : 17,2 kg / m C6 leer = 111386 N R6= 96129 N
ambient temperature : 30 ° C
T1= 265 kN T2= 113 kN
average friction value - 'f' : 0,02430 T4= 319 kN T3= 391 kN
amount belt closing upper belt : 1 Belt
T1= 326 kN T2= 113 kN
amount belt closing lower belt : 2 EP oder ST ST T4= 258 kN T3= 391 kN
material on return strand : 0,0 kg / m deflection angle in ° : 710,73
39
-600
-500
-400
-300
-200
-100
0 0 1000 2000 3000 4000 5000 6000
Rel
ativ
e he
ight
in m
Distance from the feeding point in m
Height profile
Local peaks in belt tension
Different loading cases – tension and power consumption vary
40
: input see system sketch
Part Sec length / m
+ / - height / m in
clin
atio
n
radius / m vertikal
o,u, so, su, sou a in °
radius / m horizontal α ιν °
+ / - height / m
horiz. resp vertical curve
length / m
actual horiz. curve radius
actual length in
m
actual inclination
in °
lifting height in
m 1 67,40 0,000 0,0 0,00 0,00 67,40 0,00 0,00 2 0,000 0,0 300,00 u 9,13 0,00 47,80 0,00 47,80 -9,13 -3,80 3 0,000 -9,1 320,00 5,04 -4,52 28,15 324,11 28,51 -9,13 -8,32 4 155,80 -25,039 -9,1 0,00 0,00 0,00 157,80 -9,13 -33,36 5 0,000 300,00 suu 22,86 0,00 119,69 0,00 119,69 13,73 -28,59 6 0,000 300,00 sou 11,06 0,00 57,91 0,00 57,91 2,67 -20,34
47 0,000 300,00 sou 2,19 0,00 11,47 0,00 11,47 3,00 -370,80 48 0,000 3,0 230,00 8,37 1,76 33,60 230,32 33,65 3,00 -369,04 49 0,000 3,0 260,00 25,47 6,06 115,58 260,36 115,74 3,00 -362,98 50 196,68 8,515 2,5 0,00 0,00 0,00 196,86 2,48 -354,47
0 total length : 5399,20 m horizontale Länge ====> 5332,79 conveying height : -354,47 m average inclination : -3,80 ° Power inclined loaded 2501 kW max. height : -481,03 m Art des Anlaufes ==> h Power declined loaded 487 kW theor. drive power empty : 1.390,1 kW 1387,0 h = sanft theor. drive power full : 901,8 kW 896,7 s = starr mech. efficience : 0,9000 min. nec. drive power : 1002,0 kW 996,4 1544,5556 leer 2520 kW bei +30° C installed drive power : 2520,0 kW = Head kW Tail kW 1260 1260 friction factor Belt/Drive pulley : 0,55 <<=== ========
= 0,10-0,15= plain and wet å kW 0
wrap angle : 200 ° 197,1 0,30-0,40= checkered rubber but dirty calculated by : Dr. Wiedenroth 0,45-0,60= checkered rubber dirty until dry
41
0
50
100
150
200
250
300
350
400
450
500
0 1000 2000 3000 4000 5000 6000
Bel
ttens
ion
in k
N
Distance from the feeding point in m
Belt tension steady operation
Upper Strand loaded Lower Strand loaded Upper Strand empty Lower Strand empty
Drops in belt tension to be considered
42
Belt Tension and Elongation for Curved Sections
Compression of the belt - buckling
43
Dynamical Analyses
Identifies belt tension at various points along the conveyor over short time increments during acceleration and stopping.
Belt Tension [N]
Belt Speed [m/s]
44
Pipe Conveyor Geometry
Routing
Thumb values are
Fabric belt: 300 x PC diam = curve radius
Steel cord belt: 600 x PC diam = curve radius
Avoid compound curves
Consider min. radii
Inclination/declination approx 30°
Follow Ground profile
Eaquel gantries / Structure
Eaquel Trestles
Smooth routing
Top View
Side Elevation
45
RECOMENDED MINIMAL RADII FOR CURVES
Belt Carcasse Diameter „d“ Curve radius „R“
in mm < 25° 25° bis 50° 50° bis 75° 75° bis 100°
Nylon (PP) 150 – 300 300 d 400 d 500 d 600 d
350 – 500 400 d 500 d 600 d 700 d
Polyester Nylon (EP)
150 – 300 400 d 500 d 600 d 700 d
350 – 500 500 d 600 d 700 d 800 d
Aramid (D) 150 – 300 500 d 600 d 700 d 800 d
350 – 500 600 d 700 d 800 d 900 d
Steel cord (St)
150 – 300 700 d 800 d 900 d 1000 d
350 - 500 800 d 900 d 1000 d 1100 d
46
Inclination up to 30°
47
Conveyor Routing
Smooth conveyor line Following ground elevation Optimization of steel consumption and abilities of PC
48
Road crossing Smooth design required Causes instability
49
X
X Y Z
Eaquel gantries / Structure Eaquel Trestles
50
Head end
Tail end
51
3-D-MODEL TOPOGRAPHIE PIPE CONVEYOR
52
Optimiziation of gantries and trestles
53
Optimiziation of gantries and trestles
54
Optimiziation of gantries and trestles
55
Optimiziation of gantries and trestles
56
Optimiziation of gantries and trestles
57
Optimiziation of gantries and trestles
Pipe Conveyor Manual
58
Internal PC Standards
Design rules
Standard Dimensions
Standard Components
59
Conveyor structure
Light structure suspended
Light structure On sleepers
60
Light structure L-pofile panels
Light structure Plate panels
61
Light modules onto supporting structure
Light gantry
62
Standard gantries
63
Standard gantries
64
Conveyor inside Galleries
65
Triangular Galleries
66
Triangular Galleries
67
Special application
68
Supports
portal support
1-leg support steel
1-leg support concrete
A-support
69
Optimized trestle design
X
Y Z
Transition Area
70
Thumb values are
Fabric belt: length = 30 x PC diam
Steel cord belt: length = 60 x PC diam
Has to be straight
Declined for critical materials
71
If blockages can occurs Number of Panels according stopping way Section has to be straight
Safety Flap Panels
72
Belt Turn-over
73
Belt Turn-over
3
2
the unguided turn-over
the Mordstein Type with supports guiding
the belt over the length of the turn-over
section
the guided type by vertical middle roller
74
Walkways
Walkway at one side <350 mm PC Diam. Walkway loads 150 kg/m² respectively 300 kg single load are preferred.
75
Safety covers
Plates
Meshes
Roof cover
76
Trolley Limited Access Max. Inclination 12°
77
Miscellaneous
Cold climate conditions
Conglomeration of material
Blockage of Pipe Conveyor
Freezing of Material inside Closed Belt
High Power consumption
Construction, commissioning
Time consuming belt pulling
Adjustment of rollers
Adjustment of Belt
Noise emission
More idlers – more noise emission
Values up to 88 db(A) sound pressure
78
Alignment Of Pipe Conveyor Belt
The above sketch shows an overlapping located too far left. Correction has to be carried out by adjusting the carrying idler (as shown). The selection of idler(s) to be adjusted depends on the local line and the pressing of the belt on each idler. *Note: numbers in brackets refer to the lower strand