a project report ggg

8/17/2019 A Project Report Ggg

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1. INTRODUCTION

DEFINITION

Belt Conveyor is mechanical conveying equipment to convey the bulk materials like lime

stone, coal, Stones, bauxite...etc from one place to another. Belt conveyor consists of

accessories like Head Pulley, ail Pulley !ith supporting idlers for carrying " return side of

the belt " connected to motor " gear box !ith required speed to convey the material. #ith the

design of special belts this can convey hot materials as foundry shakeout sand, coke, sinter and

iron ore pellets...etc

FIELD OF APPLICATION

Belt conveyors are the most commonly used because they are the most versatile and the cost

expensive and affordable means of conveying. hese are used in hermal po!er plant to

handle Coal " coke material, Cement plant to handle lime stone " gypsum, Steel plant to

handle iron ore " sponge iron pellets

TECHNICAL DATA

#e are involved in one of ongoing pro$ect !ith bevcon !ayors %p& 'td ( Hyderabad for designing a belt conveyor for handling lime stone " coal in simultaneously. he capacity of the

belt conveyor as per pro$ect is )*+ PH % ons per Hour&

his conveyor design involves the study of layout, material characteristics, relevant data of

existing designs " site visits.

OBJECTIVE

he main ob$ective is to design a belt conveyor using empirical formulas as per industry "

ndian Standards. Preparing dra!ings of conveyor using -utoC- " critical components are

modeled in Pro(e !here ever required and manufacture of prototype model of belt conveyor by

scaling do!n the designed conveyor for conceptual presentation

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SCOPE OF PROJECT

/nderstanding the types of conveying systemsConveying of variety of materials " its applicationsConveyor selection criteria

esign methods and standardsesigning a belt conveyor for handling lime stone of )*+ PH

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2. CONVEYING METHODOLOGY

n an industrial application to convey the material % ra! material & from one place to another

place by means of conveying

here are different types of conveying methods available based on the material characterstics

" type of handling. Belt conveyors are most accepted technology to convey the material in

large capacities perticularly for bulk material handling industries like Po!er, Steel, Chemical,

0lass, -gro, 1ood 2etc

ifferent type of conveyors are available some of them are

BELT CONVEYOR

SCREW CONVEYOR( SLURRY CONVEYING &

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BUCKET ELEVATOR ( VERTICAL CONVEYING)

ROLLER CONVEYOR( BOTTLES & BOX HANDLING)

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LONG DISTANCE CONVEYOR

POCKET CONVEYORS

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PIPE CONVEYOR

SANDWICH

CONVEYOR

INPLANT

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BULK HANDLING

. FUNCTIONAL DESCRIPTION & ANATOMY OF

CONVEYOR

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- troughed belt conveyor comprises an endless, rubberi3ed flat belt %a& suspended bet!een

pulleys at either end and supported along its length by a number of rotating idler rollers %b&.

he belt is driven via one of the pulleys %usually the head pulley %c&& and the tension in the belt

is maintained by using a sliding pulley %d& !hich is tied to a gravity take(up unit %e&.

1ig 1unctional escription

he material %f& is loaded onto the conveyor at the tail(end via a chute %g& and is transported

along the carrying(side %h& to the head(end !here it discharges into a discharge chute %i& !hich

guides the product onto the do!nstream equipment.

mpact idlers %$& are located at the loading point to support the belt !here the load impacts onto

the belt as it is dropped do!n the loading chute.

4nce the material has been discharged from the carrying belt, the return belt %k& is guided back

to the tail pulley on return idlers %l&.

he impact, carrying and return idlers are spaced at different intervals. 4n the carrying(side,

the mass of the belt plus the load conveyed is greater than the mass to be supported on the

return(side and thus, for the tension in the conveyor belt %by the take(up and induced by the

drive unit&, the idler spacing is selected accordingly. his 5sag5 in the belt bet!een the carrying

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and return idler sets must therefore be designed on the basis of the heaviest load that the

conveyor is to transport.

Snub pulleys %m& are sometimes incorporated into the design of a conveyor in order to increase

the angle of !rap %n& of the belt on the drive pulley. he greater !rap angle on the pulley

allo!s more po!er to be introduced into the belt as is passes around the drive pulley !ithout

slip occurring. n this !ay, fe!er drives are needed on longer conveyors or conveyors !ith

high conveying loads.

.1 ANATOMY OF A BELT CONVEYOR

1ig6-natomy of belt conveyor

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.1.1. BELTING

Conveyor belting is the primary component used to hold, contain and support the load

being transported along a belt conveyor.

here are t!o basic categories into !hich all troughed conveyor belting falls namely,

1abric Belting and Steel Cord Belting. 7xternally both types of belt appear to be identical

ho!ever8 the

n both fabric and steel cord belts, the carcass is covered by rubberi3ed covers to protect

the carcass or cables.

#hen the belt is installed into a conveyor structure, it is supported by means of idlers onthe carrying and return strands as indicated in the graphic.

he t!o 5side5 or 5!ing5 idlers are set at an angle of bet!een )* and 9* degrees to the

hori3ontal. he result is that the belt forms a distinctive 5trough5 into !hich the material is

deposited and hence the term 5troughed belt conveyor5.

1ig6Belting

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1ig6 dlers

.1.2. LOAD SKIRTS

o retain the material on the belt(after it leaves the loading chute and until it reaches belt

speed(skirt boards are necessary. hese skirt boards usually are an extension of the sides of the

loading chute and extend parallel to one another for some distance along the conveyor belt. he

skirt boards normally are made of metal, although !ood sometimes is used. he lo!er edges of

the skirt boards are positioned some distance above the belt. he gap bet!een the skirt board

bottom edge and the belt surface is sealed by a rectangular rubber strip, attached or clamped to

the exterior of the skirt boards.

1ig6'oad skirts

!. FEED CHUTE & DISCHARGE CHUTE

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1eed and discharge chutes enable material to be loaded and emptied from conveyor belts. he

design and layout of chutes is therefore extremely important to ensure that material is placed

on to the belt at the correct position, that unnecessary degradation of material is prevented and

that dust and spillage are contained.

1ig61eed chute and ischarge chute

!.1 FLOORING

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nvariably conveyors require access platforms and !alk!ays to enable operators and

maintenance personnel to gain access to the various components on a conveyor.

Primarily there are four types of flooring !hich can be used, depending on the particular

application and it is important that the designer understands the merits and demerits of each

type of flooring.

1ig61looring

!.2 THE BASIC FUNCTIONS OF INDUSTRIAL FLOORING ARE

). t must support any given applied or superimposed load % e.g storage of stock or

equipment or human traffic&

:. t must provide safe access routes for people and moveable equipment.

;. ts design should be such that it does not facilitate the collection of dust, dirt and

fluids.

9. ts design should be such that it prevents the slipping, sliding or skidding of feet.

*. ts design should be such that it is aesthetically pleasing

!.2.1 I"#$%

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1ig6 dlers set

dlers are used on a belt conveyor to support the belt on the carrying and return

strands. Carrying idlers also support the load in transit along the conveyor.

!.2.2 TYPES AND FUNCTIONS OF IDLERS

t has been stated above that there are basically t!o types of idlers namely, carrying and

return idlers. #ithin these categories ho!ever, there are a number of different designs of idler

sets !hich have developed as a result of particular applications, the need to minimi3e the stress

imposed onto the belt and the environment in !hich the conveyor operates.

hese different types of idlers are described belo!, together !ith a functional explanation

for each.

CARRYING IDLER SETS

hese idler sets support the carrying(side %top& conveyor belt onto !hich the material is loaded

and transported.

RETURN IDLER SETS

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hese idler sets support the return(side %bottom& conveyor belt !hich returns to the tail pulley

after having discharged product over the head pulley.

!.2. TROUGHING IDLER SETS

roughing idlers are found on the carrying(side, along the length of the conveyor. 4n any

particular conveyor these idlers are identical, as are the bases.

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!.2.! TRANSITION IDLER SETS

ransition idlers are found at either end of the conveyor, ad$acent to the head and tail

pulleys.

hese idler sets comprise standard idler rolls ho!ever the bases into !hich these rolls

are fitted, have a smaller roughing angle to that of the rest of the roughing idlers on the

conveyor.

he reason for this is that the conveyor belt is flat as it passes over the pulleys, under

high tension. -s the belt changes its5 form to a full trough of say ;* degrees %i.e. from tail

pulley to full trough angle&, the belt must be supported through this transition 3one. f the belt

!as fed directly into a full trough from the tail pulley, the belt edges !ould be over(stressed

and damage !ould result. Similarly, as the troughed angle changes to 3ero at the head( end, transition idlers provide

support through the transition 3one.

he number of transition idlers depends on the trough angle of the conveyor. n the case of a

9* degree trough angle, : or ; transition idler sets !ould be used at either end of the conveyor.

hese idler sets !ould have incrementally greater trough angles of say )*,

1ig6 ransition dler Sets

:+ and ;* degrees through the transition 3one leading up to 9* degrees.-s !ith troughing

idlers, transition idlers are available in fixed bases or the garland configuration.

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!.2.' IMPACT IDLER SETS

#herever material is loaded onto a conveyor belt, impact idlers are installed beneath

the troughed belt over the full loading length.

mpact idlers sets are spaced at intervals of typically ;*+ mm to 9*+ mm in order to

provide a comprehensive support base for the belt.

mpact idlers comprise a small diameter shell, typically 5d5 > ?@ mm diameter, fitted

!ith concentric rubberi3ed rings at close intervals. hese rubber rings provide a cushioning

effect in the event of lumps of material falling onto the belt !here an idler is located beneath

the point of impact. he overall impact idler diameter 5 5 > )*: mm

1ig6 impact idler

his cushioning ability of impact idler sets allo!s the energy associated !ith the impact to be

absorbed more efficiently and !ith much less detrimental effect to the belt.

mpact idler rolls are either mounted into rigid, fixed base frames or can be manufactured in

garland(type sets, depending on the application.

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1ig6fixed base frames

!.2. RETURN IDLERS

he mass of the return belt is the only load that return idlers are required to support. -s

such, return idler sets are spaced at t!o to three times the pitch of their equivalent carrying(side

idler sets.


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1ig6 1lat return idler

#here return idler sets comprise t!o rolls, a support frame is required !hich supports

the idler pair and attaches the idlers to the conveyor frame. his :(roll design forms the return

belt into a 5v5 trough and these return idler sets are referred to a 5A5 return idlers.

he trough angle of the 5A5 return idler is usually )+ degrees and this feature has been

developed to assist !ith belt training along the return strand.

here are a number of different types of training idler designs available in the market

!hich can be used on the carrying and return strands of the conveyor.

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1ig6 roughing dler,


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he improvements and range of designs and features of fluid couplings available to the

engineer has been driven by the need to improve the startup characteristics of a conveyor and

to increase the efficiency and reliability of fluid couplings in general.

1ig 1luid coupling and 0ear Box

'.2 REDUCERS * GEARBOXES

D$+,-, ,/-

- simple definition of the purpose of a gearbox may be stated as6

- 0earbox is a unit !hich receives the 0%, %3 ,-04 0$$" 5 "%,6,-7 0$$" source and

alters it to a ",++$%$- /4 04 0$$" 5 "%,6$- 0$$" source using a series of gears.

#hen a gearbox alters the driving speed, it is said to create a 8 $9: -,9 # "6 - 7$8

hus the fundamental purpose of a gear drive is to transmit uniform motion bet!een t!o shafts

at a constant ratio.

he basic la! of gearing states that to achieve this, the common normal to the tooth profiles atall points must pass through a fixed point called the 8 P, 9: P/,- 8

T:$ 6 %,/4 30$ /+ 7$ % : %$ 4 $" %$

S04% ( he axes of the shafts connected by the gears are P-


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B$6$# ( he axes of the shafts = 7


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1ig6 Hori3ontal rigid coupling

- coupling is a device used to connect t!o shafts together at their ends for the purposeof transmitting po!er. Couplings do not normally allo! disconnection of shafts during

operation, ho!ever there are torque limiting couplings !hich can slip or disconnect !hen some

torque limit is exceeded.

he primary purpose of couplings is to $oin t!o pieces of rotating equipment !hile

permitting some degree of misalignment or end movement or both. By careful selection,

installation and maintenance of couplings, substantial savings can be made in reduced

maintenance costs and do!ntime.

. PULLEYS

Pulleys are used on conveyors to support and deflect the belting through theconveyorstructure.

Pulleys also provide a mechanism !hereby the conveyor belt can be trained to run

%track& true along the conveyor idlers.

he follo!ing graphic indicates the location of pulleys on a conveyor.

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1ig6'ocation of pulleys

0enerally, pulleys are located at the ends of the conveyor structure and at the take(uparrangement. Pulleys are used to transmit the drive po!er into the conveyor belt and as such,

are sub$ected to the dynamic belt tension forces in a conveyor.

here are a number of different types of pulleys available for use on conveyors as !ell as

different design parameters for pulleys serving different functions on the same conveyor.

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1ig6 ypes of pulleys

.1 BEARINGS

-s far as conveyors are concerned, bearings are used in idlers, reducers, motors and on pulley

shafts. here are numerous types of bearings !hich have been developed for specific purposes

and designed to operate in different operating environment.

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1ig6 Bearings

.2. PLUMMER BLOCK

Plummer block housings usually have no provision for re(lubrication since used grease can be

easily replaced once the housing cap has been removed.

f shorter re(lubrication intervals are required a hole may be drilled and tapped to take a grease

nipple or supply line.

Plummer blocks are designed for use !ith self(aligning ball bearings and spherical roller

bearings !here the bearing either has a tapered bore and be mounted on an adapter sleeve, or

the bearing has a cylindrical bore.

7longated bolt holes are provided in the plummer block housing base to permit slight

ad$ustments to be made to the position of the plummer block during mounting.

ost housings are fitted !ith do!el pins to ensure correct location of the associated caps and

bases, !hich are not interchangeable.

Plummer blocks are designed to accommodate loads acting at right angles to the base. f the

direction of load is not perpendicular to the base, care should be taken to see that the housing,cap bolts and holding do!n bolts have sufficient strength to carry the loads involved.

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1ig6 Plummer Block

. . SCRAPER

P%, %3 ;$# 9% 0$%

1ig6 Primary scraper

Primary scrapers are installed at the head pulley and are the 5first5 or primary scraper to

remove residual material.Primary scrapers can comprise a single, continuous blade along the

!idth of the belt, or a series of short 5multiple5 blades !hich cover the belt !idth.

.! BELT PLOUGHS

Ploughs are employed on flat return belts to remove any material !hich may have fallen onto

the 5top5 of the return belt, before the material is trapped bet!een the belt and the tail pulley.

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Should lumps of material enter the tail pulley, they can cause damage to the belt, to the pulley

lagging and, if the material is allo!ed to build up on the pulley, can result in misalignment of

the belt during operation.


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i Short plant conveyors ( hori3ontal, inclined or declined.

ii 'ong overland conveyors ( straight or curved.

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1ig6 Belt Coveyor -pplications

roughed belt conveyors are used extensively throughout the bulk materials handling industry

and examples of applications !here this type of conveyor is commonly used are listed belo!

%click thumbnail for images& 6(


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;.G x 'oad Cross Section -rea %m : & x Belt Speed %mIs& x aterial ensity %kgIm ; &

2222 %:.)&

% perpendicular to the belt&


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S4%9: %7$

-7#$

I"#$% %/47:,-7 -7#$2 2' ' !'

'

1

1'

2

2'

+.9;

+.*:

+.G)

+.K+

+.K@

+.??

+.*;

+.G)

+.K+

+.K?

+.?K

+.@G

+.G)

+.G@

+.KK

+.?G

+.@9

).+;

+.G@

+.KK

+.?9

+.@:

).++

).+?

+.?)

+.??

+.@9

).+9

).+?

).)*

TABLE 2

COSINES

B$#

," :

S4%9: %7$ -7#$

' 1 1' 2 2'

1!

1'

1

?K+ @;+ @@+ )+*+ )))+

@@+ )+G+ ));+ ):++ ):K+

)):+ ):++ ):?+ );G+ )99+

1

2

22

)9)+ )*)+ )G++ )K++ )?)+

)K;+ )?*+ )@K+ :+@+ :::+

:);+ ;G++ :9;+ :*?+ :K;+

34

I-9#,- ,/- -7#$ ' 1 1' 1


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2!

2

2

:*?+ :K*+ :@;+ ;))+ ;:@+

;+G+ ;:K+ ;9?+ ;G@+ ;@)+

;*@+ ;?;+ 9+?+ 9;:+ 9*?+

B$#

," :

S4%9: %7$ -7#$

' 1 1' 2 2'

1!

1'

1

@++ @*+ )+)+ )+G+ )):+

)+:+ )+@+ ))*+ )::+ ):?+

))G+ ):;+ );++ );?+ )9*+

1

2

22

)9G+ )**+ )G9+ )K;+ )?:+

)K@+ )@++ :+)+ :):+ ::9+

::)+ ;G++ :9K+ :G)+ :K*+

2!

2

2

:GG+ :?:+ :@@+ ;)*+ ;;:+

;)K+ ;;*+ ;*9+ ;K9+ ;@9+

;K)+ ;@;+ 9)*+ 9;?+ 9G)+

=4 76 there is a !orld !ide tendency to use increased belt speeds !herever possible. for

example, bro!n coal is handled at speeds over K.* mIs and in australia, iron ore at speeds

over * mIs. such higher speeds and those sho!n under run(of (mine coal, crushed coal and

earth in the above table demand special attention to the design and maintenance of loading,

transfer and discharge point.

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. PROPERTIES OF MATERIALS

ypical densities, angles of repose and surcharge angles for various materials are sho!n in

able K belo!.

he angle of repose of material is also kno!n as the angle of natural friction is the angle at

!hich material , !hen heaped freely onto a hori3ontal surface takes up to the hori3ontal

plane.

1ig6-ngle of


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1ig6-ngle of Surcharge

1or many materials these factors are sub$ect to considerable variation, depending on the

moisture content, lump si3e, cohesive properties, etc. /nless other!ise stated, the ables

refer to dry !eight conditions, based usully on broken materials in si3es most commonly

found in conveyor systems.

he physical characteristics of the material affect the operating parameters of the belt in

other !ays, for example, typical belt speeds, recommended maximum lump si3es,

maximum slope if the belt is inclined, etc,.


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. DESIGN CONSIDERATIONS AND CALCULATIONS

R$@4,%$ $- , / "$ ,7- B$# C/-6$3/% A" 4 ;#$ I"#$% +/% 9 %%3,-7

7% 6$# /+ 1 TPH ;$ $$- 2 ", -9$

CAPACITY CALCULATIONS OF BELT CONVEYOR

C> Capacity

> CS- of material on the belt %+.+:? mL:& for roughing -ngle

M > Bulk density of gravel%+.:*+ onnes I &

A> Aelocity of belt%mIs& )mIs

N> inclination factor %)&

C > :).GK: PH

!hich is more than required capacity. Hence the safety factor in capacity design is :.

iameter of dler

=>;@K.K@ rpm

1> 'oad on each roller

1>)+;.++* =

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b>%? 1 ' &I%; ;.)9) &

1 > 'oad of the material

'> 'ength of roller

> i a of roller

b>bending stress of each roller :K;.:?+ =ImmL:

.1 MANUFACTURING PROCESS OF ADJUSTABLE IDLER

STEPS INVOLVED

). - 0alvani3ed ron %0 & pipe !ith 4 9? is taken !ith ; thickness and cut to a length of

)*+mmand machined.

:. ndian standard rod % S :+G:& is taken for shaft and machined to required dimensions of ia

:+mm and end to end length of :)+ mm

;. !o ball bearings of :+mm,4 9:mm and !idth )*mm is taken and fitted on the shaft

rod.

9.- structure for dler is prepared !ith flats of S :+G: .

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CONCLUSIONS

-d$ustable dler !ith roller 4 9? and 'ength%face !idth& )*+mm is manufactured

!hich run at 9++rpm and can be used for medium capacity conveyors. he -d$ustable dler

can compensate for the tracking for the straight motion of the belt and keep the belt aligned in

operating conditions. his dler can also can compensate for the little heavy loads than the

conveyor is designed for by increasing the cross sectional area of the material on the belt. his

dler can be maintained properly as it is made of bolted connections. Ho!ever the bearings

have to be replaced after the standard rating conditions of bearing are reached.

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REFERENCES

http6II!!!.ckit.co.3a

DBelt ension heoryD CN O he Bulk aterials Handling Nno!ledge Base.


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