CBSPT University of Newcastle 1

Belt Conveying of Bulk Solids

\
|
E = o A c E = o A 1
t
L
L
or
t
t
L
L L
= c
|
.
|

\
|
+
E
o A
= 1
t
L L
( )
2 2 2
s L z h L
t
+ + =
| | = tan z cos y s
4
Belt Elastic Modulus, E
The elastic modulus of the belt depends on the composition of the
belt and will vary depending on the properties of the carcass and
cover materials used. This will be discussed in detail in the
dynamic analysis section.
Some manufacturers supply average belt modulus values for their
belts, such as APEX.
Reference: APEX Belting Conveyor Handbook, 2000.
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Belt Elastic Modulus, E
CEMA provides an approximation based on rated belt tension, but it
should be noted that these values are conservatively high.
Belt Modulus Data (Ref: CEMA)
Warp or Longitudinal
Reinforcement
E, Approximate Belt Modulus
Cotton 50 times allowable tension
Nylon 70 times allowable tension
Polyester 100 times allowable tension
Rayon 100 times allowable tension
Steel Cable 400 times allowable tension
6
Belt Elastic Modulus, E
APEX Elastic Moduli versus CEMA Approximations
395
CEMA Approx.
kN/m width/ply
440
861
1106
1470
N/A
1230
1050
1580
2100
2600
3100
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Conveyor Belt Transitions
Hence, the increase in belt stress at the outer edges is:
Where: E = Elastic modulus of the belt
Also,
Where,
and
|
|
.
|

\
|
E = o A c E = o A 1
t
L
L
or
t
t
L
L L
= c
|
.
|

\
|
+
E
o A
= 1
t
L L
( )
2 2 2
s L z h L
t
+ + =
| | = tan z cos y s
L
L
h
z
t
B
=
=
W
|
| h
z
W
x
y y
Top Of Discharge Drum
Troughing
Arrangement
8
Conveyor Belt Transitions
Therefore:
Since
Then
The transition length, L
t
must be chosen so as to limit the stress increment, Ao.
The following tables list values of L
t
as recommended by CEMA based on the
following geometry, where z = h/2 and z = h respectively.
( )
|
.
|

\
|
+
E
o A
E
o A
+
=
2
2 2
s z h
L
t
0
2
~ |
.
|

\
|
E
o A
( )
L
h z s
t
=
+
0 707
2 2
.
A
E
o
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9
CEMA - Conveyor Belt Transitions
TABLE 4 - TRANSITION LENGTH FOR z = h/2 (Ref: CEMA)
h
z
L
t
Idler
Angle |
% Rated Tension Lt - Fabric Belts Lt - Steel Cord
Belts
20
o
>90
60 - 90
<60
0.9 B
0.8 B
0.6 B
2.0 B
1.6 B
1.0 B
35
o
>90
60 - 90
<60
1.6 B
1.3 B
1.0 B
3.4 B
2.6 B
1.8 B
45
o
>90
60 - 90
<60
2.0 B
1.6 B
1.3 B
4.0 B
3.2 B
2.3 B
10
CEMA - Conveyor Belt Transitions
TABLE 4 - TRANSITION LENGTH FOR z = 0 (Ref: CEMA)
h
z
L
t
Idler
Angle |
% Rated Tension Lt - Fabric Belts Lt - Steel Cord
Belts
20
o
>90
60 - 90
<60
1.8 B
1.6 B
1.2 B
4.0 B
3.2 B
2.8 B
35
o
>90
60 - 90
<60
3.2 B
2.4 B
1.8 B
6.8 B
5.2 B
3.6 B
45
o
>90
60 - 90
<60
4.0 B
3.2 B
2.4 B
8.0 B
6.4 B
4.4 B
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APEX - Conveyor Belt Transitions
Transition Distances for Head Pulleys
12
APEX - Conveyor Belt Transitions
Transition Distances for Tail Pulleys
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13
Conveyor Belt Transitions
Additional Comments
As noted in the previous examples when the pulley is raised ie; z
= h/2 the transition distance can be roughly halved.
While this can be good practice at the head pulley it is not
recommended at the tail pulley.
Advantages Disadvantages
Shortens transition distance to avoid
obstructions.
Decreases conveyor belt length.
The belt often lifts off the idler rolls when
unloaded generating high belt wear from
contact with sealing skirts.
The belt line will vary with load
fluctuations making it difficult to
effectively seal the transfer point.
14
Vertical Curves
Soma Power Station - Turkey
8.5km - Coal
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As the belt passes through concave vertical curves it is necessary that
the distributed weight of the belt be sufficient to maintain belt contact
with the idlers. For conservative design, the centrifugal pressure of the
belt moving around the curve is neglected.
Concave Vertical Curve (Ref: A.W. Roberts)
Concave Vertical Curves

ds
R
T
T
i
o
C C1
u
|
|
d
v
u
dN T +dT
T
dm g
ds
| d
dN
r
|
|
Elemental Section of Belt
16
Belt Lift-Off
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From the equilibrium analysis: dN = dm g cos | - T d| (100)
dT = dm g sin | +
r
dN (101)
Hence; dT = dm g (sin | +
r
cos |) -
r
T d| (102)
Also, the elemental mass: dm = q ds = q R d| (103)
where q = q
b
+ q
m
= mass of belt per unit length (kg/m)
q
b
= mass of empty belt per unit length (kg/m)
q
m
= mass of load per unit length (kg/m)

r
= idler friction
Concave Vertical Curves

ds
R
T
T
i
o
C C1
u
|
|
d
v
u
dN T +dT
T
dm g
ds
| d
dN
r
|
|
Elemental Section of Belt
18
From the equilibrium analysis: dN = dm g cos | - T d| (100)
dT = dm g sin | +
r
dN (101)
Hence; dT = dm g (sin | +
r
cos |) -
r
T d| (102)
Also, the elemental mass: dm = q ds = q R d| (103)
where q = q
b
+ q
m
= mass of belt per unit length (kg/m)
q
b
= mass of empty belt per unit length (kg/m)
q
m
= mass of load per unit length (kg/m)

r
= idler friction
Equations (100) to (103) lead to the following differential equation:
(104)
It may be shown that the general solution of this equation is:
(105)
This equation may be used to calculate T = f(|,
r
,R)
Concave Vertical Curves
( ) | + | = +
|
cos sin qgR T
d
dT
r r
( ) | | | |
+
+
(

|
|
.
|

\
|
+

+ =
|
cos sin
qgR
e qgR T T
r r
r r
r
i
r
2
2 2
2
1 2
1 1
1
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Approximate Solution
Since
r
is very small ( 0.02), equations (100) and (101) become
(106)
and dT = q g R sin | d| (107)
From (107), by integration T = - q g R cos | + K
1
Noting that when | = 0, T = T
i
Then K
1
= T
i
+ q g R
Therefore T = T
i
+ q g R (1 - cos |) (108)
Substitute in (106) gives
Hence N = q g R ( 2 sin | - |) - T
i
| + K
2
When | = 0, N
i
= q g ds; hence K
2
= N
i
Therefore N = q g R ( 2 sin | - |) - T
i
| + N
i
(109)
Concave Vertical Curves
T cos qgR
d
dN
| =
|
( )
i
T cos qgR
d
dN
| =
|
1 2
20
Concave Vertical Curves

ds
R
T
T
i
o
C C1
u
|
|
d
v
u
dN T +dT
T
dm g
ds
| d
dN
r
|
|
Elemental Section of Belt
Given N = q g R ( 2 sin | - |) - T
i
| + N
i
(109 Repeated)
The limiting condition for belt contact on the curve occurs when the normal force N = 0. For conservative
design it is assumed that N
i
= 0. Hence the radius of curvature should be such that
Hence
(110)
When | = conveyor slope angle u, equation (110) may be written as
(111)
where (112)
qg
T K
R
i c
>
( ) | |
|

>
sin qg
T
R
i
2
( ) u u
u
=
sin
K
c
2
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Concave Vertical Curves
Plot of K
c
versus u
0.9
0.95
1
1.05
1.1
5 10 15 20 25
CONVEYOR SLOPE THETA (DEG.)
R
A
D
I
U
S

F
A
C
T
O
R


K
c
g q
T .
R
b
c
min

=
11 1
u
=
cos g q
T
R
b
c
min
CEMA gives the minimum value of R corresponding
to a maximum slope angle | = u = 25
o
. Based on this
value of u, equation (111) gives K
c
= 1.067, whereas
the corresponding value from CEMA is K
c
= 1.11.
qg
T K
R
i c
>
( ) u u
u
=
sin
K
c
2
(111)
Where (112)
u
=
cos
K
c
1
( ) u u
u
=
sin
K
c
2
DIN 22101 [2000] and Yokohama give:
22
As the belt passes through vertical curves it is necessary that the
distributed weight of the belt be sufficient to maintain belt contact
with the idlers.
The worst case condition occurs when the belt is loaded to point, c.
Note: The location of point, c is indeterminate until R
min
is known. However,
after determining R
min
initially, a second more exact value should be obtained.
T
1
u
c
d
u
Intersection of the two straight
portions of the conveyor path
L
c
L
x1
x
Loaded Section
x = R tan (u/2)
R
min
R
min
T
c
Concave Vertical Curves
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Concave Vertical Curves - CEMA
The minimum radius to prevent the belt lifting off the idlers with the belt
conveyor running is:
Two further conditions also need checking:
The first involves the tendency of the belt edges to buckle when the tension
in the belt is too low.
The second is the possibility that the tension in the centre of the belt may
exceed the allowable tension in the belt.
b
c
min
q g
T .
R

=
11 1
Where: 1.11 = constant based on a 25
o
incline to the horizontal
T
c
= belt tension at point, c when the belt is loaded from the
tail pulley to the start of the curve (N)
q
b
= mass of belt per unit length (kg/m)
24
Belt Buckling
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To prevent edge buckling:
For Fabric Belts:
For Steel Cord Belts:
Note: Since the above formulae are used to avoid zero tension in the belt
edges, T
c
should be calculated for the running empty belt.
( )
B T
p E B FactorA
R
c
min
5261
2

=
( )
( ) B T .
p E B FactorA
R
c
min
5261 5 2
2

=
Where: B = Belt width (m)
E = Modulus of elasticity of the conveyor belt (N/m/ply)
p = Number of plys in the belt
T
r
= Rated belt tension (N)
Concave Vertical Curves - CEMA
26
Belt Modulus Data (Repeated)
Longitudinal Reinforcement E, Approximate Belt Modulus
Cotton 50 times allowable tension
Nylon 70 times allowable tension
Polyester 100 times allowable tension
Rayon 100 times allowable tension
Steel Cable 400 times allowable tension
Trough Angle Factor A Factor B
20
o
0.0756 0.0384
35
o
0.1272 0.0636
45
o
0.1572 0.0780
Factors
Concave Vertical Curves - CEMA
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To prevent stressing the centre of the belt beyond the rated
tension:
Note: T
c
calculated when the belt is loaded from the tail pulley to
the start of the curve, as shown in the previous diagram.
( )
c r
min
T T
p E B FactorB
R

=
2
Where: B = Belt width (m)
E = Modulus of elasticity of the conveyor belt (N/m/ply)
p = Number of plys in the belt
T
r
= Rated belt tension (N)
Concave Vertical Curves - CEMA
28
Calculating the tension, T
ac
at point c, during acceleration
The effect of acceleration of the conveyor belt when starting from
rest must be considered, as the tension in the belt at point c will
increase over the running tension.
To prevent the belt from lifting off the idlers and the centre of the
belt from overstressing during acceleration at start-up, it is
necessary to calculate the acceleration forces and determine the belt
tension at point c.
b
ac
min
q g
T .
R

=
11 1
Concave Vertical Curves - CEMA
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Calculating the tension, T
ac
at point c, during acceleration
T
ac
= T
c
+ T
a
Where; T
ac
= Total tension at point c during acceleration
T
c
= Tension at point c during normal running
T
a
= Tension induced at point c by the belt
accelerating forces
Concave Vertical Curves - CEMA
30
Therefore;
Where; F
a
= Total accelerating force for conveyor loaded from tail to point c (N)
M
c
= Total mass to be accelerated by the belt at point c (kg)
M
t
= Total equivalent mass of all moving conveyor parts plus the loaded portion
of the tail to point c, excluding the drive and drive pulley. (kg)
M
c
= L q
b
+ L q
ru
+ L
c
q
ro
+ L
c
(q
b
+ q
m
) + M
pulleys
M
t
= M
c
+ (L L
c
) q
b
+ (L L
c
) q
ro
M
pulleys
= Equivalent mass of pulleys (kg)
L = Conveyor length, centre to centre (m)
q
ro
= Mass per unit length of idler rotating parts along carrying side of conveyor (kg/m)
q
ru
= Mass per unit length of idler rotating parts along return side of conveyor (kg/m)
q
b
= Mass per unit length of conveyor belt (kg/m)
|
|
.
|

\
|
=
t
c
a a
M
M
F T
Return side mass Carry side mass
T
1
u
c
d
u
Intersection of the two straight
portions of the conveyor path
L
c
L
x1
x
Loaded Section
x = R tan (u/2)
R
min
R
min
T
c
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Convex Vertical Curves - CEMA
In the case of convex curves gravitational forces tend to press the belt onto the
idlers and as such the idlers are more heavily loaded.
As the belt passes around the curve the belt edges being at a greater radius of
curvature are under higher stress than the centre of the belt.
Furthermore, if a convex curve is positioned in a low tension section of belt it is
possible that the centre of the belt may exhibit less than zero tensile load.
Like concave curves each of these conditions must be analysed and a minimum
radius of curvature determined.
T
1
u
c
Loaded Section
R
min
T
c
u
32
To prevent overstress of the belt edges:
T
c
is calculated when the belt is loaded from the tail pulley to the start of the
curve, as shown in the previous diagram.
To prevent buckling of the centre of the belt:
Since the above formula is used to avoid zero tension in the belt centre, T
c
should be calculated for the running empty belt.
Note: If this condition governs, then consider adding more counterweight
mass.
( )
c r
min
T T
p E B FactorC
R

=
2
( )
B T
p E B FactorD
R
c
min
5261
2

=
Convex Vertical Curves - CEMA
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Trough Angle Factor C Factor D
20
o
0.0756 0.0384
35
o
0.1272 0.0636
45
o
0.1572 0.0780
Factors
Convex Vertical Curves - CEMA
34
Resultant load on idlers through convex curves:
Carry and return side idler rolls should be spaced so the sum of the belt load, plus
material load, plus the radial resultant of belt tension does not exceed the load
capacity of the idler rolls.
T
1
u
R
T
c
u
F
r
|
.
|

\
| u
=
n
sin T F
c r
2
2
F
r
= Resultant force (N)
n = Number of spaces between idlers on the
curve (integer)
Arc length of curve
|
.
|

\
| u
t =
360
2 R
a
o
Convex Vertical Curves - CEMA
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Idler spacing on convex curves:
Due to the potentially high loads experienced through a convex conveyor it is
important to determine the idler spacing based on the load rating of the idlers, F
lr
.
The maximum carry side idler spacing, a
o
is given by:
Where:
( )
m b
r lr
o
q q g
F F
a
+

=
max ,
F
lr
= Load rating of the troughing idler roll set (N)
Convex Vertical Curves - CEMA