FIXED PLANT REPORT: CONVEYOR BELTS

BY: BRIAN T. NCUBE

GRADUATE LEARNER ELECTRICAL ENGINEERING

SUPERVISOR: MR R.B. BANDA

MENTOR: MR E. BEREJENA
Contents
1.0 Introduction .................................................................................................................... 2
1.1 Belt Conveyors ............................................................................................................ 2
1.2 Characteristics of Bulk Materials................................................................................. 2
1.3 Components of a Conveyor Belt ................................................................................. 3
2.0 Belt .................................................................................................................................. 5
2.1 Belt Construction......................................................................................................... 5
2.2 Textile Fabric Belts ...................................................................................................... 5
2.3 Steel Chord Belts ......................................................................................................... 6
2.4 Carcass Material Selection .......................................................................................... 7
2.5 Belt Covers................................................................................................................... 8
3.0 Idlers................................................................................................................................ 9
3.1 Types of Rollers ........................................................................................................... 9
3.2 Types of Idlers ........................................................................................................... 10
3.3 Pulleys ....................................................................................................................... 11
3.4 Belt Tensioning Units ................................................................................................ 13
4.0 Conveyor Drive Units .................................................................................................... 17
4.1 Single Drum Drives .................................................................................................... 18
4.2 Dual Drum Geared Tandem Drive ............................................................................. 19
4.3 Dual Drum – Dual Motor – Ungeared Drive .............................................................. 19
5.0 Conveyor Belt Calculations ........................................................................................... 20
5.1 Belt Capacity .............................................................................................................. 20
5.2 Power Requirements................................................................................................. 20
6.0 Gearbox Selection ......................................................................................................... 22
6.1 Mechanical Rating and Safety Factor (FM) ................................................................ 22
6.2 Thermal Ratings and Thermal Service Factor (FT) ..................................................... 22
7.0 Case Study: 36 Level Re-Deep Belt ............................................................................... 23
7.1 Belt Capacity .............................................................................................................. 23
7.2 Belt Tension ............................................................................................................... 23
7.3 Power Requirements................................................................................................. 25
7.4 Gearbox Size .............................................................................................................. 26
8.0 Conveyor Belt Regulations ............................................................................................ 27
Appendix .................................................................................................................................. 28
1.0 Introduction
Trojan Nickel Mine Underground Engineering is divide into two sections, mobile plant and
fixed plant. The trainee has so far covered the mobile plant section. Fixed plant is
responsible for the maintenance of hoists, loading stations, electric locomotives, mine de-
watering system, 36 level crusher, mine compressed air supply and underground electrical
power supply. The training program will be to cover each of the fixed plant areas of
responsibility and produce a report for each. This report is the first of the intended ones, it
covers conveyor belts.

1.1 Belt Conveyors

Conveyor belts are used in the transportation of bulk materials from one point to another,
horizontally, vertically on inclined. Conveyor belt design and calculations are based on
properties of the bulk material to be transported.

1.2 Characteristics of Bulk Materials

Bulk material properties and response to weather conditions affect conveyor belt capacity
and performance. Understanding of these properties is of great importance in the design and
maintenance of conveyor belts. These properties are listed below:

Lump Size

Figure 1: Lump size

Determined by the distribution of particle sizes. It is a measure of the particles largest

dimension.

Bulk Density

The weight of the material per unit volume of space, i.e volume includes the spaces in
between the particles. Bulk density is always less than density.

Repose Angle

Figure 2: Repose Angle

The inclination angle made by bulk material being dropped on a flat surface by gravity is called
the repose angle. The greater the angle the less flowable the material is. Water has a repose
angle of 0°. The repose angle varies with moisture content. Surcharge angle is the inclination
made by material settling with internal agitation like conveyor belt motion.

Abrasivity
Abrasivity is the property of material to wear away the surface it comes in contact with. It
affect wear of the belt and other components of the conveyor. At tipping points the material’s
inertia does not allow it to attain belt instantly therefore it rolls and slips on the belt before it
attains belt speed therefore causing wear on the belt. It is therefore recommended to use
low belt speeds for highly abrasive material and vice versa.
Conveyor Capacity
The amount of material discharged by the conveyor per unit capacity is the conveyor capacity.
It is a function of the belt width, surcharge angle and troughing angle. Calculation of the
capacity is done in a later section of this report.

1.3 Components of a Conveyor Belt

Figure 3: Components of a conveyor belt

1. Tail pulley
2. Snub pulley (tail and head end)
3. Internal belt scrapper
4. Impact idlers
5. Return idlers
6. Belt
7. Bend pulleys
8. Takeup pulley
9. Takeup unit
10. Carrying idlers
11. Pulley scrapper
12. External belt scrapper
13. Head pulley
14. Feed chute
15. Skirting
2.0 Belt
The belt is the most important part of the conveyor belt installation. The belt requirements
are:

 Transport the load

 Absorb impact energy at the loading point
 Withstand temperature, weather and chemical effects
 Meet safety requirements

2.1 Belt Construction

The belt is constructed of three main parts, the carcass, skims and covers.

Figure 4: Belt Construction

The carcass is the reinforcement found in the centre of the belt. It is the heart of the belt and
has to:

 Provide the tensile strength necessary to move the loaded belt

 Absorb impact energy of the material being loaded on to the conveyor belt
 Provide bulk and lateral stiffness required for the load support
 Provide adequate strength for proper bolt and/or fattener holing
The carcass may be constructed using multiples layers (called plies) to render the required
belt characteristics such as tensile strength and troughability. The carcass may be woven
textile fabric or steel chord depending on application.
The rubber between plies is called a skim. Skims are important contributors to internal belt
adhesions, impact resistance, and play a significant role in determining belt load support
and troughibility. Improper or marginal skims can adversely affect belt performance in
general and can lead to ply separation and/or idler junction failure.

2.2 Textile Fabric Belts

In this type of belt the carcass one or multiple number of plies woven with textile fabric. The
ply is made by weaving warp lines running lengthwise and weft lines running crosswise of the
belt. The fabric is made from cotton, rayon, polyester, fibre glass or a mixture of the fibres.
After weaving the fabric is dip treated to provide adhesion to rubber compounds
The weave style of the textile fabric differ according to the duty of the belt, these include
plain weave, basket weave, twill weave, Leno weave and straight warp fabric.
In the plain weave, the warp yarns (lengthwise yarns) and the fill yarns (crosswise yarns) pass
over and under each other. This means that both members are crimped, each of the yarns
assumes a sine-wave configuration. The twill weave is a variation of the plain weave and
provides enhanced physical properties.
In the straight warp fabric design, tension-bearing warp yarns are straight without crimp. Fill
yarns are then laid transversely and alternately, above and below the main tension yarns.
Much thicker yarns are used in this weave than yarns in the conventional weave fabrics
because they are not crimped. The warp yarns and fill yarns are locked together by means of
another series of lengthwise yarns, known as the binder warp system. The binder warp system
locks the tension and fill cords tightly together, creating a belt which is very tough and which
has exceptional tear and impact resistance, as well as good mechanical fastener holding
strength.

Figure 5: Plain Weave (left) and twill weave (right)

Figure 6: Straight Warp

2.3 Steel Chord Belts

Steel chord belts employ a carcass made of a single layer of tensioned steel chords encased
in a rubber compound. They are found in high tension or long distance application and also in
application where minimal stretch is required. There are mainly two different types of chords,
7x7 cord for low to mid tension and the other is a 7x19 cord for mid to high tension. These
two types of cord enable rubber to fully penetrate to the centre core to prevent corrosion of
the steel chords.

Figure 7: 7×7 chord and 7×19 chord

2.4 Carcass Material Selection

The table below shows common carcass materials.
Table 1: Carcass Material

Common Material General Information

Name Composition
Cotton Natural Cotton is the only natural fiber used to great extent for
Cellulose belting. As it absorbs high amount of moisture, it is
susceptible to mildew (a form of fungus) attack
Nylon Polyamide It has high strength and high elongation. It has good
resistance to abrasion, fatigue and impact. While moisture
absorption is not as high as cotton, it will absorb up to 10%
of its own weight in moisture. It has high resistance to
mildew.
Polyester Polyester It has high strength and low elongation. It has good
resistance to abrasion and fatigue. As moisture absorption
is extremely low, it has excellent resistance to mildew.
Fiber Fiber Glass It is used in high temperature applications.
Glass
Steel Cord Steel It has very high strength and very low elongation. Very
good troughing characteristics. Good fatigue and abrasion
resistance.

International nomenclature for various carcass materials is as under:

Cotton - B
Viscose - Z
Polyamide (Nylon) - P
Polyester - E
Aramid - D
Steel – St
2.5 Belt Covers
Covers are used to protect the plies from damage and extend belt service life. General
materials for covers are rubber and PVC. Covers also provide the belt with the following
desirable characteristics:

 Cleanability
 Cut resistance
 Enhanced impact resistance
 Wear Resistance
 Fire retardance
 Oil & Chemical use
 Heat & Cold resistance
Environmental Effects on Conveyor Belts

 Moisture – causes rayon and cotton carcasses to rot. In steel chord belts moisture will
cause corrosion on the steel belts if there is cover damage. Nylon and polyester
carcasses are not affected by moisture. Surface moisture on the belt causes material
to cake on pulleys, idlers and the belt surface and will also cause slippage.
 Sunlight – sunlight has adverse effects on the rubber covers, it causes them to dry and
crack, especially in hot and dry conditions.
 Ozone – regular exposure to ozone will cause rubber to crack and lose its tensile
properties. Ozone is produced by ultra-violet rays from the sun, electric arc welders
and electrical generating equipment.
 Heat – storage of belts at high temperatures for long periods of time can dry out and
weaken covers. In carrying hot materials, the effect is the same.
 Oil – when rubber is attacked by oil or grease it swells and loses tensile strength,
abrasion resistance and adhesions. Belts will wear rapidly or curl in reverse.
3.0 Idlers

Figure 8: Idler

Idlers are the support of the belt between the head and tail pulley. These supports serve the
purpose of:

 Supporting the belt along material carrying run and return run with minimum
resistance to belt motion
 Forming the trough profile for material carrying
 Correcting and maintaining alignment of the belt
 Transition idlers change the belt profile between flat and trough as the belt
approached the tail pulley and when it leaves the head pulley.

3.1 Types of Rollers

Plain rollers – most common roller used in general application. The shell can be steel,
aluminum or plastic.

Figure 9: Plain Roller

Impact rollers – used where there is heavy impact of lumpy material. Rubber discs are used
to cushion the impact.

Figure 10: Impact roller

Disc rollers – used on the return side of the conveyor. The rubber discs have a cleaning effect
on the belt and remove stuck material

Figure 11: Disc roller

3.2 Types of Idlers

Idler sets carrying the load run of the belt are called carrying idlers and those carrying the
empty return run of the belt are called return idlers. The idler sets are further classified by
the mounting method which may be fixed frame type or garland type.
Fixed Frame Idlers
Fixed frame idlers have rollers mounted on a rigid steel frame, usually at right angles to belt
motion. The idlers are named according to their function.
Carrying idlers have to configurations flat and troughed depending on the belt speed.
Troughed belts transport more tonnage than flat belts of the same width and speed. Trough
angles determine the carrying capacity of the belt, the greater the angle the greater the
tonnage. Common troughing angles are 15°, 20° , 25° , 30° , 35° , 40° and 45°.

Figure 12: Carrying Idlers

Impact idlers are used at belt feed/loading points to cushion impact of lumpy material being
deposited on the belt.
Self-aligning carrying idlers are used to correct slight belt misalignment during operation.
Standard practice it to place these every 12th to 16th pitch of standard idler set. The idler
applies an aligning force when the belt runs away from the centre.
Return Idlers support the return run for belts. The flat return idler which employs a single flat
roller is the most common. For high tension fabric and steel chord belt a two idler V-
configuration may be employed with a troughing angle of 10° or 15°.

Figure 13: Return idlers

Garland Idlers
Garland idler sets consist of 2, 3 or 5 rollers linked in series and suspended by a steel rope.
Since the idler set is flexible, it can adapt to different load conditions on the belt. Garland
idlers are suitable only when the belt motion is horizontal. Choice of this type over fixed frame
idlers is due to the following characteristics:

 Idlers are highly tolerant to distortion and misalignment of the conveyor frame
 Lighter than fixed frame idlers because of the absence of the steel frame
 If a defect is observed the idler may be deactivated without disturbing or stopping the
running belt
 5-roll garland idlers provide better impact protection at feeding points

Figure 14: Garland Idler

3.3 Pulleys
Pulleys are necessary in the conveyor system to perform a number of functions, that is,
change the direction of the belt in the vertical plane, form an endless loop for continuous
operation and to transmit power to the belt in the case of the drive pulley. The drive pulley
transmits power to the belt and the non-drive pulley supports the belt. Other pulleys include
the snub pulley to increase the angle of warp on the dead pulley and the takeup pulley to
maintain belt tension.
Pulley Lagging
Lagging refers to materials, usually rubber used to coat the surface of the pulley. Lagging is
used to increase the coefficient of friction (≈0.25 for plain steel drums and ≈0.35 for drums
with rubber lagging) between the belt and the pulley. This increases the tractive pull by the
belt while reducing belt tension thus lowering belt cost. Lagging also reduces abrasive wear
on the pulley and effects self-cleaning action on the surface of the pulley.
Lagging grooves are employed for belts operating in wet and damp conditions to shed water
and slurry on the pulley surface.

Figure 15: Lagging grooves

In a chevron pattern, the grooves meet at the centre of the pulley face, while in the
herringbone pattern the grooves are offset by one-half the groove spacing. In the herringbone
and chevron patterns, the apex points in the direction of belt travel to allow easy escape of
material trapped between belt and pulley. Herringbone and chevron
patterns are used for uni-directional conveyor. The diamond pattern is used for conveyors
operating in both directions.
Pulley Crowning
Crowning means that the pulley diameter at the centre of face is slightly bigger than pulley
diameter at the ends. The conventional value of crowning is in the range of 5 mm to 10
mm, per metre of total face width. Pulley crowning helps to reduce belt misalignment in
certain situation. The crowned pulley operates from the basic principle of tracking that the
belt moves to the part of the component it touches first. In the case of crowned pulley, the
belt first touches the higher middle area of the pulley and so is directed into the centre. The
crowning is created during machining of rim face and subsequently on rubber.

Figure 16: Common crown profiles (exaggerated for illustration purposes)

The taper crown provides belt tracking capability, but the peak at the centre causes wear
and stretching at the centre of the belt, decreasing belt life. Trapezoidal crown provides
enhanced belt tracking capability as compared to taper crown while providing an even wear
surface, lengthening belt life. The curve crown provides enhanced belt tracking as compared
to trapezoidal crown, an even wear surface, and lengthened belt life. Crowned pulleys are
most effective on conveyors with short, low-tension belts. With higher tension, steel cable
belts, and troughed conveyors, little steering effect is obtained from the crown of the pulley.
Edge Clearance
Pulleys are manufactured in such a way that belts have a certain edge clearance. Standard
clearances are defined for belt speeds below 3 m/s, for greater belt distances agreement may
be reached between the manufacturer and the customer.

Figure 17: Pulley Dimensions showing belt clearances

Table 2: Standard Edge clearances

Belt Width, b Pulley Face Width, L
300 400
400 500
500 600
650 750
800 950
1000 1150
1250 1400
1400 1600
1600 1800
1800 2000
2000 2200

3.4 Belt Tensioning Units

The purpose if tensioning or take-up units is:

 Maintain adequate tension in the return belt during start up and varying load
conditions
 Allow for elastic and plastic stretch of the belt
 Act as storage for belt that can be used if a length of the belt is damaged and an
extension is required
Types of Take-Up
Common practice dictates that minimum take up length be 1.5% of the belt length, 1% may
be used when there are space constraints. There are four types of take-up units, these are
screw take-up, vertical gravity take-up, horizontal gravity take-up and winch take-up.
Screw Take-up
For the screw take-up the plummer block of the pulley is mounted of a guide block which can
be moved back (to tension) and forward (to slack). The guide moves along a fully threaded
screw, motion is controlled by turning the nut on the block. This manual method does not
give tension measurement therefore belt tension depends on the judgement of the
maintenance personnel.

Figure 18: Screw Take-up

Winch Take-up
Winch take up may be employed in the manual or automatic form. The manual set up requires
a person to operate the winch. A tension meter may be installed to give a more accurate
measurement of the applied tension.The automatic take-up employs a closed loop control
system. Tension of the belt is measured by the use of load cells, this measurement is
compared to a standard value to which the electric motor operated winch rotates to either
slack or tension the belt.

Figure 19: Automatic Winch Take-Up

Gravity Take-Up
The Vertical Gravity Take-Up is placed in an elevated part of the conveyor belt on the return
side. Bend pulley are used to change the direction of the belt and a take-up pulley with a
counterweight tensions the belt. This is a form of automatic take-up

Figure 20: Vertical Gravity Take-Up

For the Horizontal Gravity Take-Up the take-up pulley moves in a horizontal direction.
Location of the take up maybe at the tail pulley or an intermediate position along the
conveyor. The intermediate position is usually used for long conveyor belts. In both cases
the take up pulley moves along a trolley track due to the counterweight.

Figure 21: Horizontal Gravity Take-Up at tail pulley

Figure 22: Horizontal Gravity Take-Up at intermediate point

Take-Up Weight
The tension applied by the gravity take up is a function of the take-up weight as shown below:

Figure 23: Take-up tension

𝑾𝒕𝒖
𝑻𝒕𝒖 = [3.1]
𝟐

where: 𝑇𝑡𝑢 & 𝑊𝑡𝑢 are belt tension at take-up and weight of hanging elements
respectively.
4.0 Conveyor Drive Units
The power to drive the belt load continuously is applied at the head pulley. The diagram below
shows the parameters in play at the head pulley.

Figure 24: Tension at drive pulley

where: T1 = Tight side belt tension

T2 = Slack side belt tension
TE = Effective belt tension
µ = Coefficient of friction between and pulley surface
θ = Angle of warp in radians
At any point during belt operation:
𝑇𝐸 = 𝑇1 − 𝑇2 [4.1]
𝑇1
= 𝑒 µ𝜃 [4.2]
𝑇2

For an economic conveyor belt maximum tension, T1 should be lowered to reduce belt cost.
Therefore optimum values of T2, µ and θ need to be selected. The coefficient of friction can
be determined by either lagging the drive pulley or not. The angle of warp is optimised by
selecting different drive arrangements.
4.1 Single Drum Drives

Figure 25: Single drum drive; unsnubbed (left), snubbed (right)

The driving pulley is usually located at the head end. At this point there is minimum conveyor
length being subjected to maximum belt tension. For single drum drive without snub pulley
θ≤180°. With snub pulley the angle of warp is increased to a maximum of 230°
For a given power in snubbed single drum drive:
Single drum drive without snubber
Using Equations [4.1] and [4.2]

T  e   e
1 0.35180
180 3
T 2

T  3T 1 2

T  T  T
E 1 2
 3T 2  T 2  2T 2

T  0.5T
2 E

Lagged pulley with snub


T  e   e
1 0.35230
180  4.08
T 2

T  4.08T 1 2

T  T  T
E 1 2
 4.08T 2  T 2  3.08T 2

T  0.32T
2 E

Another term conveyor drive factor (K) is defined as the ratio of the slack side tension to the
effective tension. The drive factor for the drive without the snubber is 50% and that of the
drive with the snubber is 32%, thus proving that increase in warp angle decreases the
maximum belt tension, thus lowering the cost.
4.2 Dual Drum Geared Tandem Drive

Figure 26: Tandem drive, θ1+θ2≤450°

The dual drum geared tandem drive consists of two pulleys driven by a single power unit
geared together thus transferring more power than a single drum drive. The angle of warp
has a maximum of 450°, which is a sum of the angle of warp of both pulleys.

4.3 Dual Drum – Dual Motor – Ungeared Drive

This arrangement has the two pulleys being driven by two separate power units. The pulleys
and drive units are identical and the coupled by fluid coupling to accommodate the slight
speed differences due to belt slip. The warp angle is identical to that of the dual drum geared
tandem drive.
5.0 Conveyor Belt Calculations
5.1 Belt Capacity
Belt capacity is dependent on the characteristics of bulk materials: bulk density and surcharge
angle. Other factors affecting capacity are belt width, belt speed, troughing angle and idler
configuration.

Figure 27: Factors affecting belt capacity

The general formula for belt capacity is as follows:

Capacity (tonnes per hour) = 3.6 × Load Cross Sectional Area (m2) × Belt Speed (m/s) ×
Material Bulk Density (kg/m3) [5.1]

For common configurations belt manufacturer tables can be used to determine capacity of
belts. Fenner Dunlop provides such tables (See Appendices). Using these tables the formula
for capacity becomes:
Capacity (tonnes per hour) = Capacity × Capacity Factor × Belt Speed (m/s) × Material
Bulk Density (kg/m3)/1000 [5.2]

5.2 Power Requirements

After selecting the belt speed and belt width the power required at the prime mover is the
algebraic sum of:
(i) Power to move the empty belt over idlers
(ii) Power to move the load horizontally
(iii) Power to move the load vertically
(iv) Power to turn the pulleys
(v) Any belt losses
(vi) Power required by belt tippers (where applicable)
The power calculated below is the power requirement at the motor side. Gearbox selection
is covered in the next section. Firstly we define the following terms:

 L = length of the belt (practically corrected belt length Lc = L+60 is used to allow for
power used at belt terminals) - m
 S = belt speed – m/s
  T = maximum belt capacity – t/h
 H = vertical distance lifted or lowered – m
 M = mass of moving parts per metre of conveyor – kg/m
 µ = idler friction factor (≈0.03)
 g = acceleration due to gravity – 9.81m/s2
 D = overall efficiency of the drive unit
Power to move empty belt over idlers:
𝑃1 = µ𝑀𝐿𝑔𝑆 × 10−3 𝑘𝑊 [5.3]
Power to move the load horizontally:
µ𝑇𝑔𝐿
𝑃2 = 𝑘𝑊 [5.4]
3600

Power to lift or lower load:

𝑇𝑔𝐻
𝑃3 = 3600 𝑘𝑊 [5.5]

Total Power:
𝑔 100
𝑃 = 3600 (3.6µ𝑀𝐿𝑆 + µ𝑇𝐿 + 𝐻𝑇) 𝑘𝑊 [5.6]
𝐷
6.0 Gearbox Selection
Gearbox size can is determined with the help of gearbox power tables. These are laid for every
gearbox type. The table gives the maximum power the gearbox can transmit for a given gear
ratio and load condition. Similar tables are available for torque characteristics. Other
parameters involved in gearbox selection are mechanical and thermal ratings and service
factors.

6.1 Mechanical Rating and Safety Factor (FM)

Mechanical ratings measure capacity in terms of life and/or strength assuming 12 hr/day
continuous running under uniform load conditions.
Table 3: Mechanical Ratings for Radicon gearboxes

6.2 Thermal Ratings and Thermal Service Factor (FT)

Thermal ratings measure a unit's ability to dissipate heat, if they are not exceeded, the
lubricant may overheat and break down resulting in failure of gearbox. Thermal ratings are
affected by ambient temperature and not by mechanical considerations such as increased
running time and shock load.
Table 4: Thermal Service Factor
7.0 Case Study: 36 Level Re-Deep Belt

7.1 Belt Capacity

Taking specific gravity of massive ore = 3.2:

𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 3.2 × 997 = 3190.4 kg/m3
Capacity (tonnes per hour) = Capacity × Capacity Factor × Belt Speed (m/s) × Material Bulk
Density (kg/m3)/1000
Using Appendix 1 – 3:

 The conveyor is set to a speed of approximately 1.25m/s and the width is 1050 mm,
this gives a capacity of 551
 The 35° troughing angle gives a capacity factor of 1.08
 The specific gravity of the heaviest conveyed material (massive ore) is 4.2
 Using equation [5.2]
551×1.08×1.23×3190.4
𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = = 2335 𝑡/ℎ
1000

7.2 Belt Tension

Belt Tension calculated using OEM specifications from Dunlop, source:
https://www.ckit.co.za/secure/conveyor/troughed/belt_tension/dunlop-belting.htm
Definition of terms:
T1 – maximum belt tension T2 – slack side tension
TE – effective tension TX – tension to move empty belt
TY – tension to move load horizontally TZ - tension to move load vertically
TS – tension to raise or lower load G – mass of moving parts
Q – mass of load per unit length LC – corrected length of conveyor
C – length correction coefficient B – belt mass per unit length
fX – friction coefficient of empty belt fY - friction coefficient of loaded belt
S – belt speed K – drive factor
Id – idler spacing Sf – sag factor
Step 1:

Mass of load per unit length = (0.278 × capacity) ÷ S

= (0.278 × 2335) ÷ 1.2 = 541

Step 2:
𝐿𝐶 = 𝐿 + 60 = 78 + 60 = 138𝑚
𝐿𝐶 138
𝐶= = = 1.77
𝐿 78

Step 3: Tension for moving empty belt

For heavy duty belts with 152mm idlers, G = 82
𝑇𝑋 = 9.8𝐺 × 𝑓𝑋 × 𝐿𝐶
= 9.8 × 82 × 0.022 × 138 = 2440𝑁
Step 4: Tension to move load horizontally

𝑇𝒀 = 9.8𝑄 × 𝑓𝑌 × 𝐿𝐶
= 9.8 × 541 × 0.027 × 138 = 19755𝑁
Step 5: Tension to lift the load

𝑇𝒁 = 9.8𝑄 × 𝐻
= 9.8 × 541 × 0.16 = 848𝑁

Step 6: Effective Tension

𝑇𝐸 = 𝑇𝑋 + 𝑇𝑌 + 𝑇𝑍
= 2440 + 19755 + 848 = 23043𝑁
Step 7: Slack side tension

 Slack side tension to prevent slip

The drive factor for 230° warp and bare pulley with screw take up is 0.9

𝑇𝑀 = 𝐾𝑇𝐸
= 0.9 × 23043 = 20738.7
  Slack side tension to limit sag to 2%
Sag factor for 2% sag is 6.3 and estimated belt mass for 1050mm belt width is
21.6kg/m
𝑇𝑠 = 9.8𝑆𝑓 (𝐵 + 𝑄)𝐼𝑑

= 9.8 × 6.3 × (21.6 + 541) × 1.2 = 41682𝑁

The required slack side tension is the larger of the two, TS = 41682N

Step 8: Slope tension using estimated belt mass

𝑇𝐻 = 9.8𝐵 × 𝐻
= 9.8 × 21.6 × 0.16 = 34𝑁
Step 9: Maximum belt tension

𝑇1 = 𝑇𝐸 + 𝑇2 + 𝑇𝐻
= 23043 + 41682 + 34 = 64759𝑁
Unit Tension, T
𝑇 = 𝑇1 ÷ 𝑏𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ
= 64759 ÷ 1050
= 61.6𝑁/𝑚𝑚 or 61.6𝑘𝑁/𝑚
The closet standard belt strength for mining application would be 630/4 Grade M

7.3 Power Requirements

 From previous sections power is given by:
𝑔 100
𝑃 = 3600 (3.6µ𝑀𝐿𝑆 + µ𝑇𝐿 + 𝐻𝑇) 𝑘𝑊 (equation [5.6])
𝐷

 According to the Dunlop Catalogue the belt mass for the 630/4 Grade M belt is ≈
5.52kg/m2
 Taking Drive efficiency of 85%:

9.8
𝑃= [(3.6 × 0.03 × 82 × 138 × 1.23) + (0.03 × 2335 × 138)
3600
100
+ (0.16 × 2335)] ×
85
= 37𝑘𝑊
The closest standard motor would be 37kW, 550V, 50Hz, 4 pole motor

7.4 Gearbox Size

Using the Radicon Worm Gears CER-2.00GB0712 Catalogue:
 The conveyor operates for over 10 hours a day with moderate shock load, FM = 1.5
 The ambient temperature is ≈ 30°C, FT = 1.16

Gear ratio:

For 1.23m/s speed using 600mm diameter pulley, rotation = 39rpm

Gear ratio = 1450:39

= 37:1

Nearest standard ratio is 40:1

Output mechanical power and torque:

Power

𝑃 = 𝑚𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 × 𝐹𝑀
= 37𝑘𝑊 × 1.5 = 55.5𝑘𝑊
Torque
60𝑃
𝑇= = (60 × 55500) ÷ (2𝜋 × 39) = 13589.4𝑁𝑚
2𝜋𝑁

Equivalent thermal power and torque:

Power

𝑃 = 37 × 1.16 = 42.92𝑘𝑊
Torque

𝑇 = (60 × 42920) ÷ (2𝜋 × 39) = 10509.1𝑁𝑚

The applicable gearbox is the 17” Series ER Gearbox, Gear ration 40:1, Input Speed 1450rpm
8.0 Conveyor Belt Regulations
Installation of all mining equipment in Zimbabwe is governed by Mining (Management and
Safety) Regulations (SI109/1990). Regulation on conveyor belts is covered on Section 43: Use
of belt conveyors and is as follows:
43 In every mine, both on surface and underground, in which a belt conveyor is used—
a) the manager shall draw up and enforce a code of safety practice for the operation,
maintenance and patrolling of the conveyor system; and
b) suitable and adequate means for extinguishing fires shall be available for
immediate use along every belt conveyor; and
c) every belt conveyor shall be equipped with effective means for immediately
stopping the conveyor or for signalling to the attendant at the driving head from
readily accessible points along the conveyor; and
d) where two or more belt conveyors are used in series, sequence interlocking shall
be provided which will automatically—
(i) stop all other conveyors feeding a conveyor that has stopped; and
(ii) prevent a conveyor starting until the conveyor on to which it fees is
moving; and
e) if the mine is a coal mine, the following additional requirements shall apply—
(i) every conveyor belt which is installed or used in the underground workings
shall be of incombustible or fire-resistant material; and
(ii) all reasonable measures shall be taken to prevent coal, or coal dust
accumulating on or around the moving parts of any belt where friction is
likely to cause heating; and
(iii) every belt conveyor shall be equipped with a device which wills top the
drive automatically should the belt break, jam or slip excessively.
Appendix
1. CAPACITY FACTOR

2. COSINE FOR INCLINED BELT

3. CAPACITY OF BELTS