Selection of A Right Conveyor and A Feeder
Selection of A Right Conveyor and A Feeder
Selection of A Right Conveyor and A Feeder
CONVEYOR AND A
FEEDER
Bulk Materials Handling
Dr John Li
2024.07.17 BBA.CA
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• A conveyor system is a common piece of mechanical handling equipment that
moves materials from one location to another. Conveyors are especially useful
in applications involving the transport of heavy or bulky materials. Conveyor
systems allow quick and efficient transport for a wide variety of materials,
which make them very popular in the material
handling and packaging industries.
What Is • Materials may be unit goods, bulk, or fluids
Conveyor •
•
Unit goods – eg packages, boxes, pallets, log, etc
Bulk – sands, ores, minerals, etc
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As an Engineer Consider:
Different types of
Different applications Different limits
conveyors/feeders
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Selecting the Conveyor/Feeder Type Consider:
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Main Types of Conveyor/Feeder
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Belt Conveyor
Description
A continuous loop of material supported by idlers.
The most common conveyor, short or over long distance, small or large capacity used in mining, terminal and industrials .
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Belt Conveyor
Advantages Disadvantages
• Broad capacity range • For ROM ore and moist concentrate the angle of inclination is
• Extensive range of conveying distances limited to 18º, require more space
• Reliable movement and have long service life • Not suitable for very fine powder and sticky materials
• If protected from the elements, the operation is less sensitive to • Spillage issue if not properly maintained
inclement weather • Belt tracking issue if not properly maintained
• Suitable for the most bulk materials in various industries • Require regular maintenance for wear, tear of belt
• The most cost efficiency
• The high energy efficiency
• Comparatively silent and smooth
• Simple structure, easy to operate and maintain
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Belt Conveyor
Application and Specification
• Extensive application across various industries including mining and
quarrying, agriculture and food processing, construction and
aggregates, ports and terminals, manufacturing and warehousing,
power generation, cement and mining processing plants, recycling
and waste management.
• Suitable for the most bulk materials including coal and ore,
chemicals and fertilizers, grains and seeds, aggregates, overburden,
food products, wood chips and sawdust, recyclables.
• Distance: 10~5,000m up to 50km
• Capacity: 0.1~5,000t/h up to 10,000t/h
• Conveyor speed: 0.5~4 m/s up to 6m/s
• Belt width: 0.25~3m
• Angles of inclination: up to 18°
• Particle size: powder and lump size up to 600mm, 20% of belt width
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RopeCon Conveyor
Description
RopeCon conveyor transports material on a flat belt with corrugated side walls. The belt
performs the haulage function. It is driven and deflected by a drum in the head or tail
station.
Six fully locked steel wire track ropes form the line structure of the RopeCon system, which
are anchored at both ends. The belt is fixed to axles. Running wheels are fitted to either end
of the axles. These run on track ropes with fixed anchoring and guide the belt. The track
ropes are elevated off the ground on tower structures. Therefore, this suspended conveyor is
perfectly suited for rugged terrain or to cross obstacles of all kind.
When the conveyor belt has passed the unloading point, the belt turning unit turns the belt
by 180° to bring the soiled side of the belt upwards again. This prevents soiling of the track
and residual splliage. The conveyor belt is turned once more before it reaches the loading
point.
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RopeCon Conveyor Disadvantages
Advantages • High capital cost compared to ground-based conveyors.
• Represent a recent innovation aimed at addressing specific challenges posed by terrain- • High installation cost due to large support structure and specific
constrained environments. installation skill and equipment.
• Well-suited for transporting materials over long distances and complex terrain, • Difficulty in maintenance and inspection due elevation system.
including river crossings, valleys, and steep slopes.
• Not suitable for sticky materials.
• Capable of spanning long distances without intermediate support, allowing for greater
flexibility in route planning. • The discharge point must be positioned between the two end wire anchor
points.
• Wheel run on cables with low friction resistance, contributing to low energy
consumption and low operational costs.
• Less rotary parts contributing to low maintenance cost and energy consumption cost.
• Reduced ground disturbance and lower environmental impact due to elevated transport.
• Lower noise and dust generation compared to ground-based conveyor systems.
• Transporting material in two directions with one transport system.
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RopeCon Conveyor
Application and Specification
• Suitable for mining and quarrying where conveyor lengths exceed 1km and the
topography or possible right-of-way restrictions demand close attention to route
selection.
• Suitable for the many bulk materials including coal and ore, chemicals and
fertilizers, aggregates, overburden, cement and other powders.
• Capacity: 1000~6,000t/h
• Particle size: powder and lump size up to 500mm, 25% of belt width
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Pipe Conveyor
Description
Enclosed belt conveyor technology consists of belting folded onto itself along the center line to create a pouch for the material.
A pipe conveyor consist of two end pulleys, bend pulleys, drive unit, idlers, belt, skirtboard, headchute and takeup.
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Pipe Conveyor
Advantages
Disadvantages
Can provide up to 10 km of conveying distance.
Can navigate complex routes, including steep inclines, declines, and tight curves, Limited to a maximum lump size of 200 mm (one third of the
reducing the need for transfer points. Vertical inclination up to 30º. pipe diameter).
Minimum curve radius (horizontal and vertical). High initial capital cost.
- 300 x pipe diameter for fabric belts Not economically viable for conveyor length smaller than 1 km
due to larger number of idler rolls required.
- 600 x pipe diameter for steel cord belts
Since more idlers are required than for a standard belt conveyor,
Prevents spillage and environmental contamination, making it ideal for handling
this represents a greater frequency of seized rollers.
dusty, granular, or hazardous materials.
Higher energy consumption due to the additional friction from
Material protected from precipitation and wind.
the enclosed belt and complex routing.
Adaptation ability to topographic requirements.
Not suitable for very sticky or abrasive materials.
Simultaneous double load transport of different kinds of material in the upper and
lower strand.
Low maintenance costs.
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Pipe Conveyor
Application and Specification
• Suitable for mining and quarrying, ports and terminals, particularly
where conveyor lengths exceed 1 km or where hazardous materials
are involved.
• Suitable for granular or powdered materials such as grains, cement,
fertilizers and chemicals.
• Distance: 1000~5,000m up to 10km
• Capacity: 0.1~3,000t/h up to 6,000t/h
• Conveyor speed: 1~4 m/s up to 6.5m/s
• Angles of inclination: up to 30°
• Particle size: powder and lump size up to 200mm, one third of the
pipe diameter
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Pocket Belt Conveyor
Description
Steep inclined or vertical conveying system using flexible sidewalls and cleats.
A pocket belt conveyor consist of pulleys, blet, tensioning device and drive unit.
Pocket belt consist of the following three components:
Cross-rigid base belt with horizontal textile and/or transverse steel cord
reinforcement.
Corrugated sidewalls made of reinforced, vulcanized rubber.
Transverse cleats preventing the material to be conveyed from sliding
backward.
The corrugated sidewalls and cleats are cold vulcanized to the base belt and the
cleats are screwed to the sidewalls and can be replaced quickly and easily.
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Pocket Belt Conveyor
Application and Specification
Suitable for mining, quarrying, ports and terminals, power plants, the steel
industry, agriculture, and waste management.
Suitable for many bulk materials including coal and ore, chemicals and
fertilizers, grains and seeds, aggregates, overburden.
Shaft conveying for underground mining
Slope conveying in open pit mining
Vertical conveying up to 800m possible
Belt widths: 0.3~2.4m up to 3.2m
Capacities: up to 6000tph
Conveyor speed: 0.5~3m/s
Angles of inclination: up to 90°
Particle size: up to 400mm, 10% of belt width
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Bucket Elevator
Description
With pocket elevator (Pocketlift), the power transfer is achieved by two narrow steel cord belts or chains which are connected with rigid
triangular cross bars. The material to be conveyed is fed into the fabric reinforced rubber pockets, which are bolted at the center of the cross
bars. All three elements are connected, detachable and allow separate replacement .
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Bucket Elevator
Advantages Disadvantages
Capable of handling materials vertically. Not suitable for moist concentrates and sticky materials.
Reduced plan footprint compared to inclined conveyors. Impossible to clean the belt so the return run will have a degree
Enclosed system contributes to reduces dust emissions and of carryover spillage along the length.
protects materials from external contaminants, enhancing Lower capacity and increased power consumption.
environmental and workplace safety.
Lumps may blocked in the pocket.
Requires less energy for vertical transportation compared to
High wear.
inclined conveyors due to direct vertical lifting.
High maintenance and specialty replacement parts.
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Bucket Elevator
Application and Specification
Bucket elevator is used to transport powders, small particles, small
pieces of bulk materials vertically and continuously.
Suitable for underground mining, quarrying, ports and terminals,
power plants, the steel industry, agriculture, chemical industry, food
processing and waste management.
Suitable for bulk materials including coal and ore, chemicals and
fertilizers, grains and seeds, aggregates.
Capacity: 5~1500m³/h up to 4000m³/h
Lift height: 10~40m up to 80m
Lifting speed: 1.2~2m/s
Angles of inclination: up to 90°
Particle size: powder and lump size up to 200mm
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Sandwich Belt Conveyor
Description
Sandwich belt conveyor uses two conveyor belts, face-to-face to hold the material in place during transport along steep, near vertical inclines. A
fully-equalized pressing mechanism on the top belt secures material toward the center of the belt while sealing the belt edges together. It does not
confront material but conforms it to surface shapes without incurring high local forces. Soft, gentle pressure assures the preservation of the product
quality and a long service life for the equipment.
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Sandwich Belt Conveyor
Advantages Disadvantages
Capable of handling materials at steep angles. Reduced capacity compared with conventional belts of the same
Reduced plan footprint compared to conventional conveyors. width.
Enclosed system contributes to reduces dust emissions, spillage and Higher initial capital cost.
protects materials from external contaminants, enhancing environmental Not suitable for sticky or abrasive materials
and workplace safety. Maximum lift limited by the strength of the belting.
Standard, smooth surface belts allow continuous cleaning by belt Maintenance complexity.
scrapers or plows.
Can facilitates intermediate material discharge by belt plows.
Can handle a wide range of bulk materials, including abrasive and
corrosive materials, making it suitable for various industrial applications.
Standard conveyor idlers and pulleys.
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Sandwich Belt Conveyor
Application and Specification
• Sandwich belt conveyor is designed primarily for steep-angle conveying applications
where traditional belt conveyors are impractical or inefficient.
• Suitable for mining and quarrying, ports and terminals, power plants, industrial
applications such as cement plants, steel mills, and pulp and paper mills.
• Suitable for many bulk materials including coal and ore, tunnel muck, wood chips,
gypsum, slag, excavated silts, clay, refuse and municipal sludge, grains and seeds, crushed
stone, gravel, sand.
• Distance: up to 3km
• Capacity: 100~5,000t/h up to 10,000t/h
• Conveyor speed: 1~5 m/s
• Belt width: 0.45~3m
• Angles of inclination: 30° ~ 90°
• Particle size: powder and lump size up to 350mm
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Screw Conveyor
Description
Helical screw blades rotating within a tube to move materials along the axis.
A screw conveyor consist of a central shaft to which a helical flight is fitted, conveying the bulk solid in a trough with circular or U-shaped cross
section.
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Screw Conveyor
Advantage Disadvantage
•Simple operation •Low energy efficiency
•Relatively low cost •Not for abrasive, friable, and large lump materials
•Not having a return strand •30-45% space utilization
•Smaller space requirements •Limited capacity
•Can be fully enclosed (ideal for dusty materials) •Limited distance
•Can be installed at an incline or decline • Friction between the screw and the material can generate heat,
•Low maintenance due to fewer moving parts which may be a concern for heat-sensitive materials.
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Screw Conveyor
Application and Specification
• The most widely used conveyors in the processing industries for very small
distances conveying. Suitable for mining and minerals, agriculture, chemical
industry, food processing, construction, wastewater treatment and
manufacture.
• Suitable for sticky (shaftless type), powders, small particles, small pieces and
high temperature materials such as and fertilizers, grains and seeds,
aggregates and cement, flour, sludge.
• Capacity: up to 1000t/h
• Distance: 1~15m up to 45m
• Rotating speed: 50~150rpm
• Inclined angle: 0~25°
• Particle size: powder and lump size up to 200mm
• Material temperature: up to 200°C
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Drag Chain Conveyor
Description
Drag chain conveyors use one or multiple chains or cables to pull material along a trough. They are suitable for heavy-duty applications and can handle
heavy, abrasive and high-temperature materials.
A drag chain conveyor comprises scrapers, chain, casing, tensioning device, trough, housing and drive unit.
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Drag Chain Conveyor
Advantage Disadvantage
• Low initial cost • Limited capacity
• Simple design • Limited distance
• Relatively low cost of operation • Low energy efficiency
• Smaller space requirements • 50% space utilization
• Totally enclosed housing, inherently safe, reduced dust and • High noise level
spillage.
• Not suitable for overly free-flowing, large lump, sticky, high abrasive,
• Constructed with robust materials that ensure a long operational fibrous, friable and corrosive materials.
life.
• Durable construction and fewer moving parts leading to lower
maintenance requirements.
• Suitable for high temperature materials.
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Drag Chain Conveyor
Application
• Suitable for mining and minerals, agriculture, chemical industry, food
processing, power generation, recycling, cement and construction.
• Suitable for transporting powders, small particles, small pieces, and high
temperature materials such as grains, coal and ore, wood chips, ash,
cement, aggregates, fertilizers.
• Capacity: up to 400 t/h
• Distance: up to 120 m long
• Speed: 0.1-0.5 m/s
• Inclined angle: up to 45°
• Lift height: up to 30m
• Particle size: powder and lump size up to 50mm
• Material temperature: up to 450°C
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Rake Conveyor
Description
A rake conveyor, also known as a rake carrier, is specifically designed to handle and
transport materials that are challenging to move due to their fibrous, tangled, or bulky
nature. This type of conveyor uses a series of rakes or blades attached to chains to
push materials along a trough. A rake conveyor consists of rakes, chains, a casing, a
tensioning device, and a drive unit.
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Rake Conveyor
Advantage Disadvantage
• Handling challenging materials like fibrous • 50% space utilization, low energy efficiency
• High angle conveying, smaller space requirements • Not suitable for other materials except fibrous materials
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Rake Conveyor
Application and Specification
• Rake conveyors are essential in industries where the
handling of fibrous and tangled materials is required.
• Suitable for agriculture, wood processing, recycling,
biomass energy.
• Suitable for transporting fibrous materials such as cane,
straw, husks, and stover, wood strands, chips, barks
• Capacity: up to 400 t/h
• Distance: up to 50 m long
• Speed: 0.1-0.5 m/s
• Inclined angle: up to 60°
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Pneumatic Conveyor
Description
A pneumatic conveyor uses air pressure to transport materials through pipes
or tubes, commonly for fine powders and granular materials. There are two
main types: dense phase and dilute phase. Additionally, pneumatic conveyors
can operate using either vacuum or pressure systems.
A pneumatic conveyor comprises gas mover, feeder, charger, pipeline and
receiver.
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Pneumatic Conveyor
Advantage
Disadvantage
• Can transport materials around obstacles, making them adaptable
• High initial cost
to various layouts.
• • Limited capacity.
The enclosed nature reduces dust and spillage, enhancing
workplace safety and cleanliness. • High pipeline wear.
• Enclosed pipelines minimize the risk of contamination, preserving • 5 to 20 times the horsepower required by a mechanical system for
material quality. the same duty, especially for dense phase systems.
• Fewer moving parts compared to mechanical conveyors, resulting • Some materials may degrade due to the high velocity and friction
in lower maintenance requirements. during transport.
• Multiple pick-up points and delivery points (combination type) • Not suitable very heavy, large lump and abrasive materials
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Pneumatic Conveyor
Application and Sepcification
• Pneumatic conveyors are used to transport powder, granular and sticky
• Capacity: up to 100 t/h
(vacuum type) materials.
• Distance up: to 3,000 m
• Suitable for industries such as agriculture, mining, chemical, food
processing, pharmaceuticals, paint manufacture, and metal refining • Inclined angle: up to 90 deg
and processing. • Air velocity: 1~40m/s
• Dilute phase conveyor suitable for light, granular, non-abrasive, non- • Particle size: fine powder~50mm
fragile and free-flow materials such as grain and rice, sugar and tea to
coffee, animal feed pellets, fertilizers.
• Dense phase conveyor suitable for heavy, abrasive, fragile, sticky
materials such as cement, sand, and minerals, pellets, tablets, food
pastes, wet powders, coal and ore.
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Belt Feeder
Description
A belt feeder is used to extract a specific quantity of material from a hopper, discharging it into an onward system in a flood-loaded, continuous and
uniform manner. It is widely employed in various industries. A belt feeder consists of two end pulleys, a drive unit, idlers, a belt, a skirtboard, a head
chute, and a take-up mechanism.
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Belt Feeder Disadvantage
Advantage • High initial cost
• Consistent and controlled feeding • Belt wear
• Can handle a wide range of materials • Material spillage
• Relatively simple structure • Can not bear high-impact loading
• Reliable operation • Not suitable for very hard, tough, hot, sticky and large lumps
• material
Low energy consumption
• Ease of maintenance
• Can extract the material from hopper outlet
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Belt Feeder
Application and Sepcification
• Belt feeders are versatile and widely used across various industries for handling granular material or materials of comparatively lesser lump
size.
• Belt feeders are suitable for industries such as mining and quarrying, ports and terminals, aggregate and construction, chemical and
fertilizer Industry, the steel industry, power generation and the cement and lime industry.
• Suitable for coal and ore, chemicals and fertilizers, grains and seeds, aggregates, overburden, food products, wood chips and sawdust,
recyclables.
• Receiving materials under bins, hoppers or stockpiles. Maximum lump size not to exceed 20 percent of feeder width.
• Distance: 3~50m
• Capacity: 50~5,000t/h
• Speed: 0.1~1.5 m/s
• Belt width: 0.5~3m
• Inclined angle: up to 15°
• Particle size: fine~100mm
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Apron Feeder
Description
Apron feeders are designed to feed lumpy, abrasive, heavy, and high-
temperature materials at a desired handling capacity to downstream
equipment. The conveyed material is carried on overlapping pans
attached to chains.
An apron feeder consists of apron pans, chains, a tensioning device,
sprockets, skirtboard, headchute and a drive unit.
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Apron Feeder
Disadvantage
Advantage
• High initial cost
• High handling capacity
• Severely abrasive working conditions
• Robust and durable construction
• High noise level
• Continuous and uniform feeding
• High power consumption and high operational costs
• Versatility in material handling
• Complex maintenance requirements
• Effective in harsh environments
• Not suitable for powder and fine materials
• Slow motion creates minimal wear throughout the lifetime
• Require a belt conveyor underneath for leaked fine material
• Bear high-impact loading
• Suitable for high temperature materials
• Can provide positive material extraction
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Apron Feeder
Application and Specification
• Apron feeders are used to transfer materials at a controlled rate. They are essential for robust and reliable material handling, especially for large
lumps, heavy, or abrasive materials and high impact loads.
• Apron feeders are suitable for industries such as mining and quarrying, ports and terminals, aggregate and construction, the steel industry, and the
cement and lime industry.
• Suitable for many bulk materials and high temperature materials including coal and ore, rock and overburden, limestone, gypsum.
• Receiving materials from truck dumping or direct loading by dozer, shovel or dragline or under a large primary crusher, or stockpile. The
maximum lump size not to exceed 75 percent of feeder width.
• Capacity: 100-5,000t/h up to 14,500 t/h
• Length: up to 30 m long
• Speed: 0.1-0.5 m/s
• Pan width: 0.5~3m
• Inclined angle: up to 25°
• Particle size: 20~1500mm up to 2000mmm
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Vibrating Feeder
Description
Vibrating feeders use vibrations to move materials along a trough pan. They are
suitable for applications requiring gentle handling, such as for fragile or abrasive
materials. A vibrating feeder consists of a feeding trough, springs, isolation gate and a
vibrating motor.
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Vibrating Feeder
Advantage Disadvantage
• Consistent and controlled feeding • Not suitable for free flow materials and sticky materials
• Small size, light weight, simple structure, easy installation • High noise and vibration level
• Low initial cost • Can cause material segregation
• Low operation cost • The discharge rate is susceptible to variation in flowability
• High reliability and low maintenance • Can't provide positive material extraction
• Low power consumption • The flow rate and flowability strictly depend on the hopper
• Less wears opening dimensions
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Vibrating Feeder
Application and Sepcification
• Vibrating feeders are used to transfer materials at a controlled rate. They are suitable for
industries such as mining and quarrying, ports and terminals, aggregate and
construction, the steel industry, chemical and pharmaceutical industries, food
processing, and recycling.
• Suitable for granular materials or materials of limited lump sizes and high temperature
materials such as gravel, cement, food often used in food processing, mining, and
recycling.
• Receiving materials under a small primary crusher, a stockpile or a storage bin.
• Capacity: 1~2,000t/h up to 6,000t/h
• Speed: 0.05-0.5 m/s
• Trough size: 1200x1800mm~3000x3600mm
• Particle size: fine~305mm
• Inclined angle: 0~-15°
• Material temperature: up to 200°C
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Summary of Conveyors Features Max lump size for belt
Capacity Max. Inclined
width b, if all material Max. Length Energy Cost
Type Range Angle Suitable Materials Not Suitable Materials Applications
lumps m Efficiency $/t
t/h deg
mm
10~5,000 up very fine powder and sticky The most common conveyor, used in mining, terminal, thermal
Belt conveyor up to 10,000 18 b/5* most bulk materials high low
to 50,000 materials power plant, iron and steel plant, cement and recycling
RopeCon 1000~5,000 long distances and complex terrain used in mining and
1,000~6,000 20 b/4* most bulk materials sticky materials high low
conveyor up to 10,000 quarrying
mining and quarrying, ports and terminals, particularly where
Pipe 1000~5,000
0.1~6,000 30 d/3** granular or powder very sticky or abrasive materials low medium conveyor lengths exceed 1 km or where hazardous materials
conveyor up to 10,000
are involved
Pocket belt 10~30 up to Underground mining, quarrying, ports and terminals, power
up to 6,000 90 b/10* most bulk materials concentrates and sticky materials high high
conveyor 800 / lifting plants, the steel industry, agriculture, and waste management.
Underground mining, quarrying, ports and terminals, power
Bucket 5~1,500m³/h up 10~40 up to moist concentrates and sticky
90 200 granular or powder high high plants, the steel industry, agriculture, chemical industry, food
elevator to 4,000m³/h 80 / lifting materials
processing and waste management
Sandwich belt 100~5,000t/h up Steep-angle conveying applications where traditional belt
90 b/10* up to 3,000 granular or powder sticky or abrasive materials high low
conveyor to 10,000t/h conveyors are impractical or inefficient
sticky (shaftless type),
Screw 1~15, up to abrasive, friable, large lump and The most widely used conveyors in the processing industries for
up to 1,000 25 200 powders, granules, high low high
conveyor 45 heat-sensitive materials very small distances conveying such as dust collection system
temperature materials
overly free-flowing materials, large
Drag chain 5~30, up to powder, granules and high Cement plant, mineral processing, chemical, food process plant,
up to 400 45 50 lump, sticky, high abrasive, fibrous, low high
conveyor 120 temperature power plant
friable and corrosive materials
Rake
up to 400 60 up to 50 fibrous materials other bulk materials low high Wood process plant
conveyor
Pneumatic 10~300 up to powder, granular, sticky Agriculture, cement and minerals, chemical, pharmaceuticals,
1~100 90 50 large lump and abrasive materials low high
conveyor 3,000 (vacuum type) paint manufacture, and metal refining and processing
very hard, tough, hot, sticky and
Belt feeder 50~5,000 15 b/5* 3~50 powders, small lumps, high low Receiving materials under bins, hoppers or stockpiles
large lumps material
Receiving materials from truck dumping or direct loading by
100-5,000 up to large lump, heavy, wet and hot
Apron feeder 25 b/1.5* up to 30 powder and fine materials high medium dozer, shovel or dragline or under a large primary crusher, or
14,500 materials
stockpile
Vibrating friable, high temperature and overly free-flowing and sticky Receiving materials under a small primary crusher, a stockpile
up to 2,000 -15 305 up to 3.6 high high
feeder other bulk materials materials or a storage bin
* - based on 20º material surcharge angle
** - d is the pipe diameter
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Questions?
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