The Belt Conveyor - A Concise Basic Course
This book describes all parts of belt conveyors, their functions and different types presented one after the other with necessary illustrations covering all the basic aspects so that the reader can obtain an overall understanding of their operation and implementation within the field of bulk material handling, mining and mineral processing. Dedicated study of this work will also enable engineers to carry out minor repairs on their own without having to wait for maintenance personnel.
This is an introductory preliminary book for beginners in the field of bulk material handling, mining and mineral processing, written in lucid, easy-to-understand language, well-illustrated, and with self-explanatory descriptions that do not compromise in maintaining academic standards while dealing with the subject matter. A salient feature of this book is that all the new terminology used to describe the components and their functions has been included and explained.
Much of the content of this book has been tested and evaluated positively by graduate and postgraduate students and professional engineers of several bulk material handling plants during training programs over the last twenty-five years in India.
Table of Contents
1 BELT CONVEYOR COMPONENTS
1.1 Components of a belt conveyor
1.2 Conveyor arrangements
2 PROPERTIES OF BULK MATERIALS
2.1 Properties of bulk materials
2.1.1 Particle size
2.1.2 Particle shape
2.1.3 Surface area
2.1.4 Particle density (density of bulk solids or bulk materials)
2.1.5 Bulk density
2.1.6 Flowability of material
2.1.7 Hardness
2.1.8 Cohesion and adhesion
2.1.9 Angle of repose
2.1.10 Angle of fall
2.1.11 Angle of difference
2.1.12 Angle of spatula
2.1.13 Angle of slide
2.1.14 Angle of surcharge
2.1.15 Abrasion
2.1.16 Corrosion
2.1.17 Friability (degradation)
2.1.18 Dispersibility or dustiness
2.1.19 Flowability index
2.1.20 Floodability index
2.1.21 Permeability
2.1.22 Moisture content and hygroscopicity
2.1.23 Static charges
2.1.24 Temperature limits
2.1.25 Explosiveness
2.2 Behaviour of materials on a moving belt
3 BELT TENSION
3.1 Wrap factor, CW
3.2 Drive arrangements
3.3 Maximum and minimum belt tensions
4 CONVEYOR BELT
4.1 Parts of conveyor belt
4.2 Belt carcass
4.3 Types of conveyor belts
4.3.1 Fabric/Textile belts
4.3.2 Steel cord belts
4.3.2.1 Special features of steel cord belts
4.3.3 Metaflex belts
4.3.4 KEVLAR belts
4.4 Top and bottom covers of the belt
4.4.1 Top and bottom cover quality
4.4.2 Thickness of the belt covers
4.4.3 Cover quality and thickness for replacement belts
4.4.4 Types of belts and their applications
4.5 Factors to be considered for the belt design
4.5.1 Tension rating
4.5.2 Load support
4.5.3 Troughability
4.5.4 Quality and thickness of the belt covers
4.5.5 Belt width
4.5.6 Belt thickness
4.5.7 Belt speeds
4.5.8 Belt conveyor capacity
4.5.9 Minimum pulley diameters
4.6 Storage and handling of conveyor belts
4.7 Belt splicing
4.7.1 Mechanical splicing
4.7.2 Vulcanization
4.7.3 Mechanical vs vulcanized splicing
5 IDLERS/ROLLERS
5.1 Components of the roller
5.1.1 Tube (shell)
5.1.2 Bearing housing
5.1.3 Shaft
5.1.4 Bearings
5.1.5 Sealing
5.1.6 Circlips and locking arrangements
5.1.7 Fixing arrangement of the roller to the frame
5.2 Types of rollers
5.2.1 Carrying rollers
5.2.2 Return rollers
5.2.3 Fixed-type rollers
5.2.4 Garland (catenary or suspended) rollers
5.2.5 Rollers for training or tracking the belt
5.3 Roller spacing
5.4 Belt alignment
5.5 Roller maintenance
6 PULLEYS, SHAFTS AND DRIVES
6.1 Pulleys
6.1.1 Flat- or straight-face pulleys
6.1.2 Spiral drum pulleys
6.1.3 Crowned pulleys
6.1.4 Wing pulleys
6.1.5 Pulley lagging
6.1.6 Ceramic lagging
6.1.7 Pulleys for different purposes
6.1.8 Pulley diameter
6.1.9 Pulley face width
6.2 Shafts
6.3 Drives
7 BELT TAKE-UPS, CLEANERS AND ACCESSORIES
7.1 Belt take-ups
7.2 Belt cleaners
7.2.1 The ideal scraper design
7.2.2 Types of belt cleaners
7.2.2.1 Static-type cleaners
7.2.2.2 Dynamic-type cleaners
7.2.3 The present state of belt cleaning technology
7.3 Accessories
7.3.1 Protection of belt conveyor
7.3.2 Tramp iron detectors
7.3.3 Conveyor belt scales
7.3.4 Automatic sampling
8 TRANSFER POINTS
8.1 Material storage vessels
8.2 Feeders
8.2.1 Belt feeders
8.2.2 Apron feeders
8.2.3 Screw feeders
8.2.4 Vibrating feeders
8.2.5 Reciprocating plate feeders
8.2.6 Rotary drum feeders
8.2.7 Rotary vane feeders
8.2.8 Rotary table feeders
8.2.9 Rotary plough feeders
8.2.10 Drag-scraper feeders
8.3 Chute
8.3.1 Chute angle 114
8.3.2 Chute dimensions
8.3.3 Chute construction
8.3.4 Lining of chutes
8.4 Flow aid devices
8.5 Direction of feeding
8.6 Centralizing the material
8.7 Minimizing the impact
8.8 Material speed equal to belt speed
8.9 Skirtboards
8.9.1 Skirtboard dimensions
8.9.2 Skirtboard to belt distance
8.10 Wear liners
8.10.1 Wear liner styles
8.10.2 Labyrinth seal
8.11 Methods of discharging from the belt
8.11.1 Discharge over an end pulley
8.11.2 Discharge chutes
8.11.3 Trippers
8.11.4 Ploughs
9 SPILLAGE AND DUST CONTROL 131
9.1 Spillage
9.1.1 Causes of spillage
9.1.2 Effects of spillage
9.1.2.1 Reduced material-handling efficiency
9.1.2.2 Reduced plant safety
9.1.2.3 Diminished quality
9.1.2.4 Increased conveyor maintenance costs
9.1.2.5 Lowered employee morale
9.1.3 Steps to control spillage
9.2 Dust
9.2.1 Dust prevention measures
9.2.1.1 Spiral lowering chute
9.2.1.2 Bin lowering chute
9.2.1.3 Rock ladder or stone box
9.2.1.4 Telescopic chute
9.2.2 Dust control
9.2.2.1 Dust containment systems
9.2.2.2 Dust collection systems
9.2.2.3 Wet dust suppression systems
10 BELT TRAINING
10.1 Knocking and tilting the rollers
10.2 Mechanical training aids
11 OPERATION, MAINTENANCE AND SAFETY
11.1 Opration
11.2 Maintenance
11.3 Safety
12 TROUBLESHOOTING
Bibliography