This document summarizes the design of a belt conveyor system with the following key specifications:
1) Required material handling capacity of 1650 tonnes/hour
2) Belt width of 1200mm and speed of 4.5m/s
3) Belt center distance of 15.5m, requiring a vertical height increase of 4.06m
4) Calculated theoretical capacity of 1974.47 tonnes/hour, exceeding the required capacity.
5) Estimated motor power requirement of 32.1kW and recommended 70.38kW motor.
6) Recommended pulley diameters of 630mm, 530mm and 330mm.
7) Selected gear reducer type and size of B
This document summarizes the design of a belt conveyor system with the following key specifications:
1) Required material handling capacity of 1650 tonnes/hour
2) Belt width of 1200mm and speed of 4.5m/s
3) Belt center distance of 15.5m, requiring a vertical height increase of 4.06m
4) Calculated theoretical capacity of 1974.47 tonnes/hour, exceeding the required capacity.
5) Estimated motor power requirement of 32.1kW and recommended 70.38kW motor.
6) Recommended pulley diameters of 630mm, 530mm and 330mm.
7) Selected gear reducer type and size of B
This document summarizes the design of a belt conveyor system with the following key specifications:
1) Required material handling capacity of 1650 tonnes/hour
2) Belt width of 1200mm and speed of 4.5m/s
3) Belt center distance of 15.5m, requiring a vertical height increase of 4.06m
4) Calculated theoretical capacity of 1974.47 tonnes/hour, exceeding the required capacity.
5) Estimated motor power requirement of 32.1kW and recommended 70.38kW motor.
6) Recommended pulley diameters of 630mm, 530mm and 330mm.
7) Selected gear reducer type and size of B
This document summarizes the design of a belt conveyor system with the following key specifications:
1) Required material handling capacity of 1650 tonnes/hour
2) Belt width of 1200mm and speed of 4.5m/s
3) Belt center distance of 15.5m, requiring a vertical height increase of 4.06m
4) Calculated theoretical capacity of 1974.47 tonnes/hour, exceeding the required capacity.
5) Estimated motor power requirement of 32.1kW and recommended 70.38kW motor.
6) Recommended pulley diameters of 630mm, 530mm and 330mm.
7) Selected gear reducer type and size of B
1 Belt Capacity Required Q 2 t/h 825 2 Belt Width B mm 1200 3 Belt Speed Required v m/s 1.13 4 Angle of Inclination o 12.8 5 Belt Center Distance L m 154.4 Vertical height to elevate= Lsin H m 18 Skirt board length each side m 3 sbl = 6 6 Material / Bulk density t/m 3 1.4 7 Capacity Factor k 0.89 H/L = 0.28 8 Trough Angle o 35 o 10 9 Total Moisture % 28 Material Temperature o C 35 Lump Size mm 100 10 Weight of Moving Part Conv. G kg/m 45 see table 7 if s1 and s2 and density < 1.5 s1 m 1 see table 7 s2 m 3 see table 7 11 Additional l m 100 see table 8 if center distance >100 m. L m 154.4 see table 8 12 Coefficient of friction of rolling parts parts f 0.023 see table 9 Check Theoritical Capacity Qt 1 Qt' = = 584.22 m3/h See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't = 614 m3/h with ; Belt Width B mm 1200 Trough Angle o 35 o 15 2 Qt = = 619.32 m3/h 3 Q = = 867.05 t/h Q > Q 2 CALCULATION OF BY PASS CONVEYOR C - 12A {Q2/(v x x k)} Q't x v x k Qt x PT. Protech Asia Engineering. By Pass System RCD-1 to SP-3 RCD-2 to SP2 Pelabuhan Batubara Tarahan Power Requirement 1 Power Required to drive empty Conveyor N1 (kW) N 1 = = 2.93 kW 2 Power Required to convey material on the level N2 (kW) N 2 = = 13.82 kW 3 Power Required to elevated material N3 (kW ) N 3 = = 42.53 kW 4 Additional Power Requirement N4 (kW), see table 10 N 4 = = 0.54 kW * Theoritical Necessary Motor Capacity Nn (kW) Nn = = 59.82 kW * Motor Capacity (Nm) Nm = = 70.38 Kw * Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = D1 = 733 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION Service Factor sf= 2 * Nominal Power Rating P N = = 140.75 kW * Gear Reducer output speed n 2 = = 29.54 rpm * Gear Reducer Ratio i = = 50.77 * Thermal Rating P G = = 149.29 kW P G1 = 143 According above mention , choice gear reducer type and size ; FLENDER type : i = 50 or HANSEN P4 type: i = 50 B3HH11 QHRF3 (QxH)/367 0.08x v x length of skirt board 500 mm Pm x sf (v x 60)/(3.14 x D1) 1500 / n 2 P G1 x 0.87 x 1.2 P N < P G the Gear Reducer no need extra cooling. {G(L+l)fxv}/102 {Q(L+l)f}/367 N 1 + N 2 + N 3 + N 4 Nn / PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP2 Pelabuhan Batubara Tarahan. 1 Belt Capacity Required Q 2 t/h 1650 2 Belt Width B mm 1200 3 Belt Speed Required v m/s 4.5 4 Angle of Inclination o 16 5 Belt Center Distance L m 15.5 Vertical height to elevate= Lsin H m 4.06 Skirt board length each side m 3 sbl = 6 6 Material / Bulk density t/m 3 0.9 7 Capacity Factor k 0.89 H/L = 0.28 8 Trough Angle o 35 o 10 9 Total Moisture % 28 Material Temperature o C 35 Lump Size mm 100 10 Weight of Moving Part Conv. G kg/m 45 see table 7 if s1 and s2 and density < 1.5 s1 m 1.5 see table 7 s2 m 3 see table 7 11 Additional l m 50 see table 8 if center distance < 30 m. L m 15.5 see table 8 12 Coefficient of friction of rolling parts parts f 0.023 see table 9 Check Theoritical Capacity Qt 1 Qt' = = 457.76 m3/h See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't = 493 m3/h with ; Belt Width B mm 1200 Trough Angle o 20 o 15 2 Qt = = 1974.47 m3/h 3 Q = = 1777.02 t/h Q > Q 2 CALCULATION OF BY PASS CONVEYOR C - 12A Q't x v x k Qt x {Q2/(v x x k)} PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP2 Pelabuhan Batubara Tarahan. Power Requirement 1 Power Required to drive empty Conveyor N1 (kW) N1 = = 2.99 kW 2 Power Required to convey material on the level N2 (kW) N2 = = 7.29 kW 3 Power Required to elevated material N3 (kW ) N3 = = 19.66 kW 4 Additional Power Requirement N4 (kW), see table 10 N4 = = 2.16 kW * Theoritical Necessary Motor Capacity Nn (kW) Nn = = 32.10 kW * Motor Capacity (Nm) Nm = = 37.77 Kw * Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = D1 = 630 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION Service Factor sf= 2 * Nominal Power Rating PN = = 75.54 kW * Gear Reducer output speed n2 = = 136.49 rpm * Gear Reducer Ratio i = = 10.99 * Thermal Power Rating P G = = 53.24 kW P G1 = 51 According above mention , choice gear reducer type and size ; FLENDER type : B2HH4 i = 11.2 or HANSEN P4 type: QHRA2 i = 11.2 0.08x v x length of skirt board N1 + N2 + N3 + N4 Nn / {G(L+l)fxv}/102 {Q(L+l)f}/367 (QxH)/367 P G1 x 0.87 x 1.2 PN < PG the Gear Reducer no need extra cooling. 500 mm Pm x sf (v x 60)/(3.14 x D1) 1500 / n2 PT. Protech Asia Engineering. 1 Belt Capacity Required Q 2 t/h 1650 2 Belt Width B mm 1200 3 Belt Speed Required v m/s 4.5 4 Angle of Inclination o 16 5 Belt Center Distance L m 17 Vertical height to elevate= Lsin H m 4.06 Skirt board length each side m 3 sbl = 6 6 Material / Bulk density t/m 3 1.1 7 Capacity Factor k 0.89 H/L = 0.28 8 Trough Angle o 35 o 10 9 Total Moisture % 28 Material Temperature o C 35 Lump Size mm 100 10 Weight of Moving Part Conv. G kg/m 67 see table 7 if s1 and s2 and density < 1.5 s 1 m 1.5 see table 7 s 2 m 3 see table 7 11 Additional l m 50 see table 8 if center distance < 30 m. L m 17 see table 8 12 Coefficient of friction of rolling parts, on dusty running periodic f 0.03 see table 9 overloaded. Check Theoritical Capacity Qt 1 Qt' = = 374.53 m3/h See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't = 396 m3/h with ; Belt Width B mm 1000 Trough Angle o 30 o 15 2 Qt = = 1585.98 m3/h CALCULATION OF BY PASS CONVEYOR C - 12A {Q2/(v x x k)} Q't x v x k 3 Q = = 1744.58 t/h Q > Q 2 No need to modify the speed , belt size , trough angle Power Requirement 1 Power Required to drive empty Conveyor N1 (kW) N1 = = 5.94 kW 2 Power Required to convey material on the level N2 (kW) N2 = = 9.55 kW 3 Power Required to elevated material N3 (kW ) N3 = = 19.30 kW 4 Additional Power Requirement N4 (kW), see table 10 N4 = = 2.16 kW * Theoritical Necessary Motor Capacity Nn (kW) Nn = = 36.96 kW * Motor Capacity (Nm) Nm = = 43.48 Kw * Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = D1 = 630 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION * Prime Mover Electric motor P1 = 55 kW Motor speed n1 = 1500 rpm Max. starting torque T A = 525 Nm * Driven machine Belt Conveyor P 2 = 45 kW {G(L+l)fxv}/102 {Q(L+l)f}/367 (QxH)/367 0.08x v x length of skirt board Qt x N1 + N2 + N3 + N4 Nn / Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor ) 500 mm * Output rotation need n 2 = = 136.49 rpm * Gear Reducer Ratio i = = 10.99 * Service factor for Gear Units with 24 hours operation. Factor for driven machine Belt onveyor. = f 1 1.30 table 1, page 12 Factor for prime mover use electric motor = f 2 1.00 table 2, page 12 Peak torque factor with load peaks per hour 6 - 30 = f 3 0.95 table 3, page 12 Thermal factor = f 4 0.71 table 4, page 12 Thermal factor with cooling = f 5 1.19 table 5, page 12 Factor for altitude = f 6 1.00 table 6, page 12 Factor for altitude with cooling = f 7 1.00 table 7, page 12 Oil supply factor for horz. = f 8 0.95 table 8, page 13 Thermal capacity = f 9 1.20 table 9, page 13 Thermal capacity factor with fan = f 10 1.49 table 10, page 13 * Determination of Nominal Power P N = 58.50 kW rating * Selected from power rating table: type B2 gear unit size 4 , with P N = 81 kW page :22 = = 149.85 kW * Checking the starting torque P N = 78.34 kW * Thermal Power Rating without P G1 = 51 page:23 auxiliary cooling * Thermal capacity for gear units P G = = 41.28 kW without auxiliary cooling Check thermal power rating with auxiliary fan cooling * Thermal Power Rating with P G2 = 67 page:23 ( v x 60 )/( 3.14 x D1 ) n 1 / n 2 P 2 x f 1 x f 2 3.33 x P 2 P N P G = 41.28 kW < P 2 = 45 kW Gear unit need auxiliary fan cooling 149.85 kW > PN = 82 kW (T A x n 1 ) / 9550 x f 3 P N = 81 kW > 78.34 kW P G1 x f 4 x f 6 x f 8 x f 9 auxiliary fan cooling * Thermal capacity for gear units P G = = 67.34 kW with auxiliary fan cooling According above mention , choice gear reducer type and size ; FLENDER type : B2DH4 i = 11.2 Hollow Shaft for shrink disk mounted, Right Angle with auxiliary cooling fan ` P G2 x f 4 x f 6 x f 8 x f 10 P G = 67.88 kW > P 2 = 45 kW 63.2238 54.3467 59.1293 63.9373 power yang diminta 75 2 150 97.5 By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan 1 Belt Capacity Required Q 2 t/h 1650 2 Belt Width B mm 1200 3 Belt Speed Required v m/s 4.5 4 Angle of Inclination o 16 5 Belt Center Distance L m 15.5 Vertical height to elevate= Lsin H m 4.06 Skirt board length each side m 3 sbl = 6 6 Material / Bulk density t/m 3 1.1 7 Capacity Factor k 0.89 H/L = 0.28 8 Trough Angle o 35 o 10 9 Total Moisture % 28 Material Temperature o C 35 Lump Size mm 100 10 Weight of Moving Part Conv. G kg/m 67 see table 7 if s1 and s2 and density < 1.5 s 1 m 1.5 see table 7 s 2 m 3 see table 7 11 Additional l m 50 see table 8 if center distance < 30 m. L m 15.5 see table 8 12 Coefficient of friction of rolling parts, on dusty running periodic f 0.03 see table 9 overloaded. Check Theoritical Capacity Qt 1 Qt' = = 374.53 m3/h See table 4, choice the Qt' corresponding with Belt width, trough angle, basic angle and find out; Q't = 396 m3/h with ; Belt Width B mm 1000 Trough Angle o 30 o 15 2 Qt = = 1585.98 m3/h 3 Q = = 1744.58 t/h Q > Q 2 CALCULATION OF BY PASS CONVEYOR C - 12A {Q2/(v x x k)} Q't x v x k Qt x No need to modify the speed , belt size , trough angle PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan Power Requirement 1 Power Required to drive empty Conveyor N1 (kW) N1 = = 5.81 kW 2 Power Required to convey material on the level N2 (kW) N2 = = 9.34 kW 3 Power Required to elevated material N3 (kW ) N3 = = 19.30 kW 4 Additional Power Requirement N4 (kW), see table 10 N4 = = 2.16 kW * Theoritical Necessary Motor Capacity Nn (kW) Nn = = 36.61 kW * Motor Capacity (Nm) Nm = = 43.07 Kw * Recommended Pulley Diameter (mm) for Multiply Belt (4PN150) with 65% ~ 100 % utilization; see table 16 D1 = Driving Pulley = D1 = 630 mm D2 = Tail Pulley = 400 mm D2 = 530 mm D3 = Snub Pulley = 315 mm D3 = 330 mm GEAR REDUCER SELECTION * Prime Mover Electric motor P1 = 55 kW Motor speed n1 = 1500 rpm Max. starting torque T A = 525 Nm * Driven machine Belt Conveyor P 2 = 45 kW * Output rotation need n 2 = = 136.49 rpm * Gear Reducer Ratio i = = 10.99 * Service factor for Gear Units with 24 hours operation. Can use the motor 45 kW / 55 kW ( Nm x 1.25 for normal starting service factor ) {G(L+l)fxv}/102 {Q(L+l)f}/367 (QxH)/367 0.08x v x length of skirt board N1 + N2 + N3 + N4 Nn / 500 mm n 1 / n 2 ( v x 60 )/( 3.14 x D1 ) PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan Factor for driven machine Belt onveyor. = f 1 1.30 table 1, page 12 Factor for prime mover use electric motor = f 2 1.00 table 2, page 12 Peak torque factor with load peaks per hour 6 - 30 = f 3 0.95 table 3, page 12 Thermal factor = f 4 0.71 table 4, page 12 Thermal factor with cooling = f 5 1.19 table 5, page 12 Factor for altitude = f 6 1.00 table 6, page 12 Factor for altitude with cooling = f 7 1.00 table 7, page 12 Oil supply factor for horz. = f 8 0.95 table 8, page 13 Thermal capacity = f 9 1.20 table 9, page 13 Thermal capacity factor with fan = f 10 1.49 table 10, page 13 * Determination of Nominal Power P N = 58.50 kW rating * Selected from power rating table: type B2 gear unit size 4 , with P N = 81 kW page :22 = = 149.85 kW * Checking the starting torque P N = 78.34 kW * Thermal Power Rating without P G1 = 51 page:23 auxiliary cooling * Thermal capacity for gear units P G = = 41.28 kW without auxiliary cooling Check thermal power rating with auxiliary fan cooling * Thermal Power Rating with P G2 = 67 page:23 auxiliary fan cooling * Thermal capacity for gear units P G = = 67.34 kW with auxiliary fan cooling According above mention , choice gear reducer type and size ; FLENDER type : B2HH4 i = 11.2 Hollow Shaft for shrink disk mounted, Right Angle with auxiliary cooling fan ` P G2 x f 4 x f 6 x f 8 x f 10 P G = 67.88 kW > P 2 = 45 kW P N = 81 kW > 78.34 kW P G1 x f 4 x f 6 x f 8 x f 9 P G = 41.28 kW < P 2 = 45 kW Gear unit need auxiliary fan cooling P 2 x f 1 x f 2 3.33 x P 2 P N 149.85 kW > PN = 82 kW (T A x n 1 ) / 9550 x f 3 PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan 63.2238 53.8366 58.5742 63.3371 power yang diminta 75 2 PT. Protech Asia Engineering. By Pass System RCD-1 to SP3 RCD-2 to SP-2 Pelabuhan Batubara Tarahan 150 97.5 PT. Protech Asia Engineering. h 10 Nama Umur Nama O.T Alamat b 9 t 6.8 ab bd e 8.6 q 7 ad sb r 8.2 w 7.5 ac mn y 8 y 8 as kl w 7.5 r 8.2 an ji q 7 e 8.6 am lo t 6.8 b 9 ak kp c 5 h 10 ao rt
t 6.8 ab bd q 7 ad sb w 7.5 ac mn y 8 as kl r 8.2 an ji e 8.6 am lo b 9 ak kp h 10 ao rt