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Belt Conveyors For Bulk Materials Calculations by CEMA 5 Edition
Belt Conveyors For Bulk Materials Calculations by CEMA 5 Edition
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- piotr.kulinowski@agh.edu.pl
( 12617 30 92
B-2 ground-floor room 6
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TYPICAL BELT CONVEYOR TRAVEL PATHS
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Design Considerations
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Flowability–angle of surcharge–angle of repose
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Characteristics of BuIk Solid Materials - CEMA
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Very dusty L
Aerates and develops fluid characteristics M
Contains explosive dust N
Contaminable, affecting use or saleability P
Degradable, affecting use or saleability 0
Miscellaneous Characteristics Gives off harmful fumes or dust R
(Sometimes more than one of Highly corrosive S
these characteristics may Mildly corrosive T
apply) Hygroscopic U
Interlocks or mats V
Oils or chemical present—may affect rubber products W Example: A very fine material that is free-
Packs under pressure X flowing, abrasive, and contains explosive dust
would be designated:
Very light and fluffy—may be wind-swept
Elevated temperature
V
Z
Class A26N.
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Material characteristics and weight per cubic foot - CEMA
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Recommended
maximum belt
speeds
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Example: Belt Conveyor Parameters
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Area of load cross section
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1 lb = 0.4536 kg
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The surcharge angle, on the average, will be 5 degrees to 15 degrees less than the angle of repose.
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Idler Spacing
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Factors to consider when selecting idler spacing are belt weight, material weight, idler load rating, belt
sag, idler life, belt rating, belt tension, and radius in vertical curves
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Example: Belt Conveyor Parameters
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The Selection of Idlers
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Idler life is determined by a combination of many factors, such as seals, bearings, shell thickness,
belt speed, lump size/material density, maintenance, environment, temperature, and the proper
CEMA series of idler to handle the maximum calculated idler load.
CEMA B load rating based on minimum L10 of 30,000 hours at 500 rpm
CEMA C load rating based on minimum L10 of 30,000 hours at 500 rpm
CEMA D load rating based on minimum L10 of 60,000 hours at 500 rpm
CEMA E load rating based on minimum L10 of 60,000 hours at 500 rpm
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Step No. 1 Troughing Idler Series Selection
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Calculated Idler Load (lbs) = CIL = ((WB + (WM x K1)) x SI) + IML
Where:
WB = Belt weight (lbs/ft) use actual or estimate from Table 5-5
WM = Material weight (lbs/ft) = (Q x 2000) / (60 x Vee)
Q = Quantity of material conveyed (tons per hour)
Vee = Design belt speed (fpm)
SI = Spacing of idlers (ft)
Kl = Lump adjustment factor (see Table 5-6)
IML = Idler misalignment load (lbs) due to idler height deviation and
belt tension = (D x T) / (6 x SI)
Where:
D = Misalignment (in.)
T = Belt tension (lbs)
SI = Idler spacing (ft)
© piotr.kasza@agh.edu.pl, piotr.kulinowski@agh.edu.pl Department of Mining, Dressing and Transport Machines AGH tel/fax +48126335162
Step No. 1 Troughing Idler Series Selection
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Step No. 1 Troughing Idler Series Selection
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Idler Series Selection 1 lbf = 4.45 N
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Calculated Idler Load (lbs) = CIL = ((11+ (55 x 1.0)) x 4.5) + 0 = 297 lbs
Where:
WB = 11 lbs/ft
WM = (1000 x 2000) / (60 x 600 ) = 55 lbs/ft
Q = 1000 tons per hour
Vee = 600 fpm
SI = 4.5 ft
Kl = 1.0
IML = 0
Calculated Return Idler Load (lbs) = CILR = (11 x 10) + 0 = 110 lbs
SI = 10.0 ft
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Load ratings for CEMA idlers, lbs
Notes:
1. Troughing idler load ratings (Tables 5.7–5.10) are for three equal length rolls.
2. Load ratings also apply for impact rolls.
3. Troughing idler load ratings are based on a load distribution of 70% on center roll and 15%
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on each end roll for all trough angles.
4. Unequal length rolls or picking idlers are not covered by this standard.
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K2 = Effect of load on predicted bearing L10 life
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1 deg F = 0.5556 C
C = 5/9 (F-32)
F = 9/5 * C + 32
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Basic Power Requirements
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Effective tension,Te
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Kt — Ambient Temperature Correction Factor
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79 °F Kt = 1.0
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Kx — Idler Friction Factor, lbs/ft
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Wb = 11 lbs/ft
Wm = (1000 x 2000) / (60 x 600 ) = 55 lbs/ft
Si = 4.5 ft
CEMA B4
Kx = 0,00068(11+55)+2.3/4.5 = 0.0449 + 0.51 = 0.555 lbs/ft
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Ky — Factor for Calculating the Force of Belt and Load
Flexure over the Idlers
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Wb + Wm = 66 lbs/ft
Si = 4.5 ft
Lenght: 3300 feet
Height: 115 feet
Slope: 2 degrees
Ky = 0.020
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Corrected factor Ky
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Ky = 0.0214
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Ky vs. Belt Tension
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After estimating the average belt tension and selecting an idler spacing, refer to Table 6-4
to obtain values for A and B for use in the following equation:
Wb + Wm = 66 lbs/ft
Si = 4.5 ft
Ky = 0.04036
Ky = 0.01261
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Tp = total of the belt tensions required to rotate each of
the pulleys on the conveyor
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Pulleys
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Tam — force to accelerate the material continuously as it
is fed onto the belt
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Where:
Q = Capacity of loading point, tph
g = 32.2 ft/sec2
V = design belt speed, fpm
V0 = initial velocity of material as it is fed onto
belt, fpm
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Tac — resistance generated by conveyor accessories
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Conveyor accessories such as trippers, stackers, plows, belt cleaning equipment, and skirtboards
usually add to the effective tension, Te
Ttr — from trippers and stackers
Tpl — from frictional resistance of plows Ttr= 0 lbs
Tpl= 0 lbs
Tbc= 0 lbs
Tbc — from belt-cleaning devices
Tsb= 113.8 lbs
Tsb — from skirtboard friction
Tsb = Lb (Cshs2 + 6)
Lb = skirtboard length, ft one skirtboard,
=10 ft
hs = depth of the material touching
the skirtboard, in =10 in
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Resistance Calculations
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Cw = 0.08
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Tension Relationships and Belt Sag Between Idlers
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T0 = 1856.2 lbs
where :
W = weight, (Wb + Wm), lbs/ft of belt and material
Si = idler spacing, ft
T = tension in belt, lbs
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Maximum and Minimum Belt Tensions
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Belt stress = T1 / Belt width = 17166/42 = 409 lbs per inch of width(PIW)
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Questions?
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© piotr.kasza@agh.edu.pl, piotr.kulinowski@agh.edu.pl Department of Mining, Dressing and Transport Machines AGH tel/fax +48126335162