Belt Feeder FDR 002

Client Name TATA STEEL Designer E.
MUÑANTE
Project Name Sukinda Blue Sky Project Company WOOD
Conveyor Name BP-SI-BP-BP-FDR-002 Filename belt feeder FDR 002
Location INDIA Date junio 24, 2019
Description Coarse Hub Waste Rock (Crushed rock)
System Information Series name C4 C4

Calculation method...........................CEMA 7th (default) Number of rolls 1 1
Conveyor Length / Height..................................6 / 0.0 m Trough angle (deg) 0 0
Material lift..............................................................0.0 m Type Inline Inline
Ambient temperature range..............................8 to 47 °C Idler spacing (m) 0.20 3.00
Number of idler sets 8 2
Roll diameter 102 102
Material Properties Roll rpm 56 56
Type....................................................Coarse Waste Rock Total drag (N) 3.4 3.4
Design Tonnage.....................................................124 t/h Drag range (N) 1.7 - 5.5 1.7 - 5.7
Density............................................................2670 kg/m3 Roll length 891 891
Maximum lump size..............................................12 mm Shaft diameter (mm) 25 25.0
Surcharge angle......................................................20 deg Rating (N) 1,112 1,112
Calc Idler Load (N) 740 604
Belt Properties L10 life1 (1000 hrs) 350.0 0.0
1
L10 life above which 95% of idlers exceed
Type............................................................Fabric (3-Ply)
Width....................................................................800 mm Drive Station
Rating...............................................................800 N/mm
Speed...................................................................0.30 m/s Type...........................................................Variable speed
Top / bottom cover thickness.....................12.0 x 4.5 mm Synchronous RPM...........................................1500 RPM
Total thickness.......................................................22 mm Motor quantity / rating...................................1 / 11.0 kW
Weight (new / worn)...............................20.0 / 12.8 kg/m Total installed power...........................................11.0 kW
Modulus.........................................................7,254 kN/m Nominal empty / full power..........(8 / 60%) 0.9 / 6.7 kW
Tape length...........................................................13.60 m Min / max demand power.............(8 / 65%) 0.9 / 7.1 kW
Belt cycle time............................................................45 s Frame Size........................................................IEC 160M
Motor Voltage..........................................................400 V
Tension Summary Running Momentary Efficiency....................................................93.5 to 97.5%
Maximum starting torque........................................123%
Maximum tension (kN) 44.6 58.2
Inertia - Motor...................................................0.1 kg·m²
Minimum safety factor 14.35 10.99
Pulley lagging type................................................Rubber
Minimum tension (kN) 23.7 18.2
Motor wrap angles......................................................180
Maximum belt sag (%) 0.33 0.42
Lagging friction factor (run / accel).................0.32 / 0.38
Cross Sectional Loading
Material mass (wm)..........................................114.8 kg/m Take-up Data
Combined mass (wm + wb)..............................134.8 kg/m
Type..........................................................................Fixed
Edge distance (required / actual)................................N/A
Location....................................................Tail / Pulley #2
Cross sectional area....................................................N/A
Steady state tension..................................23.7 to 29.1 kN
Cross sectional loading (utility / total).......................N/A
Momentary tension..................................18.3 to 29.1 kN
Bed depth....................................................................N/A
Required pulley displacement................................1.26 m
Dynamic displacement (incl thermal)................0.00 m
Permanent elongation.........................................0.09 m
Flooded belt tonnage..............................................124 t/h

Flooded (wm + wb)...........................................134.8 kg/m
Idler Set Data

Carry Return
Sidewinder - v7.42 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 1 / 8
Client Name TATA STEEL Designer E. MUÑANTE
Splice length (2 included)..................................0.93 m Splice step length.................................................300 mm

Clearance............................................................0.25 m 22 degree bias angle.............................................325 mm
Total splice length................................................925 mm
Backstops
Backstop type.............................................None installed Other Information
Loaded beltline mass (excluding motors)...........2,989 kg
Brakes Total inertia (ref HS shaft)...............................0.01 kg·m2
Brake type..................................................None installed
Demand Power (kW)
Reducer Information Demand % Motor
Case
power Nameplate
Manufacture................................................................N/A
Empty - NF 0.9 8.0
Frame size...................................................................N/A
Full - NF 6.7 60.5
Reducer ratio........................................................170.970
Full - LF 5.1 46.1
Catalog reducer ratio................................................0.000
Full - HF 7.1 64.9
RPM (High Speed)..........................................1500 RPM
RPM (Low Speed)..............................................8.8 RPM Din Factor and Total Equivalent Mass
Configuration................................................Shaft Mount Belt line
Number of stages............................................................3 Case Din factor
mass (kg)
Service factor...............................................................1.5 Empty - NF 0.0218 29,065
Power rating.................................................................0.0 Full - NF 0.0144 29,639
Full - LF 0.0095 29,541
Motor Torque Full - HF 0.0210 29,652
100% Motor Torque - High Speed........................71 N·m
Motor Shaft Torque - Running (FN).....................43 N·m Maximum Belt Tensions (kN)
Motor Shaft Torque - Starting (FN)......................84 N·m Case Running Dynamic
100% Motor Torque - Low Speed.................12,155 N·m Empty - NF 30.2 30.2
Low Speed Shaft Torque - Running (FN)........6,889 N·m Full - NF 43.9 57.6
Low Speed Shaft Torque - Running (Max).....7,213 N·m Full - LF 41.0 54.6
Low Speed Shaft Torque - Starting (FN).......13,217 N·m Full - HF 44.6 58.2
Low Speed Shaft Torque - Starting (Max).....13,542 N·m
Belt Safety Factor
Case Running Dynamic
Starting and Stopping Empty - NF 21.19 21.16
Start control......................................................Fixed time Full - NF 14.56 11.11
Start time...................................................................5.0 s Full - LF 15.61 11.72
Emergency stop control.............................................Drift Full - HF 14.35 10.99
Emergency stop time.......................................0.7 to 3.2 s
Material buildup in chute........................................0.0 m³ Splice Safety Factor
Empty - NF 14.12 14.11
Tension Ratios Full - NF 9.71 7.41
Allowable (running)...................................................2.73 Full - LF 10.41 7.81
Running tension ratio.................................................1.88 Full - HF 9.57 7.33
Allowable (dynamic)..................................................3.30
Starting tension ratio..................................................3.19 Minimum Belt Tensions (kN)
Transition Lengths Empty - NF 29.1 29.1
Full - NF 23.9 18.5
Transition method...............................................CEMA 7 Full - LF 25.2 19.7
Tail transition length (inline)..................................1.00 m Full - HF 23.7 18.2
Head transition length (inline)...............................1.30 m
Maximum Belt Sag (%)
Estimated Splice Data Case Running Dynamic
Splice type..............................................................2-Step Empty - NF 0.25 0.25
Full - NF 0.31 0.40
Page 2 / 8
Client Name TATA STEEL Designer E. MUÑANTE
Full - LF 0.19 0.24

Full - HF 0.33 0.42

Page 3 / 8
Conveyor Profile
Overall length = 6 m - Overall height = 0.0 m - True Length = 6.0 m
Pulleys
Pulleys - Top View
Maximum Pulley Tensions (without any additional safety factors)

Running (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 44.6 29.1 68.3 58.2 29.1 84.8
Take-up Pulley 1-HT 180 29.1 58.8 29.1 58.8
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # L10 Life Shaft Force Angle Torque Moment
Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)

Page 4 / 8
1 2.10 6.22 0.067 500 49.0 26.0 484 75.2 184 7.6 7.2
2 3.13 5.36 0.057 500 32.0 32.7 484 64.9 356 0.2 6.2
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
1 Rubber 630 12.0 654 900 110 90 1125 520 23220 543
Pulley Shaft Information

Hub Bearing Overhung
Tensile Yield Fatigue Hub Fillet Overhung
Locking Shaft Center to Fillet Moment
Type Strength Strength Strength Diameter Radius Load
Device Material Distance Distance Arm
(MPa) (MPa) (MPa) (mm) (mm) (kN)
(mm) (mm) (mm)
1 XT-45 SAE 1045 565.0 310.0 282.5 110 740 85 30 0.0 180

Page 5 / 8
Load Case # 2 - Loading Point # 1 27. Material Shear Force..............................28,781 N
Calculation Method..........................................CEMA
Calculation Data
28. Shear Coefficient (u)....................................0.643
29. hc ...............................................................0.00 m
30. Qc/Ac ............................................................0 Pa
31. Beta............................................................0.0 deg
32. X - Factor.................................................0.00 deg
33. Y - Factor.................................................0.00 deg
Total Drag
1. Steady State..............................................17,566 N
2. Starting.....................................................36,558 N
Dimensions
3. Slot Length...................................................3.00 m
4. Slot Width at Front.......................................0.53 m
5. Slot Width at Rear........................................0.43 m
6. Exit Length...................................................0.00 m
7. Material Depth on Skirtboards...................370 mm
Hopper
8. Hopper Width...............................................5.00 m
9. Hopper Length.............................................3.00 m
10. Hopper Half Angle..................................39.0 deg
11. Hopper Wall Friction Angle.....................18.0 deg
12. Hopper Shape Factor........................................0.0
Bin - Area Above Hopper

13. Material Height in Bin...............................0.00 m
14. Bin Shape Factor..............................................0.0
15. Material Surcharge Height in Bin..............0.00 m
16. Surcharge Shape Factor....................................0.0
Other Forces
17. Drag Forces - Slot.....................................7,766 N
18. Drag Forces - External....................................0 N
19. Sliderbed Drag Forces.....................................0 N
20. Material Acceleration....................................10 N
Pullout Forces
21. Surcharge Factor (qf)......................................0.85
22. Vertical Load..........................................15,230 N
23. Material Shear Force................................9,790 N
Startup Forces
24. Surcharge Factor (qi)......................................2.50
25. qi/qf................................................................2.94
26. Vertical Load..........................................44,775 N

Page 6 / 8
Load Case # 3 - Loading Point # 1 27. Material Shear Force..............................28,781 N
Calculation Method..........................................CEMA
Calculation Data
29. hc ...............................................................0.00 m
30. Qc/Ac ............................................................0 Pa
31. Beta............................................................0.0 deg
32. X - Factor.................................................0.00 deg
33. Y - Factor.................................................0.00 deg
Total Drag
1. Steady State..............................................13,683 N
2. Starting.....................................................32,675 N
Dimensions
3. Slot Length...................................................3.00 m
6. Exit Length...................................................0.00 m
Hopper
8. Hopper Width...............................................5.00 m
9. Hopper Length.............................................3.00 m

14. Bin Shape Factor..............................................0.0
Other Forces
Pullout Forces
22. Vertical Load..........................................15,230 N
Startup Forces
24. Surcharge Factor (qi)......................................2.50
25. qi/qf................................................................2.94
26. Vertical Load..........................................44,775 N

Page 7 / 8
Load Case # 4 - Loading Point # 1 Startup Forces
Calculation Method..........................................CEMA 24. Surcharge Factor (qi)......................................2.50
25. qi/qf................................................................2.94
26. Vertical Load..........................................44,775 N
27. Material Shear Force..............................28,781 N
Calculation Data
29. hc ...............................................................0.00 m
30. Qc/Ac ............................................................0 Pa
31. Beta............................................................0.0 deg
32. X - Factor.................................................0.00 deg
33. Y - Factor.................................................0.00 deg
Total Drag
1. Steady State..............................................18,343 N
2. Starting.....................................................37,334 N
Dimensions
3. Slot Length...................................................3.00 m
6. Exit Length...................................................0.00 m
Hopper
8. Hopper Width...............................................5.00 m
9. Hopper Length.............................................3.00 m

14. Bin Shape Factor..............................................0.0
Other Forces
Pullout Forces
22. Vertical Load..........................................15,230 N

Page 8 / 8

Belt Feeder FDR 002

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Belt Feeder FDR 002

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Client Name TATA STEEL Designer E.

System Information Series name C4 C4

Flooded belt tonnage..............................................124 t/h

Idler Set Data

Sidewinder - v7.42 - Conveyor Design Software

Splice length (2 included)..................................0.93 m Splice step length.................................................300 mm

Full - LF 0.19 0.24

Sidewinder - v7.42 - Conveyor Design Software

Pulleys - Top View

Maximum Pulley Tensions (without any additional safety factors)

Pulley Shaft Results

Sidewinder - v7.42 - Conveyor Design Software

Pulley Geometry Details (Pulley Types)

Pulley Shaft Information

Sidewinder - v7.42 - Conveyor Design Software

Bin - Area Above Hopper

Sidewinder - v7.42 - Conveyor Design Software

Bin - Area Above Hopper

Sidewinder - v7.42 - Conveyor Design Software

Bin - Area Above Hopper

Sidewinder - v7.42 - Conveyor Design Software

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