The attached sketch shows a typical burden surcharge gauge for a 900 min wide belt. For wider belts you will need a few more rods and a longer cross member. The loaded conveyor is stopped and isolated and then the gauge placed on to the stringers. The rods are dropped down on to the burden and the length of each rod below the cross member recorded together with the distance from the edge of the belt to the tip of the wing roller and from the edge of the belt to the edge of the burden on both sides. It is some times worthwhile taking 2 or 3 readings at different locations on the conveyor. If only taking one reading, do it just after the loading point. This information together with the idler dimensions can then be drawn by a draftsman. A single circular curve, that approximates to the measured Surface profile, is superimposed on the drawing and the angle of this Curve at the point of contact with the belt is measured to obtain the surcharge angle. \ Mite Boe ban Wiel PAP Ageless Jo |? | Mio wut | | 1 yi was ro RAG 1 19x16~ oe 450 Love, é ti Souteve ~ i | Acre! Clpat f IT STenGces joe] Bett SodsPractical Belt Conveying Part I, Chapter 4 Page 1 of 7, Rev.2, 4.6 47 48 49 4.10 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 CHAPTER 4 URDEN SURCHARGE ANGLE TABLE OF CONTENTS INTRODUCTION FULLNESS RATIO LOADING CHUTE DESIGN SLOPE REDUCTION FACTOR. BELT VELOCITY CONVEYOR LENGTH BELT SAG RIPPERS HORIZONTAL CURVES ESTIMATION OF SURCHARGE ANGLE General Material Reduction Allowance Kay Slope/Velocity Reduction Allowance K, Special Reduction Allowances K, Examples of Surcharge Angle Calculations Copyright“ROM” MANUFACTURERS OF HIGH QUALITY CONVEYOR EQUIPMENT BULK MATERIAL CHARACTERISTICS Table 4.0 ty lek [fom © [fk | amon MATERIAL siet, [emleeeel cx MATERIAL one, [aeetesiee| oan om” | gees | eae Cn | sees | tages ‘ian tre rave02 835 | Genet, 102mm sip ‘64308 wa ‘ky. ain 35 Corea. 150rm snp tne 2405 | [ra [ Riri 202-1082 | TO | 70:12 [Bara —| conn ove ~ | itzt acs 2 oa 7a 1603:3405 Asbestos sired 20401 aa a Aah tick, goon i 7 ean 7a ‘Ashes, oly Si ae und |B -F 3075 1200 483 | Ashes coat di. Tenm ander S66 | ‘9 i608 rae | 25 | asa 73-808 earrei || 2095 fie 1250 D47T | ah, we casing cy 60317 -sphat binderfor peg 125.1980 645 | Felten tam eeronngs [22-89 Asta shed. 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For 2.1988 | 48 be [Cement mor ise ieecensted ri || ~ [oe Champ 12021965 Ire = —Trer hak, 10 mesh nar | Toro 202 ‘ron or fi zc ‘cheer SEEM of evshad prises ‘hip, papr na 520404 Tron oie, pre [aos ‘his. per mil slinood—— aa ian ca Ton vd ier | 1010 | Gey tne aso Beni, irre wah flrs aah ain ~ Pain ne mos ara 88 hy clcned “a Ten Lead oes 206 4329 hy dy toes ont824 | 15 | BOB Timeton, are Gay dy py wez i202 | 45 | 1820 Sire and one [Got antec, vero cn, ——[tivestons. cused 2mm and undo 82 19_| ossty_[Umestore ait one Coal antacid enzo 1026 | Wi nea aren [Coa bri, ined Manganese ae 008 28s 0 mesh and under ones | 20 | 24 | seer | Nckatcobo subivie oe | war sane Cosi, bominous, ined ad sind | 724 2 | 15 —F8 [rons mn oa. baninni mined Paper pl aoak tno nine revase | 20 | te | past _ | Phosphate; ne ete onl Bs aa Sat ca Phosphate sine mnedaect. nm ander lesse02 | zo | 2 | cast | gomsemce sone _| 20 | a0 | pose Cos. bitrincus, Pression baie Ay frene Dea] 1s [eis [bas —| stipeng rot lane 02962 ser | Phoepnin osk verses 20 | 35 | Coal. Ugite ear rat {20 | ae | ast —| Pytes en ono Tor ang | se 2I05 Dorr ‘eke, 360.961 0 | paraVT | Pyles pees ‘224.2086 | | feast — Coke, perioum cated | eexr2t 20 bev a ae | |r | Cake trnre, ane and der [aor sot | 1590-| ao99 | CaF Toate | — core Covet, Str simp 1643005 24-26 [098 | Outs Smo Fn tne | THEE TRE are 414 * May vary considerablyPractical Belt Conveying Part I, Chapter 4 Page 2 of 7, Rev.2 4, 44 BURDEN SURCHARGE ANGLE INTRODUCTION The burden surcharge angle is defined as ‘the angle between the top surface of the material burden and the horizontal when measured at the edge of the burden.” The idealised burden profile shown in Fig.4-1 is formed by a circular are, which is tangential at its edges to the surcharge angle. ‘This idealised profile is used in ISO 5048, BS 2890 and CEMA. However the German Standard DIN 22 101 shows the burden surcharge profile as a triangle, Fig.4-2. A note at the end of DIN 22 101 states that the angle of the surcharge triangle should be two thirds of the ISO angle. The circular are profile is more representative of the actual burden profile and is therefore recommended. Fig.4-1 Fig.4-2 CEMA, ISO, BS DIN 22 101 COMPARISON OF SURCHARGE ANGLE REPRESENTATION The surcharge angle of a given material is not only a function of the physical properties of the material but itis also effected by various aspects of the conveyor design. It is not therefore a true material property and it is possible to have a series of conveyors all handling the same material at the same flow rate but due to different features of conveyor, a different surcharge angle may be applicable to each conveyor ch ‘The following factors will effect the surcharge angle and they should be taken into consideration when selecting a suitable surcharge angle for the design of a new conveyor or when evaluating the material surcharge angle on an existing conveyor:~ ©The angle of repose of the material * The internal friction angle of the conveyed material. © The material particle size and the lump to fines ratio. The moisture content of the material and the possible variations that could occur. * The fullness ratio of the material on the belt. The design of the loading chute. * The angle of inclination of the conveyor at the loading point. Copyrightof Bulk Materials Mi laterial Characteristi ‘The successful design of a belt conveyor must begin with an accurate appraisal of the characteristics of the material to be transported. A few important characteristics require definition. ‘The angle of repose of a material is the acute angle which the surface of a normal, freely formed pile makes to the horizontal. ‘The angle of surcharge of a material is the angle to the horizontal which the su face of the material assumes while the material is at rest on a moving conveyor belt, This angle usually is 5 degrees to 15 degrees less than the angle of repose, though in some materials it may be as much as 20 degrees less, The flowability of a material, as measured by its angle of repose and angle of sur- charge, determines the cross-section of the material load which safely ean he carried (ona belt. Italso is an index of the safe angle of incline of the belt conveyor. The flowability is determined by such material characteristics as: size and shape of the fine particles and lumps, roughness or smoothness of the surface of the mate rial particles, proportion of fines and lumps present, and moisture content of the material, Table 3-1 illustrates and defines the normal relationship of the foregoing proper: ties and the general characteristics of materials, Table 3-1, Flowability-angle of surcharge-angle of repose, Flow fa Very ree towing 1" | _ Free tlowing 2° Average flowing 3° Slugaish a Angle of Surcharge e io] 20° 2 30 e ate ~T if z Angle of Repose 019" 20-25" 30-34" 35-39° 40° up Material Characteristics [Uniform si very Rounded dorpok regular ramior | Type common | regular avg Anal rounded part ished partes of | ortonny meriaeof | nmeriahsuchachita | firene inertcteg des either very et or | metvm wight such | meium weight snch | sui cal sane, | meneal nce verydry such asdry | aswholegrainand | asanthrate coal cat | mest mec re wood hips Fase sien sand. cement, | beans tensed mea clay. ee tempered fry wet coneet te cant et *Code designations conform to hulk material characteristics chart, Table 3-2 Consideration should also be given to the weight per cubic foot of the material; its dustiness, wetness, stickiness, abrasiveness; its chemically corrosive action; and its temperature, Some general information concerning these properties of many mater 30Practical Belt Conveying Part I, Chapter 4 Page 3 of 7. Rev.2 42 43 * The maximum angle of inclination of the conveyor. + The belt velocity «The length of the conveyor. ‘©The belt sag between the idlers. ‘©The inclusion of a tripper in the conveyor. © The inclus - foarte mn of one or more horizontal curves in the conveyor ‘The following subsections provide additional detdil orf sOme of these aspects and their effect on the surcharge angle FULLNESS RATIO. Ne E Guckage ‘The fullness ratio is defined as ‘the ratio of the cross sectional area of material on a conveyor divided be the normal design cross sectional area.’ Generally, the fuller the belt the greater the surcharge angle. a ~ fet LOADING CHUTE DESIGN [faded ‘The design of the loading chute, particularly the amount of redirection of the material stream in the direction of belt travel, can have a major effect on the surcharge angle. Ideally the material stream at the loading point should have a horizontal velocity component equal to the belt velocity. The use of *V" shaped loading boots mounted close to the belt or curved chutes can also help to improve the surcharge angle. The angle of inclination of the conveyor at the loading point will also affect the surcharge angle. Photo 4a shows a conveyor transporting fine iron ore, This conveyor has a horizontal loading zone and the burden surcharge angle is in the order of 10°. Photo 4b shows another conveyor handling similar material. In this case, the loading zone is inclined at 15° and the burden surcharge angle is closer to 0°. Photo 4b 15° loading point Photo 4a Horizontal loading point CopyrightPractical Belt Conveying Part I, Chapter 4 Page 4 of 7, Rev.2 44 4.6 47 48 49 SLOPE REDUCTION FACTOR Many conveyor design standards and manuals recommend a reduction in the cross sectional area of the conveyed material where sections of the conveyor are inclined (Refer ISO 5048 and DIN 22 101). This reduction in cross sectional area is based n the assumption that the surcharge angle will change as the angle of the conveyor increases. In practice, once the material has settled 10 its surcharge angle at the Joading point, subsequent changes to the surcharge angle do not appear to occur on inclined sections. A reduction in the surcharge angle is not therefore considered necessary for normal conveying angles of up to 20 degrees, provided the material is capable of being conveyed up the slope without slippage and provided the inclined section of conveyor does not include the loading point. BELT VELOCITY Belt velocity can have an effect on the surcharge angle and generally higher belt velocities will result in some loss of surcharge angle. This is particularly noticeable on steeply inclined loading points. CONVEYOR LEN 3TH On long conveyors, the vibration caused by the belt passing over the idlers can cause a reduction in the surcharge angle. However, the reduction in surcharge angle is generally accompanied by consolidation of the conveyed material such that the burden edge distance is not reduced. BELT SAG On conveyors with relatively low belt tensions, ic. belt sag between the idlers exceeding 1% of the idler spacing, the opening up of the burden at the mid span and the subsequent bunching at the next idler set will have a detrimental effect on the surcharge angle. In cases where the belt sag is excessive or where the centre roll of an idler is higher than the adjacent sets, the material burden can actually become airborne as it passes up and over the idler and this lifting of the burden also results in loss of surcharge angle. TRIPPERS In the approach curve to a tripper, the belt will lift off the idlers and flatten out. When the belt is retroughed, the surcharge angle and the burden edge distance will often be reduced and material spillage may occur. For this reason a reduction in the nominal burden surcharge angle is recommended for conveyors fitted with trippers. HORIZONTAL CURVES. In horizontal curves, the conveyor belt is pulled towards the centre of the curve and the idlers have to be banked (0 counter this effect. The effect of this idler banking on the burden surcharge angle will depend on the material being handled and the CopyrightPractical Belt Conveying Part I, Chapter 4 Page 5 of 7, Rev.2, 4.10 4.10.1 4.10.2 4.10.3 banking angle. It is generally prudent to use a reduced surcharge angle or alternatively, an increased burden edge distance on horizontally curved conveyors. ESTIMATION OF SURCHARGE ANGLE General If there is no reliable surcharge angle information available for similar materials on similar conveyors, the following method offers a guide to the selection of a suitable surcharge angle. The method is based on reducing the angle of repose to allow for (a) the material properties, (b) the belt velocity and angle of inclination at the loading point and (c) special allowance for trippers ete. Nominal surcharge angle A= YW —Ky~K,—K, degrees Where: y =angle of repose degrees Ky, = material reduction allowance degrees K, = slope/velocity reduction allowance degrees K, = special reduction allowance degrees Note: if the surcharge angle obtained is a negative value, a rethink on belt velocity or the angle of the loading point may be necessary. Material Reduction Allowance Kn, For this allowance the following three reduction values are recommended:- Material description Reduction allowance Ky, Fine material with 5% moisture - content o interlocking material Dry material with low fines content, 10° e.g. crushed rock Dry, free flowing fine material 15° Slope/Velocity Reduction Allowance K, This allowance takes into consideration the belt velocity and also the angle of the conveyor at the loading point. The following table gives surcharge angle reduction values for a range of belt velocities and loading angles. These reduction values are proportional to the time taken to accelerate the material at the loading point with an assumed coefficient of friction between the belt and the material of 0.5. ‘These reduction values are for typical transfers where there is some material redirection at the loading point. If the feed chute provides effective material redirection, these values could be reduced. If the feed chute does not provide any material redirection, these values should be increased, CopyrightPractical Belt Conveying Part I, Chapter 4 Page 6 of 7, Rev.2 4.10.4 4.105 Conv. Angle Conveyor surcharge angle reduction allowance K, at loading Belt velocity nvs Point degrees 1 2 3 4 5 6 0 # £ & 8 10° 12° 1 2 £ & & 10° 12° 2 28 a oe 9 ie 13° 3 2 ¥ Pr xe ue 1° 4 2 = Ee e 12 1° Hotes ae & 7 10° 12° 15° 6 Ey ¥ 8° 10° 13° 15° 7 = 5° 8° ue 13° 16° 8 3° e s ue 1 7 9 3% © ° 12° 15° 18° 10 = oF - Be 16° is Ln al - 10° 13° via 20° 12 # Pr ue 1 ise [2° 3 ae Be ue 15° 19° 23° See ila ae 8° 19° 16° me 25° 15 cm - 13° 18° 22° 27° 16 10° 15° 20° 24° 29° Special Reduction Allowances Ky The special reduction allowance for belt sag, trippers and horizontal curves will depend in part on the design of these features of the conveyor and also the nominal surcharge angle obtained from the other factors. If the nominal surcharge value is, high, say greater than 15°, some additional reduction in the surcharge angle is recommended to allow for the effect of these special features. For conveyors with a tripper a K, value of 5° to 10° should be adequate. If the belt sag is high, i.e. exceeding 1% of the idler centres, a special reduction allowance of 5° should be made. Examples of Surcharge Angle calculations (a) Crushed rock Angle of repose 37° Belt velocity 2 m/s Horizontal loading High belt sag 37° - 10° 4° 5° = 18° CopyrightPractical Belt Conveying Part I, Chapter 4 Page 7 of 7, Rev.2 (b) Fine iron ore, dry Angle of repose 34° Belt velocity 4 mis 15° inclined loading Surcharge angle = 34° — 15° 18° = 1° (©) Fine iron ore, 4% moisture Angle of repose 37° Belt velocity 4 m/s 15° inclined loading Kn=5° K, 8° ‘Surcharge angle = 37° — 5°-18° = 14° (d)_ As for (c) but horizontal loading Ks 5° kK Surcharge angle = 37° — 5° — 8° = 24° Copyright