SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ
THE LONGEST PIPE CONVEYOR OF THE WORLD WITH DOUBLE LOAD TRANSPORT AT CEMENTOS LIMA IN PERU
J. Wiedenroth, Koch FLSmidth MVT GmbH, Wadgassen, Germany
INTRODUCTION
Since the end of the 1970s Pipe Conveyors have become
increasingly important for conveying bulk materials because they have
some specific advantages over conventional troughed belt conveyors.
FLSmidth KOCH Pipe Conveyor represent the marked-leading know
how of the former KOCH Transporttechnik GmbH, which belongs to
the FLSmidth Group since January 2007. Pipe Conveyors from
FLSmidth KOCH are already being used successfully at more than 260
locations around the world. Their special properties, their extreme
flexibility, the horizontal and vertical changes in direction without
transfer points, the small space requirement, the low-noise running and
their optimum protection of environment and material without any
additional casing mean that Pipe Conveyors can provide transport
solutions that are often far superior to other conveying systems. The
utilization of these many advantages will be illustrated in the following
example of the world’s longest Pipe Conveyor at Cementos Lima, the
Peruvian cement producer.
DEFINITION OF THE PROJECT
Cementos Lima, a privately owned company, produces cement in
Peru and the USA. The parent works is located between Atocongo and
Conchan, two towns on the southern outskirts of the Peruvian capital
Lima. The route between the cement works with the quarry (right) and
Pacific Ocean Coast with the loading terminal (left) is shown in Fig. 1.
Figure 1. Aerial view of the Cement plant (right) and the loading
terminal at the Pacific coast (left).
In-between is the town of Conchan with its many streets, lanes,
houses, craft businesses and shops. Between the Coast (left) and the
cement factory there is a height difference of 160 m.
The terrain is hilly. The transport of all the materials for cement
production, the limestone from the adjacent quarry and the limestone
delivered via the loading terminal, the coal to provide the energy, and
the other cement constituents as well as the outward transport of
clinker and cement had previously been carried out by lorry. In the past
200 to 250 lorries had to pass through the town every day. This led to
a high traffic density with numerous accidents, poor road conditions,
severe air pollution and excessive noise levels. The cement works
wanted to further increase production and at the same time lower
transport costs, so they had to look for an environmentally friendly and
inexpensive solution for transporting the future streams of material.
In future a conveying system should transport 600 t/h cement or
500 t/h clinker from the works to the terminal, 450 t/h coal or 500 t/h
limestone or other cement constituents like gypsum from the terminal
to the works with simultaneous transport of different bulk materials in
both directions. An additional margin of 15 % of the nominal capacity
shall be handled as peak load by the conveying system.
1 Copyright © 2010 by SME
Preprint 10-041
PLANT PLANNING
Route Planning
If you draw a straight line from the cement silos of the plant to the
cement silos of the terminal you find a distance of 6.5 km starting at a
level of 185 m above MSL, crossing the hills at 325 m and reaching the
terminal at 25 m above MSL. Besides the vertical profile you cut
through hundreds of houses and private properties. A route like this
would be impossible because of all the private areas which were not
available for building the conveyor system through the town. So it was
suggested that the conveyor system should be installed underneath
the main roads because these are public properties. This required the
construction of a 6.5 km tunnel, which is shown by the broken red line
in Fig. 2. Outside the town the conveying system could be designed on
bridges, preventing access of unauthorized persons (playing children)
and allowing unobstructed traffic routes below. The conveyor system
also had to wind between the existing silos and buildings within the
cement works and had to be kept away from the high voltage lines.
Figure 2. Route of the KOCH Pipe Conveyor with control stations
under the main roads of Conchan
The conveyor system had to follow the existing road accurately so
this automatically led to 15 horizontal and 20 vertical curves, some of
them with small radii (e.g. 60 degree curve with 300 m radius). The
conveyor system had to be made very compact so the tunnel could be
as small as possible, and it was necessary to avoid transfer points in
the tunnel, with the resulting risk of pollution, large space requirement
and expenditure on maintenance. For all these reasons the best option
was to use a KOCH Pipe Conveyor. The tunnel has eight entrances for
safety reasons shown in Fig. 2 by black lines – at the entry and exit
portals and at six other side entrances at a distance of about 900 m
that are called Control Stations. These access tunnels for air, power,
communication and also, in an emergency, for rescue teams open onto
pieces of ground next to the road where there had previously been
houses. These areas now contain small buildings with watchmen.
These access tunnels were also of great advantage for installing the
Pipe Conveyor and pulling in the belt and will be needed in future for
maintenance and repair work.
To obtain authorization from the authorities for the construction of
the tunnel, which could of course not be built without any noise or dust
pollution and without disturbing the traffic, it was agreed that the entire
new road would be constructed with all underground infrastructure,
green central strip and central lighting by Cementos Lima (Fig. 3). The
cement company also undertook to look after the green central strip
and the whole road in the future
The production plant can be seen in the background in Fig. 4; the
silos with the cement packing plant and the lorry loading point are in
the centre and the cement works’ canteen is on the left.

Old road before the tunnel was built New road with green central strip
and central lighting
Figure 3. Old and new road of Conchan.
Figure 4. View towards the cement works.
The transfer point for the Pipe Conveyor was to be constructed in
the immediate vicinity of the cement silos, so the conveyor system was
routed between the buildings and past the residential houses of the
works’ housing estate to the tunnel entrance just in front of the town.
The life in the works’ housing estate was not to be adversely affected
by noise or dirt. Obviously, it was also necessary to ensure the safety
of the residents and their children under all circumstances.
The cement silos, the clinker store and the coal store, which form
the land-based infrastructure of the ship loading terminal, can be seen
in Fig. 5. This is where clinker, cement and coal are held in
intermediate storage so that the ships can be loaded and unloaded as
quickly as possible. The transfer point for the Pipe Conveyor was to be
built on the right, next to the silos.
Figure 5. Land-based infrastructure of the ship loading terminal.
2 Copyright © 2010 by SME
SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ
The operating principle of a Pipe Conveyor with double load
transport
The illustration Fig. 6 shows the mode of operation of a Pipe
Conveyor with double load transport. Bulk material 1 is fed onto the
troughed upper strand and thrown off at the discharge pulley, precisely
as with a conventional troughed conveyor. Between these points the
belt is rolled up into a dust- and water-proof pipe. However, for double
load transport the lower strand has to be turned over in a belt turnover
station so that the bulk material can again be fed onto the carrying
side. Bulk material 2 is fed onto the troughing zone of the lower strand
and enclosed by the surrounding belt. The overlap is again at the top,
as with the upper strand. The belt opens up before the discharge
pulley for the lower strand and is flat when it runs over the pulley. The
bulk material is directed sideways by a chute so that there is sufficient
space for the belt to continue onwards. The belt is then turned over
again so that it runs over the tail pulley in the original position.
conventional disposal
loading-bottom run
loading-top run closed pipe
belt turn over 1
disposal return conveying
belt turn over 2
Figure 6. The operating principle of a Pipe Conveyor with double load
transport
Along its length the Pipe Conveyor can easily pass through
vertical, horizontal and even three-dimensional curves with relatively
tight radii.
The double load transport system permits simultaneous transport
of different bulk materials in two different directions. The pipe cross-
sections filled with two different bulk materials (in this case cement and
coal) can be seen in Fig. 7. In both cases the overlap is on the top.
Each strand of the belt is held in a circular shape by six rollers with
overlapping coverage. Three idlers are located in front of the panel and
three behind it (off-set arrangement). The patented idler brackets allow
to adjust the idlers individually to control the belt.
Thumb Values for Volumetric Capacity and Minimum Radii of Pipe
Conveyors
Table 1 can be used for a first rough dimensioning of a Pipe
Conveyor system. Here you find the maximum volumetric capacity of
Pipe Conveyors of different sizes combined with common belt speeds.
Of course you can adapt the speed according to the individual
properties (length, bulk material properties, inclination, curve radii,
etc.).
The possible mass flow depends on the density of the bulk
material because the Pipe Conveyor is in principle a “volumetric”
conveyor. In Table 1 you find values for coal or iron ore as an example.
Table 2 contains guide values for designing minimum curve radii
as a function of the tensile medium in the conveyor belt, the diameter
of the belt and the deflection angle of the curve.
The radii result from the additional elongation of the belt on the
outer side of the curve compared with the inner side. Here the stress-
elongation behavior of the tensile medium plays a decisive role. A
nylon belt (PP) with pipe diameter of 300 mm can pass round a 45 °
curve with a radius of 120 m, but a steel cord belt requires a radius of
240 m for the same curve.
 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

Panel
Belt
Patented idler
brackets
Bulk material 1

Idlers

Bulk material 2

Figure 8. Self-supporting lattice structure of the bridges with a span

up to 26 m.
Figure 7. Double load transport by Pipe Conveyor System.
Inside the tunnel very light panels on feet were used, connected
Table 1. Maximum capacity of a Pipe Conveyors in groups by longitudinal beams with cross bracing, thus ensuring the
Coal Iron Ore necessary stability and the exact parallel alignment of the panels.
Gravity [t/m³] 0,8 2,4
Diameter Speed Volumetric flow Handling rate Handling rate The photograph (Fig. 9) also shows the pull cord safety switch
in mm in m/s in m³/h in t/h in t/h (emergency stop). This safety device is provided at all accessible
150 2,1 94 75 224 areas of the Pipe Conveyor. The emergency pull cord switches are
200 2,1 165 132 396 designed such that the staff in the control room can monitor which pull
250 3,0 366 292 877 cord switch has been actuated. A targeted search and reset of the
300 3,0 520 416 1248 switch is therefore guaranteed.
350 3,0 716 573 1718
400 3,7 1131 904 2713
450 3,7 1430 1144 3432
500 3,7 1761 1409 4227
550 4,5 2630 2104 6312
600 4,5 3152 2521 7564
650 4,5 3675 2940 8820
700 5,4 5103 4083 12248

Table 2. Guide values of minimum curve radii of Pipe Conveyors.

Diameter Curve Radius „R“ depending on the
Reinforcement
„d“ deflection angle of the curve
75° to
in mm < 25° 25° to 50° 50° to 75°
100°
150 – 300 300 d 400 d 500 d 600 d
Nylon (PP)
350 – 500 400 d 500 d 600 d 700 d
Polyester 150 – 300 400 d 500 d 600 d 700 d
Nylon (EP) 350 – 500 500 d 600 d 700 d 800 d
150 – 300 500 d 600 d 700 d 800 d
Aramid (D)
350 – 500 600 d 700 d 800 d 900 d Figure 9. Light panels on feet connected in groups are used inside the
150 – 300 700 d 800 d 900 d 1000 d tunnel.
Steel Cord (St)
350 - 500 800 d 900 d 1000 d 1100 d
Transfer area Atocongo Cement Plant
Pipe Conveyor route inside and outside the tunnel Figure 10 shows the transfer area in the Atocongo cement works.
Outside of the tunnel a self-supporting lattice structure of the The lower strand of the Pipe Conveyor loaded with coal comes from
bridges with a span up to 26 m is used (Fig. 8). The panels with the the right, opens and discharges into the chute at the drive pulley. The
idlers are part of the supporting structure. The one-side walkway chute carries the bulk material past the belt to an intermediate
allows for easy control and maintenance of the plant. Bridges with underground hopper that can hold the entire contents of the lower
larger spans are designed as gallery bridges, which support the Pipe strand.
Conveyor. The belt is deflected down and to the right by the pulley and then
Up to a height of 8 m concrete columns are used, which were passes through the supported belt turnover station. The belt can then
inexpensively fabricated by the cement factory itself. For greater be washed and dried while it rises to the upper level. Cement or clinker
heights of up to 18 m lattice supports were utilized which are are supplied by a conveyor belt and distributed by the diverter flap to
considerably lighter in weight. High concrete foundations were built in the cement weighing silo on the left or the clinker silo on the right. The
order to protect against collision and for access guarding against cement is fed from the aerated silo and onto the Pipe Conveyor at the
unauthorized persons. conveying speed by a metering unit and an accelerating screw, while

3 Copyright © 2010 by SME

 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

the clinker is extracted by a vibrating feeder from the clinker silo. The Table 3. Design data of the Pipe Conveyor.
upper strand then closes to form the pipe belt. Units Value
Speed m/s 4.0
Diameter of the Pipe mm 300
Panel spacing at straight line m 1.75
Panel spacing in curves m 1.40
No. of panels -- 5005
No. of idlers -- 60080
Sum of bending angles of all curves degree 286

The result of the calculations is shown in Fig. 12. At each end the
Pipe Conveyor has a drive pulley with rubber-ceramic friction lagging,
each with two drive units with installed ratings of 800 kW. The drives
are provided with frequency converters and external aeration to ensure
the necessary acceleration ramp time of 240 s. Under normal
circumstances the belt conveyor system is stopped over a ramp-down
time of 45 s. A ST 2500 6T+6T steel cord belt is used that is also
suitable for elevated temperatures of the material being transported.
Figure 10. Transfer area in the Atocongo Cement Plant. Feeding point Cement
and Clinker Belt ST 2500 6T+6T
Transfer area Conchan 2 drives à 800 kW incl.
frequency converter
The Pipe Conveyor leaves the tunnel again at Conchan, i.e. on
the Atlantic coast, where the loading terminal is situated (Fig. 11). The
upper strand separates from the lower strand and rises over a distance
of 248 m to the discharge point at the top of the silos. The lower strand Take-up carriage incl.
weights and Kapstan break
rises only slightly to the feeding point for the coal or limestone. The
routing was chosen as it had the least conflict with the existing
facilities. 2 drives à 800 kW incl.
frequency converter Belt turnover 1

Feeding point Coal

and Limestone

Belt turnover 2
Figure 12. Results of the calculations of the double strand Pipe
Conveyor at Cementos Lima in Peru.
The diagram in Fig. 13 shows the development of the calculated
belt tension during normal operation when the upper strand is loaded
with cement (600 t/h) and the lower strand with limestone (500 t/h).

Gurtzugkräfte in der Beharrung Ober- und Untertrum beladen

Obertrum beladen
Untertrum beladen
Obertrum leer
Untertrum leer
OT steigend beladen
OT fallend beladen
Gurtzugkraft in kN

Figure 11. Discharge pulley with drive units; transfer chute cement
and clinker; take up system; belt turning station and material loading
point for coal or limestone.
Special emphasis had been placed on an excellent dedusting
system and a dust-free transfer of material, respectively.
The take-up system consists of a take-up carriage which is
connected to two counterweights by two tension ropes. Between the 0 1000 2000 3000 4000 5000 6000 7000 8000 9000
take-up carriage and the counterweights the ropes run through a so- Abstand vom Aufgabepunkt Atocongo in m
called “Capstan Brake”, which artificially increases the counterweight in Figure 13. Belt tension in the upper and lower strand.
case of an emergency stop. This artificial counterweight increase
prevents the counterweight from bouncing up during these dynamic The following loading conditions have been calculated:
processes and an extreme decrease of the belt traction forces at
critical points can thus be Upper strand and lower strand loaded
Upper strand and lower strand empty
DIMENSIONING OF THE PIPE CONVEYOR Upper strand loaded in ascending sections only
Upper strand loaded in descending sections only
Detailed calculations to determine the belt tensile forces and drive
rating were carried out for the design of the Pipe Conveyor on the For a conveying system as long and as complex as the Cementos
basis of the specified route. First of all it was necessary to define all Lima Pipe Conveyor System with the different loading conditions, a
the sub-sections accurately with respect to length, gradient, vertical dynamic calculation is required in order to ensure a safe design. Belt
and horizontal curves with radius and angle. Table 3 lists some traction forces, strains on and speed of short belt sections in short time
important design data of this Pipe Conveyor. intervals in transitional phases (start-up and slowdown) are calculated.

4 Copyright © 2010 by SME

 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

The results of the dynamic calculations show whether the
selected take-up system is appropriate and reveal the maximum
movements of the take-up pulley, the occurring forces and speeds of
the belt etc.
distance of 8.2 km between centers makes it the longest Pipe
Conveyor in the world. The Pipe Conveyor, which has 15 horizontal
and 20 vertical curves and which can transport two different bulk
materials simultaneously in opposite directions, came into operation at
the end of 2007 and was accepted by the client in January 2008 after a
successful 24-hours performance test. This presentation starts by
describing the situation and provides interesting information about the
planning, design, installation and commissioning of the Pipe Conveyor.

Figure 14. Guided belt turn-over.

The guided belt turn-over has the advantage of a shorter turning
length for a steel cord belt (min. 15xB) and is superior with high belt
speeds (4 m/s). It corresponds almost exactly to the Pipe conveyor
shape in the middle of the turning process. Both minimum belt traction
force and minimum turning length have to be re-calculated in order to
avoid compression in the belt centre and excessive belt tension in the
belt edges.
COMMISSIONING AND PERFORMANCE ACCEPTANCE TEST OF
THE PIPE CONVEYOR
Cold commissioning took place in the months of
September/October 2007 after the installation had been completed and
the conveyor belt had been pulled into place. The first cement was
transported from the cement works to the loading terminal on 17th
December 2007. In the performance acceptance test carried out on
20th January 2008 the conveyor system was successfully
demonstrated in a test run over 24 hours and handed over to the client
(Fig. 15). A nominal transport capacity of 600 t/h was achieved over
the entire period, with a peak load of 690 t/h for 10 minutes. During the
test run an emergency stop was also carried out at peak load and the
plant was then started again without any problems.

Figure 15. 24-hours continuous operation with the nominal capacity of

600 t/h of cement.
CONCLUSION
The Peruvian cement producer Cementos Lima decided to install
a Pipe Conveyor system. The goal was to make the transport of raw
material (coal and limestone) and the products (cement and clinker)
between the cement plant and the loading terminal 8.2 km away more
reliable, less expensive and more environmentally friendly. At the
same time the transport capacity should be increased. FLSmidth
KOCH was awarded the contract to supply a modern Pipe Conveyor
with dual transport system. For a distance of 6.5 km this system runs
through a tunnel under the main roads of the town of Conchan. The

5 Copyright © 2010 by SME