Team Names:

Ahmed Yasser Roshdy Ragab

Ahmed Yahia Gaafar Mohamed
Osama Hisham Mohamed Kandl
Islam Farag Seliem Abozied
Islam Mahmoud Shaaban Mahmoud
Alaa Mahmoud Abdelmoati Mohamed
Alhassan Abdelmonaem Abdelhameed
Ola Abdallah Faried Shokry

BELT CONVEYOR
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Abstract

Belt conveyors are widely recognized as critical components in material handling systems, facilitating the seamless
transportation of goods across industries. This academic report presents a comprehensive examination of belt conveyor
systems, with a focus on optimizing their efficiency and promoting sustainability. By integrating advanced technologies,
innovative design solutions, and environmental considerations, this study aims to provide valuable insights for engineers and
researchers seeking to enhance the performance and eco-friendliness of belt conveyors.

The report highlights the fundamental role of belt conveyors in modern industrial operations and the challenges associated
with their design and operation. It emphasizes the need for optimization to address issues such as energy consumption,
maintenance requirements, and system reliability.

To achieve these optimization goals, the report explores a range of analytical and computational techniques. It covers
mathematical models that accurately estimate belt tensions, power demands, and material flow rates, enabling engineers to
design and analyze conveyor systems effectively.
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Contents
Introduction .................................................................................................................................................................................. 4
1-Belt Conveyor ............................................................................................................................................................................ 5
2-Design and Selection of Belt Conveyors ................................................................................................................................... 6
3-Types Of Conveyor Belt............................................................................................................................................................. 7
4-Application And Uses Of Belt Conveyor ................................................................................................................................... 7
5-ADVANTAGES AND DISADVANTAGES OF BELT CONVEYORS .................................................................................................... 8
6-Common Belt Conveyor Problems And Environmental Effects .................................................................................................. 9
7-Companies that use and manufacture belt Conveyors..........................................................................................................10
8- A Brief History of the Conveyor Belt System.........................................................................................................................10
9- Belt Conveyor Safety:.............................................................................................................................................................10
References ..................................................................................................................................................................................11
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Table of Figures
Figure 1 Belt Conveyor system ______________________________________________________________________________________ 5
Figure 2 Troughed Rollers Figure 3 Trainer Roller ________________________________________ 5
Figure 4 Belt conveyor Frame _______________________________________________________________________________________ 6
Figure 5 Airport Belt Conveyor System [12] ____________________________________________________________________________ 8
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Introduction

Belt conveyors are essential tools used in various industries to transport materials efficiently over long distances. They play a
crucial role in streamlining material handling processes, enabling the movement of bulk goods with minimal manual labor.
However, with the increasing demand for improved efficiency and environmental sustainability, it becomes necessary to
analyze and optimize belt conveyor systems.

This academic report aims to provide a comprehensive understanding of belt conveyor systems and present practical
approaches to enhance their performance and sustainability. It targets engineers, researchers, and industry professionals
seeking valuable insights and solutions to overcome challenges related to energy consumption, maintenance, and operational
limitations.
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1-Belt Conveyor
A belt conveyor is a system that moves materials, goods, and even people from one place to another. Belt conveyors differ
from other conveyors as a belt is used instead of chains, spirals, hydraulics, etc. to move things. It uses a loop of flexible
material stretched between rollers that are moved by an electric motor.
The belt's material varies depending on the system it is employed in. It frequently appears as a rubber or polymer belt.[1]

Figure 1 Belt Conveyor system

Main Components of Belt Conveyor

1- Head/Drive Pulley: is used for driving a conveyor belt. It is normally mounted in external type bearings and driven by a motor
and reducer. Conveyor head pulleys can be flat faced or crowned and many have lagging to reduce belt slippage by increasing
the belt’s grip by putting a rough jacket over its outside. The jacket is known as a lagging.
Types Of Pulley Lagging:
• Ceramic lagging: is the process of bonding strips of rubber lagging straight onto the steel pulley. Cold bonding has low
application cost as it’s easy to perform. However, cold bonding does not offer 100% rubber tear adhesion as over time, the glue
and filler used to bond the rubber strips can wear away, creating gaps where water can penetrate the lagging. This can result in
pulley shell corrosion which significantly affects the pulley’s performance.[3]
• Hot Vulcanizing: is the highest quality, maintains higher friction between belt and pulley, improving the efficiency and preventing
material build-up and protects pulley from corrosion.[3]
2- Return / Tail Pulley: is used to redirect a conveyor belt back toward the drive pulley. It commonly serves the purpose of a Take-
Up pulley to keep tension on the belt.
It sometimes has a wing shape that lets material fall away from the belt and onto the support members, which cleans the
belt.[2]
3- Idler Rollers: are used to support the belt and prevent sagging, for example:
• Troughing Idlers: Three idler rollers will be arranged in a way to form a trough. While the two on the ends can be modified, the
idler in the center is immovable which allows flexibility in the trough’s depth and angle
• Trainer idlers: make sure the belt goes in the right direction. It does this with the help of a central pivot that turns the roller
back to the middle if the belt moves to the side. It also has two guide rollers that help keep the belt in place. [1],[2]

Figure 2 Troughed Rollers Figure 3 Trainer Roller

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4- Conveyor Belt it is made of 3 main parts which are illustrated in the following:
• Conveyor Carcass: this is the belt’s skeleton, it needs to have the tensile strength to move the belt and the lateral
stiffness to support the load. Carcasses are made of textile fibers, commonly cotton, nylon, polyester and aramid.
• Conveyor Covers: This is a flexible material made from rubber or PVC. It should not be hygroscopic as if the material
to be transported is wet (moist), the material will not stick on the belt. The material should also have a low bulk
density so as not to increase the load on the drive motor.
• Conveyor Frame: will be different depending on how much it needs to carry, how high it needs to be, and how far it
needs to go. It is a metal structure made of normal and stainless steel. [1]

Figure 4 Belt conveyor Frame

2-Design and Selection of Belt Conveyors

When designing a belt conveyor, it’s important to consider some parameters including [5]:
• Speed of belt
• Motor power
• Belt conveyor Take-ups
These are affected by multiple factors including [5]:
• Mass flowrate desired of the material to be conveyed.
• Characteristics of material conveyed, e.g., the bulk density.
• Material of the conveyor belt.
• Distance to be moved.
• Working conditions, e.g., temperature.
Speed of belt:
Speed is decided by the desired flowrate of material to be conveyed, the higher it’s the higher the mass flow rate.
For belt conveyors typically the speed ranges between 1 to 2 m.s-1 with a maximum speed of 4 m.s-1 [4]
It can be calculated by knowing the circumference of the drive pulley and the revolutions per unit time from this relation [6]:
v= F x C
v: speed of the conveyor belt in m.s-1
F: revolution per second (RPS) of the drive pulley.
C: circumference in meters
Motor power:
Calculation of motor power is done by calculating the driving force of the drive pulley which is a function of the total mass,
and the speed of the conveyor belt from this relation [4]:
(𝑇𝑑 ⋅ 𝑣) Where:
𝑃=
735 ⋅ 𝜂 P is the motor power in hp
Td is the driving force in N
v is the speed of conveyor in m.s-1
𝜂 Is the overall efficiency (from the motor to the drive and from the drive to the belt)

Belt conveyor Take-ups:

All conveyor belts will experience stretching, new belts will stretch an additional 2% of their length, this can cause slacking
which causes problems in the conveying process. Take-up pulleys play a vital role in belt conveyor design by ensuring optimal
tension control as the belt stretches over time due to operating conditions such as thermal expansion [7].
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There are different types of belt conveyor take-ups such as:

• Screw Take-up
• Gravity Take-up
• Horizontal Take-up

3-Types Of Conveyor Belt

1- Roller Bed Conveyor Belt :
The surface of this type of conveyor belt is made up of rollers that are selected to match production requirements, such as
the weight or needed speed of the products that will be transported along the belt. Roller bed conveyor belts are a good
option for transporting items over long distances as they reduce friction, making it easier for products to move along the
belt.[6]
2- Flat Belt Conveyor :
Is the most widely used conveyor systems in existence now. When moving objects inside a building, or internal conveyance,
flat belts come in handy. This kind of conveyor belt moves a continuous flat belt made of synthetic or natural materials using
a succession of powered pulleys (ex. polyester, nylon). This kind of conveyor belt is extremely adaptable because its belts can
be manufactured of various materials.[6]
3- Modular Belt Conveyors :
Modular conveyor belt systems use a single loop made of countless interlocked pieces, usually made of hard plastic. These
segments can be removed and replaced individually, in contrast to having to discard the entire belt. They’re also easier to
wash, as well as more resistant to sharp and abrasive materials. This makes modular belt conveyors simpler to maintain and
repair than their flat belt counterparts. Modular belt conveyors are well-suited to applications that involve travelling around
corners. [6]
4- Cleated Belt Conveyors :
Cleated belt conveyors feature vertical cleats or barriers in their designs. These cleats can keep loose materials secure during
inclines and declines, to provide consistent spacing between items, and more. Furthermore, cleats come in different shapes,
each with its own application.
* Inverted Capital “T.”
* Forward-Leaning Capital “L.”
* Inverted “V.”
* Lugs and Pegs[6]

4-Application And Uses Of Belt Conveyor

Belt conveyors can be of great help in various environments such as [8]:

• Manufacturing • Packaging industries • Food and drug industries

industries
• Pharmaceuticals • Textile industries • Airports/ Shipyards

• Chemical • Sorting and assorting • Bakery and ice cream

The usageindustries/plants manufacturers
of belt conveyors in an industrial environment can be for packing, sorting, or even assembling the parts of the final
product. Another application is their use in airports where a complex system of different belt conveyors is used, some for
changing elevation from the plane to ground to straight belts that will then load belts to elevate the baggage back to circular
belt for passengers to receive their baggage [9].
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Figure 5 Airport Belt Conveyor System [10]

5-ADVANTAGES AND DISADVANTAGES OF BELT CONVEYORS

A belt conveyor offers numerous advantages and disadvantages when considered as a mechanical method for conveying
bulk materials.
Advantages: Disadvantages:

• Cost-effectiveness for long-distance material transport.
• Minimal degradation of conveyed products.
• Capability for elevation changes.
• Visibility of materials while in transit on the belt.
• Flexibility in loading points along the conveyor.
• Ability to incorporate "trippers" for unloading at various
points.
• Integration of metal separators into the conveyor design.
• Addition of weigh belt sections for continuous product
weighing.
• Option for pivoting at one end, enabling discharge
movement over an arc (radial
• stacking).
• Incorporation of cleats on incline belts to prevent product
rollback.
• Attachment of sidewalls to prevent product spillage.[11]
• The standard design of a belt conveyor is open. If your
product requires containment, adding covers or drip
pans can be both costly and inconvenient.
• Cleaning the belt can be challenging and often
ineffective, particularly with sticky materials.
• Material carryover from the belt discharge is almost
unavoidable, leading to maintenance
• Sticky materials tend to transfer to the return side of
the belt and accumulate on rolls,
• Controlling odors is nearly impossible in such
situations.[11]
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6-Common Belt Conveyor Problems And Environmental Effects

(1): COMMON BELT CONVEYOR PROBLEMS:
Problem 1: The Conveyor Runs to One Side at a Certain Point Problem 2: The Conveyor Belt Slips
in the System.
The causes of this would include:
The causes of this would include:
• Traction is poor between belt and pulley.
• Material building upon the idlers or something causing the
• Idlers stuck or not rotating freely.
idlers to stick.
• Worn out pulley legging (the shell around the
• Idlers no longer run square to the path of the conveyor.
pulley that helps increase friction).
• Conveyor frame tilted, crocked, or no longer level.
• The belt was not spliced squarely. [12]

Problem 3: Overstretching of the Belt
The causes of this would include:
• The belt tensioner is too tight.
• Belt material selection not done properly, probably
“under belted.”
• Conveyor counterweight is too heavy.
• The gap between the idler rolls is too long.
Problem 4: The Belt Wears Excessively at the Edges
The causes of this would include:
• Belt is loaded off-center.
• High impact of material on the belt
• Belt running against conveyor structure.
• Material is trapped between belt and pulley.[1]

(2): Environmental Effects on Belt Conveyors

Water, petroleum products, chemicals, heat, sunlight, and cold all influence the belt conveyor’s performance and life.
The causes and the effects can be categorized as:
Moisture Effects Effects of Sunlight and Heat
• The belt rots and cracks. • Rubber will dry out and weaken.
• Belt loose adhesion. • The rubber will crack.
• Causes slippage.

Cold Effects Effects of Oil

• The belt stiffens and becomes harder to guide and
train.
• On incline systems, frost can build up and cause
slippage.
• Ice can build up in chutes and clog them.
• Rubber will swell.
• Rubber will lose tensile strength.
• The belt will be worn quicker.[12]
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7-Companies that use and manufacture belt Conveyors

• Nationally:
1. Egyptian Engineering Company (EEC): for mining, cement, and construction
2. Egyptian German Company for Engineering Industries (EGCI): for food processing, pharmaceuticals, and automotive in
Egypt.
3. Egyptian Italian Co. for Conveyors (EIC): for agriculture, mining, and manufacturing.
4. Egyptian Packaging & Plastic Systems Corp. (EPPS): for e packaging, logistics, and e-commerce
5. Misr Development Company (MDC): for mining, quarrying, and construction.
6. Egyptian Group for Construction & Trade (ECAT): for construction, agriculture, and mining in Egypt. [13]
• Internationally:
1. Hytrol Conveyor Company: manufacturing, distribution, and logistics.
2. Dorner: food processing, packaging, and pharmaceuticals.
3. FlexLink: automotive, electronics, and consumer goods.
4. Interroll: food processing, airport logistics, and e-commerce.
5. Siemens: mining, cement, and automotive.
6. Bosch Rexroth: automotive, electronics, and general manufacturing.
7. FMH Conveyors: e-commerce, parcel handling, and distribution centers.
8. Beumer Group: mining, logistics, and bulk material handling.[13]

8- A Brief History of the Conveyor Belt System

• 1892 – Thomas Robin invented the conveyor belt to move coal and ore for Thomas Edison and his Edison Ore-Milling
Company in Ogdensburg, New Jersey.
• 1901 – Sandvik was a Swedish engineering company that produced the first steel conveyor belts.
• 1905 – Richard Sutcliffe, an Irish born mining engineer, invented the world’s first underground conveyor belt.
• 1913 – Henry Ford developed conveyor belt assembly lines at Ford Motors’ Highland Park, Michigan factory to speed
up motor production.
• 1970 – Intralox, a Louisiana- based company, introduced and registered the first patent for all plastic, modular
belting.
• 1972 – The longest straight conveyor in the world was made by Hyacynthe Marcel Bocchetti and the French Society
REI. It measured 13.8km in length.
• 2015 – The longest conveyor in the world is located in West Sahara. It runs over 60 miles from a Moroccan phosphate
mine to the edge of the ocean.

9- Belt Conveyor Safety:

• Stay off the moving belt: It's like a giant moving escalator, and you don't want to get stuck in it.
• Watch out for pinch points: These are places where the belt meets rollers or other parts - getting caught
there can be really bad.
• Give the conveyor space: Especially if it's going uphill or carrying heavy stuff.
• Be alert and pay attention: Listen for warnings and watch what's going on around you.
• Wear the right gear: Hard hats, glasses, gloves, and shoes with good grip will help protect you.
• Don't reach into a moving conveyor to clear jams. Use tools or wait until it stops.
• Report any broken parts right away. Don't use a broken conveyor, it's dangerous!
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References

[1] Accessed (2023, February 16). Belt Conveyors - Components, Types, Design, and Applications. DPH Engineering.
https://dphengg.com/blogs/belt-conveyors-components-types-design-and-applications/

[2] Conveyor Pulley: Head, Tail, Drum and Belt pulley. (n.d.). Heinrich Brothers. Retrieved April 18, 2024, from
https://heinrichbrothers.com/product/conveyor-pulleys/#:~:text=Drive%20Pulley%20%2F%20Head%20Pulley

[3] Solutions, A. E. (2021, May 6). Conveyor Pulley Lagging - Different types of lagging, the steps involved & the variables that
impact on the lagging selection process. Arolco Engineering Solutions.

https://arolcoengineeringsolutions.com/conveyor-pulley-lagging-different-types-of-lagging-the-steps-involved-the-
variables-that-impact-on-the-lagging-selection-process/#:~:text=Pulley%20lagging%20is%20the%20process

[4] 3.TRANSPORTATION OF SOLIDS 3.1. Classification of Conveyors. (n.d.). Retrieved April 18, 2024, from
https://scholar.cu.edu.eg/?q=magdi/files/chapter_3_updated.pdf

[5] Ananth, Konakalla Naga Sri, Vaitla Rakesh, and Pothamsetty Kasi Visweswarao. "Design and selecting the proper conveyor-
belt." International Journal of Advanced Engineering Technology 4.2 (2013): 43-49.

[6] Accessed (2023, February 16). Belt Conveyors - Components, Types, Design, and Applications. DPH Engineering.
https://dphengg.com/blogs/belt-conveyors-components-types-design-and-applications/

[7] feeco. (2021, April 1). Take-up Options for Belt Conveyors. Feeco.com.

https://feeco.com/choosing-between-take-up-options-for-belt-
conveyors/#:~:text=A%20gravity%20take%2Dup%20assembly

[8] TriMech India. (2021, March 13). Belt Conveyor - Major Uses and Application. Trimech India.
https://www.trimechindia.com/blog/belt-conveyor-major-uses-and-application/

[9] 8 Basic Types of Conveyor Belts and Their Applications. (2020, June 12). Industrial Equipment Supplier - Elixir Philippines.

https://www.elixirphil.com/types-conveyor-belts-applications/

[10] Airport Baggage Conveyor Belt. (n.d.). Indiamart.Com. Retrieved April 18, 2024, from
https://m.indiamart.com/proddetail/airport-baggage-conveyor-belt-23686607548.html

[11] https://www.thomasandmuller.com/products/belt-conveyors/

[12] https://dphengg.com/blogs/belt-conveyors-components-types-design-and-applications/