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Abstract Bulk material transportation requirements have continued to press the belt conveyor industry to carry higher tonnages over longer distances and more perse routes. In order keep up, significant technology advances have been required in the field of system design, analysis and numerical simulation. The application of traditional components in non-traditional applications requiring horizontal curves and intermediate drives have changed and expanded belt conveyor possibilities. Examples of complex conveying applications along with the numerical tools required to insure reliability and availability will be reviewed. 21084
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Introduction
Although the title of this presentation indicates “new” developments in belt conveyor technology will be presented, most of the ideas and methods offered here have been around for some time. We doubt any single piece of equipment or idea presented will be “new” to many of you. What is “new” are the significant and complex systems being built with mostly mature components. What is also “new” are the system design tools and methods used to put these components together into unique conveyance systems designed to solve ever expanding bulk material handling needs. And what is also “new” is the increasing ability to produce accurate Energy Efficiency computer simulations of system performance prior to the first system test (commissioning).
As such, the main focus of this presentation will be the latest developments in complex system design essential to properly engineer and optimize today’s long distance conveyance requirements.
The four specific topics covered will be:
Idler Resistance
Energy Efficiency
Distributed Power
Analysis and Simulation
Energy Efficiency
Minimizing overall power consumption is a critical aspect of any project and belt conveyors are no different. Although belt conveyors have always been an efficient means of transporting large tonnages as compared to other transport methods, there are still various methods to reduce power requirements on overland conveyors. The main resistances of a belt conveyor are made up of:
Idler Resistance
Rubber indentation due to idler support
Material/Belt flexure due to sag being idlers
Alignment
These resistances plus miscellaneous secondary resistances and forces to over come gravity (lift) make up the required power to move the material.1
In a typical in-plant conveyor of 400m length, power might be broken into its components as per Figure 1 with lift making up the largest single component but all friction forces making up the majority.
Figure 1
In a high incline conveyor such as an underground mine slope belt, power might be broken down as per Figure 2, with lift contributing a huge majority. Since there is no way to reduce gravity forces, there are no means to significantly reduce power on high incline belts.
Figure 2
But in a long overland conveyor, power components will look much more like Figure 3, with frictional components making up almost all the power. In this case, attention to the main resistances is essential.
Figure 3
The specifics of power calculation is beyond the scope of this paper but it is important to note that significant research has been done on all four areas of idlers, rubber indentation, alignment and material/belt flexure over the last few years. And although not everyone is in agreement as to how to handle each specific area, it is generally well accepted that attention to these main resistances is necessary and important to overall project economics.
At the 2004 SME annual meeting, Walter Kung of MAN Takraf presented a paper titled “The Henderson Coarse Ore Conveying System- A Review of Commissioning,
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