1.

INTRODUCTION
Belt conveyor is constantly operating transporting equipment which is mainly used to convey
mass bulk material like mineral, coal, sand, etc in powder or block as well as packed freight in
metallurgy, mining, building heavy industries and transportation industry. Belt conveyor is the
most perfect conveying equipment for coal-mining, because it can work efficiently and
continuously. Compared with other transporting equipments, belt conveyor not only has the
merits of long conveying distance, big capacity, constant working operation, but also with the
features of operational reliability, easy to have automated and concentrated control. Belt
conveyor has become the key equipment especially for high-output and high-efficiency coal
mine.
A conveyor can move material, like cardboard boxes, wood boxes and plastic boxes. This is
called gravity conveyor (Figure 1). When the conveyor can move boxes up against gravity, down
or horizontal, it is a belt conveyor, whose moving belt is controlled by electric power. long
conveying distance, easy maintain, noise reduction, low energy consumption, reliability and
safety to use and so on. At present, the conveyor system is developed in the direction of
automation control by which man made operating mistakes can be reduced. Although the
structure of the belt conveyor is simple, enough attention should be paid to make sure the belt is
installed correctly in the centerline of the driving shaft and driven shaft, or the belt may be offset
or even get loose, which can cause the reduction of belt service life.

Basic drawing of a belt conveyor

2. The main advantages of conveyor belt system are:

1. A wider range of material can be handled which pause problems in other transportation means.
Belt conveyor can be used for abrasive, wet, dry, sticky or dirty material. The lump size of the
transported material is limited by the width of the belt. Belts up to 2500 mm wide are used in
mining industry.
2. Higher capacity can be handled than any other form of conveyor at a considerably lower cost
per ton kilometer. Conveyor belts with capacity of 11000t/h and even higher can be deployed to
match with higher capacity mining machinery.
3. Longer distances can be covered more economically than any other transportation system. A
single belt conveyor o
4. By the use of many forms of ancillary equipment such as mobile trippers or spreaders bulk
material can be distributed and deposited whenever required.
5. Many other functions can be performed with the basic conveying like weighing, sorting,
picking, sampling, blending, spraying, cooling, drying etc.
6. Structurally it is one of the lightest forms of conveying machine. It is comparatively cheaper
and supporting structures can be used for many otherwise impossible structures such as crossing
rivers, streets and valleys.
7. The belt conveyor can be adopted for special purposes (fire resistant, wear resistant, corrosion
resistant, high angle negotiation etc.) and can be integrated with other equipment.
8. It can be horizontal, incline or decline or combination of all.
9. Minimum labour is required for the operation and maintenance of belt conveyor system.
10. In underground mine transport, belt conveyor can be used in thin seams as it eliminates the
rock works that might otherwise be required to gain haulage height. Moreover, belt conveyor can
provide continuous haulage service from pit bottom to the surface.
The limitations of conveyor belt are:
1. The loading and transfer points need to be properly designed.
2. Numbers of protective devices have to be incorporated to save the belt from getting damaged
by operational problems.
3. The belt needs higher initial tension (40-200% of useful pull).
4. The use of belt is restricted by the lump size. If the maximum diagonal of a irregular lump is X
then the belt width (B) is approximately given by: B Xa + 200 where, B: Belt width, mm
X: Longest diagonal of irregular lump, mm ;a: Factor to account for grading. a is taken as 2.5 for
graded material and 3 for un-graded material. However, for particular material these values must
be properly estimated.
5. Higher elongation of the belt (4% elongation may take place at the working load).

3. MAJOR EQUIPMENTS OF BELT CONVEYOR SYSTEM

A. Conveyor Belt
B. Pulleys and Idlers
C. Coupling
D. Bearing
E. Motor
F. Pneumatic Cylinder

G. Structural Frame
H. Hopper.
3.1. Conveyor Belt
The different types of belt conveyor systems demand differences in the design, manufacturing
techniques, operation and maintenance of the belting on a conveyor. This section provides
information on each type of belt and elaborates on the standard types of belting as well as factors
to be considered when choosing a particular belt. In addition to the selection of a belt based on
the minimum number of plies, the stiffness of a fabric belt across its width is affected by the
number of plies in the belt i.e. more plies result in a stiffer belt. If the belt is too stiff, it will not
stay correctly in the troughed idler sets (see example below) in an empty condition. This often
results in misalignment of the belt relative to the conveyor structure. The following table
indicates the maximum number of plies, which a fabric belt should have, to ensure the correct
troughability and belt alignment Conveyor belt is the most expensive but the least durable part of
a conveyor. During the working process of a conveyor, the loading effect with distinctive nature
and in variable size is acted on the belt, which makes the belt in a complex state of stress. There
are several kinds of typical damage forms of the belt: choosing a suitable belt according to the
conditions where the conveyor will be used, enhancing maintenance and management during the
working process are essential to prolong the belts service life, to boost the conveyors efficiency
as well as to reduce the cost of manufacturing the conveyor. Conveyor belt has two kinds of
categories: rubber belt and plastic belt. Rubber belt is normally suitable for the working
temperature of -10oC to +40oC, and the material temperature cannot be over +50oC, or the belts
elasticity will disappear. If the temperature is too low, the belt will become hard and have cracks.
A fireproof belt should be used when the temperature is higher than +90oC while a cold-proof
belt is tilized when the temperature is from -15oC to -55oC. (3, p.3)

3.2. Pulleys
The most commonly used conveyor pulley is the standard steel pulley. They are manufactured in
a wide range of sizes and consist of a continuous rim and two end discs fitted with compression
type hubs. In most wide faced conveyors pulleys, intermediated stiffening discs are welded
inside the rim. Outer pulleys available are self cleaning wing types, which are used at the tail,
take up or snub locations where materials tends to built up on the pulley face, and magnetic types
which are used to remove tramp iron from the material being conveyed
Choosing a right pulley is important. When the belt of a fabric belt core is used, the
pulley is chosen on the basis of the belts thickness. The conveyor belt needs to move
around the pulley repeatedly during the working process, and bending occurs. When the
belt is bent, the external surface is stretched and while the internal surface is
compressed, the stress and strain of each layer vary. The rubber layers have mechanical
fatigue and are damaged due to the scaling when the repetitive bending reaches a certain
level. The smaller diameter of pulley, the bigger the deflection of conveyor belt and the
faster the scaling occurs. Therefore, the diameter D of a driving pulley is decided by the
allowable crook degree of the belt, and D can be fixed by the following formula:
Vulcanized joint: D125Z;
Mechanical joint: D 100Z;
Mobile conveyor: D80Z.
Z- The layers of coated canvas of the belt

3.3. Idler
Idler is the supporting device for belt and cargo of a belt conveyor. Idlers move as the belt
moves so as to reduce the running resistance of the conveyor. Idlers qualities depend on the
usage of the belt conveyor, particularly the life span of the belt. However, the maintenance costs
of idlers have become the major part of the conveyors operating costs. Hence, idlers need to
have reasonable structure, durability in use, small ratio of steering resistance, reliability, and dust
or coal dust cannot get in bearing, due to which the conveyor has a small running resistance,
saves energy and prolongs the service life The idler has steel idler and plastic idler types. The
steel idler is manufactured of seamless steel tube. The diameter of the idler roller has something
to do with the belts width. In the design process of the belt conveyor, when the width B is equal
to or less than 800mm, the idler diameter should be 89mm. When the width is 1000-1400mm,
then the roller diameter should be 108mm

Trough idler

Flat idler
2.6 Idler manufacturing
Idler is a small part of a belt conveyor, but to manufacture a high-quality one is not an easy job.
In this chapter, the process of manufacturing an idler is described in details.
2.6.1 Structure and lifetime of idler
An idler is made up of shaft, sealing, bearing housing, steel tube, and bearing. The form of
idlers sealing is the major design point of an idler, which ensures that the idler is dust-free and
be water proof. Currently, labyrinth style sealing is used.

Fig.Idler structure (6)

1-shaft 2-sealing 3-bearing housing 4-steel tube 5-bearing
Idlers life time is decided by the shafts lifetime, so idlers service time is related to the
following factors:
(1) Load and velocity of the belt conveyor
(2) Lumpiness and impact effect of the conveying material
(3) Continuous operation time
(4) Corrosion of the material and environment
(5) Production and maintenance condition

3.4. Coupling
Couplings are the device used to couple or connect two shafts; this is one of the most important
components of any drive system. Since it is impossible to maintain co linearity
between two shafts couplings are designed to provide better flexibility to allow initial or running
shaft misalignment.
Following are the type of flexible couplings.
Fluid Coupling
Chain Coupling
Geared Coupling
Grid coupling

3.5. Bearing
Bearings are used to give support the shaft of the roller or idle pulley at both ends. They give
also rotational motion of shaft by giving it support with very less friction. Though some friction
is taken place due to the metal to metal contact inside the bearing between metal balls and metal
casings, it is very negligible as compare with the direct contact of rotating shaft and main frame
of the conveyor.

TYPES OF BEARINGS:
There are many types of bearings, each used for different purposes. These include1. Ball bearings

2. Roller bearings
3. Ball thrust bearings
4. Roller thrust bearings
5. Tapered roller thrust bearings.

3.6. Driving device

Driving device is the power transmitting mechanism of a belt conveyor. It is made up of an
electromotor, coupling, reducer and driving pulley and so on. According to different using
conditions and working requirements, the drive mode of a belt conveyor can be grouped to single
motor driving, multi-motor driving, single-pulley driving, and double-pulley driving and multipulley driving. Single motor and single pulley driving is adopted by a belt conveyor. The driving
device is installed at the discharge point which is located at the conveyor head. When the
power is big, a single motor and double-pulley driving is used, precisely, one motor has two
driving pulleys, and the two pulleys are connected by a pair of exposed gear which has the same
number of teeth.

TYPES OF DRIVE UNIT

A) Direct gear motor drive.
B) Drive through parallel shaft gear box.
C) Drive through primary reduction by v belt and secondary
by gear box.
D) Drive through spiral bevel or worm gear box.

3.7. Pneumatic Cylinder

A pneumatic cylinder is a device with two chambers separated by a bore. Each chamber has 1
valve and each has two ports (orifices): One port (The supply port) connects the chamber to a
compressor and the other port (The exhaust port) connects the chamber to atmospheric pressure.
A small cylinder typically has a bore diameter of 5/16 and a stroke of 2 inches. Larger, yet
typical cylinders have bore diameters of 3 inches stroke lengths of about 6 inches.

3.8. Framework
The framework of a fixed belt conveyor is a structure welded of angle iron and trough iron. The
framework can be grouped as drive frame, end frame, middle frame and driving device frame.
Drive frame is used to install driving pulley and return pulley. its side is installed together with a
driving frame. A tail drum is set up on the end frame the structure of end frame has something to
do with the adopted tension device, so the end frame should be chosen by the tension device.
Middle frame is for the installing of upper and down idlers; it is assembled by pieces of frame.
Two ends of the middle frame are connected with a drive frame and end frame respectively

3.9. Drive pulley

The shell face of the conventional drive pulley or the motorised drum may be left as
normal finish or clad in rubber of a thickness calculated knowing the power to be transmitted.
The cladding may be grooved as herringbone design ; or horizontal grooves

to the direction of travel ; or diamond grooves ; all designed to increase the coefficient of friction
and to facilitate the release of water from the drum surface. The drum diameter is dimensioned
according to the class and type of belt and to the designed pressures on its surface.

3.10. Return pulleys

The shell face does not necessarily need to be clad except in certain cases, and the
diameter is normally less than that designed for the drive pulley.

3.11. Hopper
The hopper is designed to allow easy loading and sliding of the material in a way to absorb the
shocks of the load and avoids blockage and damage to the belt. It caters for instantaneous
charging of load and its eventual accumulation.
The hopper slide should relate to the way the material falls and its trajectory and is designed
according to the speed of the conveyor. Lump size and the specific gravity of the charge and its
physical properties such as humidity, corrosiveness etc. are all very relevant to the design.

3.12. Conveyor covers

Covers over the conveyor are of fundamental importance when it is necessary to protect the
conveyed material from the atmosphere and to guarantee efficient plant function.

3.12. Rollers
Support the belt and are guaranteed to rotate freely and easily under load. They
are the most important components of the conveyor and represent a considerable value of the
whole cost. The correct sizing of the roller is fundamental to the guarantee
of the plant efficiency and economy in use

3.13. Brake device

When the belt conveyor is used to transport material aslant, to avoid inversion or slip because of
a fully load which makes the machine halt, when the average angle is more than 4o, aback
stopping or brake device should be added. (3, p.20) There are variable kinds of backstopping and
brake devices in the belt conveyor. Different types of backstopping or brake apparatus should be
utilized according to the specific using conditions. In standard design, there are the belt brake,
the roller brake and the hydraulic solenoid valves brake.

3.14. Cleaning device

When the belts working surface bypasses the unloading drum, it is impossible to clean the
scattered material completely, especially when the material is moist. If this residual material is
not swept away, belt is easily broken due to the extrusion of the residuals when it passes the
return pulley or idlers. Hence, the cleaner is meaningful in prolonging the using life of the belt.
A spring cleanser is often used for the belt conveyor. The rubber scraper of
the cleaner is compacted on the belt surface by a spring and a screw to clean residual
material. The spring cleansers structure is simple.

Spring cleanser
If idlers have the same structure but different lifetimes, then the reason can be imputed to
manufacturing, which is often neglected when idlers lifetime is calculated. To make sure that the
idler is working in an ideal state is the responsibility of every manufacturer. In the manufacturing
process, concentricity error of the bearing at idlers both ends and external circular beating of the
idler are in the range of allowable value. Meanwhile, clearance of the idler cannot be ignored.
4. The recommended components of a belt conveyor requiring routine maintenance and
service:
Electrical: Motors - lubricate internal bearings as recommended by the manufacturer.
Safety switches check electrical connections and any signs of broken parts.
Reducers: Lubricate internal bearings and fill oil level as recommended by the
manufacturer.
Chain drives: Check for proper tension and worn rollers and sidebars.
Screw Take-ups: Check for proper belt tension and remove any built up material.
Idlers: Check for free rotation and excessive worn areas, if any type lubricate as recommended
by the manufacture. Remove any built up material.
Training Idlers: Check for proper alignment to belt and free rotation or excessive worn areas, if
any type lubricate as recommended by the manufacture. Remove any built up material.
Pulleys: Check pulley alignment and surface of lagging if lagged. Pulley assemblies should
rotate freely. Remove any built up material.
Bearings: Check for proper alignment to frame and lubricate as recommended by the
manufacture. Remove any built up material.
Belting: Check for proper tension of excessive wear areas, torn, or ripped areas, if a mechanical
splice check fasteners.
Belt Cleaners: Check for proper tension and wear on the cleaner blade and replace if needed to
keep cleaner from rolling under

5. BELT CONVEYOR TRAINING

.
1. Check that the conveyor structure is perfectly straight and correctly leveled.
2. Check that the head, tail, take-up bend and snub pulleys are all correctly.

mounted. They must be on level and with their axes perpendicular (right angled) to the center
line of the conveyor
3. Ensure that all troughing and return idlers are correctly mounted and with their axes
perpendicular (right angled) to center line of the conveyor. All rollers must rotate freely.
4. Ensure that all self-aligning idlers, when fitted, are pivoting freely.
5. In the case of gravity or winch take-up, ensure that the take-up assembly is square and free to
move. In the case of manually operated screw take-up gears, ensure that the pulley is correctly
square to the line of the belt.
6. Ensure that all parts of the conveyor are greased and / or oiled where necessary.
7. Ensure that all pulleys and idlers are clean and in proper condition.
8. Where skirt plates are involved, check that the seal skirt board is correctly fitted and adjusted.
9. Check along the conveyor and make sure, that there are no items, which could cause damages
to moving equipment.
10.Check that the belt splice is correctly installed and that the belt is straight.

CONCLUSION:
The methodology developed should be used when evaluating alternative conveyor system. with
the operation costs considered in a n economic analysis conveyor system the lowest initial costs
conveyor may not always be the best alternative, These operating costs are extremely important
since they are based on a labour and energy both are subjected to inflation.
The belt conveyor is probably one of the most efficient method Of moving material through a
plant. Proper conveyor system analysis with respect to both operating and purchase cost will
result in the most cost effective system.