1.

5 Belt Conveyors

™ All belt conveyors shall be designed in accordance with DIN, CEMA or ANSI
standards.

1.5.1 Drive

™ Gear reducer shall be shaft mounted or directly coupled to the head shaft.
™ Non-return stops for inclined arrangement shall be integrated.

1.5.2 Belt Design

™ Belt seams shall be exclusively vulcanized.

™ Trough angles shall not be less than 30 degrees.
™ Belt speed:
™ Maximum belt velocity shall not exceed 2.0 m/s.
™ Conveyors handling dry fine material (i.e. raw meal, cement) shall not
exceed 1.25 m/s.
™ Belt velocity for conveyors less than 50 meters in length shall not exceed
1.5 m/s.
™ Overland conveyors may operate at velocities in excess of 2.0 m/s but
shall not exceed 4.0 m/s.
™ For solid alternative fuel belt velocities shall not exceed 1.0 m/s.
™ Belt width shall not be less than 800 mm. For special applications 650 mm belts
may be used, subject to written approval by the Project Owner. In packing
plants 500 mm flat belts may be used.
™ Vertical (concave) curves shall be designed to avoid lifting of the belt from the
idlers under any conditions and hence shall have a radius of at least 300 m. Any
deviation in design is subject to written approval by the Project Owner.
™ A minimum of 3 plies for synthetic fabric rubber belts shall be provided.
™ Conveyor belt quality shall be standardized as far as reasonable for each belt
width.
™ For alternative fuel applications oil resistant, fire retardant and antistatic type
belts shall be used.
™ Minimum distance between the centre of the tail end pulley and the skirt
arrangement shall be greater than 2 times the belt width. As a minimum, the
skirt shall not start until full belt trough has been achieved.
™ Maximum conveyor slope:
Maximum Slope Raw Material, Clinker Cement Coal/Petcoke
wet Slag
All sections other
16 degrees 10 degrees 6 degrees (1) 15 degrees
than loading point
At loading point 6 degrees (2) 0 degrees 0 degrees 5 degrees
 Maximum Slope Raw Material, Clinker Cement Coal/Petcoke
wet Slag
(1)
Consideration shall be given to maximize the horizontal section after the last feed point thus
allowing the cement to properly de-aerate and prevent back-flushing on inclined section. Change
from horizontal only after a distance equivalent to 60 seconds belt travel from the feed point is
desirable. Steeper slopes can be accepted depending on the usage of grinding aids and/or
material bed thickness on the belt etc., subject to the Project Owner's written approval.
(2)
Steeper slopes may be acceptable depending upon the application, subject to written
approval by the Project Owner.

Table 1: Maximum Conveyor Slope

1.5.3 Pulleys

™ All drive pulleys shall have rubber lagging.

™ Tail and take up pulleys: rubber lined or spiral wrapped wing pulleys. Wing type
pulleys without spiral are not acceptable.

1.5.4 Idlers

™ Carrier and return idler diameter shall be designed according to DIN (15207-
1/22107) or CEMA (Class C, D or E).
™ Carrier and return idler diameter:
™ 89 mm for 650 mm belts
™ ≥ 100 mm for > 650 to 1000 mm belts
™ ≥ 127 mm for belts greater than 1000 mm
™ Carrier idler spacing shall not exceed 1250 mm for all belt widths.
™ Carrier and return idler spacing for overland conveyors must be selected in
order to limit the belt sag to maximum 1 % (100 % is defined as the
distance between the idler centre lines).
™ High-density polyethylene impact bars or rubber protected impact idlers with
spacing of maximum 300 mm shall be used at loading points.
™ Return idler spacing shall not exceed 3000 mm for all belt widths. Self-aligning
belt idlers and guide idlers shall be used where necessary.
™ For conveyors handling sticky materials, return idlers shall be rubber disc rolls
or anti-adhesive rubber tubes.
™ Permanent lubrication for all idler bearings sealed for life, shall be provided.

1.5.5 Belt Tensioning Stations

™ For belt conveyors less than or equal to 50 m horizontal centre distance screw
tensioning shall be used.
™ For belt conveyors over 50 m horizontal centre distance vertical gravity,
horizontal gravity, or winch tensioning shall be used.

1.5.6 Skirt Plates and Dust Hood

™ Skirt plates and dust hood shall extend not less than 2 m but maximum 5 m
from loading point.
 ™ Skirt plates shall be made of wear resistant material.
™ Skirt plates shall be equipped with adjustable sealing rubber stripes or pads and
shall be of the quick release type for easy adjustment.

1.5.7 Covers

™ Conveyors or parts thereof installed outside of buildings shall be covered.

™ Belt covers shall be semi-circular metal sheets with handles on the accessible
side of the conveyor and hinges on the opposite side.
™ For conveyors handling dry fine material (e.g. cement) the lower edges of the
covers shall extend to 300 mm below the return belt line.

1.5.8 Belt Cleaning Devices

™ Primary and secondary belt cleaners, counter-weight loaded or leaf spring

loaded with segmented scraper blades shall be provided for all conveyors.
Accessible inspection door(s) shall be provided for maintenance.
™ V-ploughs shall be used on return belts to remove spillage in front of tail pulleys,
bend pulleys and for vertical gravity tensioning stations.
™ Reversible belts shall have belt cleaners at both ends and diagonal type belt
ploughs. Cleaners shall be attached to the tail pulley take-up frame.
™ Conveyor layout shall allow both primary and secondary belt cleaners to
discharge directly into head chutes/hoppers. Adequate slope shall be provided
to direct the material to the next following Equipment without build-up.
™ Metal deck plates between carrying belt and return belt at feeding points shall
be provided.

1.5.9 Conveyor Discharge

™ Discharge curve (trajectory) of the material corresponding to the selected belt

velocity shall be considered for all transfer stations.
™ Conveyor head chute shall have replaceable wear liners where abrasive
materials are conveyed. Suitable liner material such as UHMW polyethylene or
stainless steel shall be used for the conveying of sticky material.

1.5.10 Dedusting

™ For belt conveyor transfer points requiring nuisance dust collection at least 3
dust take-off points shall be installed at each transfer point: at the top of the
transfer chute, before and after material impact on the following conveyor.
™ Design of discharge chutes shall minimize hood openings by using bolted
closing plates with adjustable rubber seals.

1.5.11 Spillage Conveyors

™ Conveyor discharge arrangements shall include spillage chutes or scraper-type

spillage conveyors to capture spillage and feed to downstream Equipment, thus
ensuring a spillage-free operation. In any case, the provision for the future
installation of a spillage conveyor shall be made.
1.5.12 Uncovered Belt Conveyors

™ Long, horizontal belt conveyors running in the open (typically alongside pre-
blending stockpiles) shall be equipped with a special device enabling the
discharge of accumulated rain water during stoppage.