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Contents to be discussed
1. introduction

2. Belt Conveyors

3. Chain Conveyors

4. Screw Conveyors

5. Pneumatic Conveyors

6. Oscillating Conveyors

1 2

Conveyor Systems
Introduction
• Conveyors are gravity or powered equipment commonly used
for moving bulk or unit load continuously or intermittently.
• Uni-directionaly from one point to another over fixed path,
where the primary function is conveying of the materials by the
help of movement of some parts/components of the equipment
• Conveying Equipment is a group of machines which move
materials in relatively large quantities in a continuous flow
between specific locations over a fixed path.
• Conveyors divided into two basic categories:
1. Powered conveyors
2. Non-powered conveyors.
• In powered conveyors, the power mechanism is contained in
the fixed path, using belts, rotating rolls, or other devices to
propel loads along the path.
• They are commonly used in automated material transfer
systems.

3 4

• In non-powered conveyors, materials are moved either manually Belt Conveyor

or by human workers who push the loads along the fixed path.  Consists of an end less flat and flexible belt of sufficient strength
• There are over 400 types of conveyors. made of plastic, fabric rubber, leather or metal which is laid on two
• The commonly used type of conveyors are metallic pulleys at two ends and driven in one direction by driving
Belt Conveyors one of the two pulleys.

Oscillating Conveyors  Material is placed on this moving belt for transporting.

Chain Conveyors and Bucket Elevators  The active half of the belt is supported by idler rollers or slider

 Screw Conveyors bed, the return half may or may not be supported as it do not carry
any load other than its own.
 Pneumatic Conveyors

5 6

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Cont’d…
They are the most versatile and widely used of all conveyors. Cont’d…
They are suitable for handling a wide variety of materials.  Belt conveyors have attained a dominant position in
They can handle a wide range of capacities over longer transporting bulk materials due to such inherent advantages
distance than possible with other types of conveyor systems as their
 economy and safety of operation,

 reliability,

 versatility, and

 practically unlimited range of

They are adaptable for performing numerous other functions
capacities.
such as weighing, blending sampling(mixing) and stock
piling(stocking over)
7 8

Cont’d…

Sample of belt Conveyor

They can be used as a sorting

equipment in some food
processing Industries beyond
conveying the materials. Belt conveyors are suited to the carrying of all material, wet or dry, from
the lightest to the heaviest, and in any quantity.
9
Used in mass production ,shipping, assembly operation e.t.c 10

Cont’d… Cont’d…

11 12

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Cont’d…
Belt Conveyor Components/parts
 The belt conveyor is composed of the belt, the idlers, the
pulleys, the drive equipment, the take-up and the supporting
structure.

Flat conveyors
13 14

Cont’d…
The belt The belts must have:-
 The belt is an endless moving rubber-covered conveyor for
 flexibility, in order to wrap around the pulleys,
transporting materials.
 Width, enough to carry the required quantity of the
 made up of fibers having longitudinal strength for pulling the material (standard)
load, transverse strength for supporting the load.  strength, enough to bear the weight of the load and
 The belt cover is made of special wear-and impact- resisting transmit the pull in the conveyor
rubber compound with cord breaker strips imbedded in tough
rubber.

 Wire covered in rubber

Typical Cross-section of the Conveyor Belt 15 16

Cont’d…
1. Cotton-Fabric Ply-Constructed Belting: is the most widely
used kind of rubber covered conveyor belt
 the fiber is made up of a number of layers or plies of woven
cotton fabrics of various weight.
2. Cord Belts are made up of longitudinal fibers or steel cords
imbedded in rubber provide greater strength, more flexibility and
somewhat greater impact resistance.
 The steel cord belt has the further very desirable characteristic of
low stretch ability, making possible ever-increasing conveyor
Cont’d…
3. Heat Service Belts are available for jobs where hot materials up to
1200C must be handled.
Belt Idlers: Thus are rollers used at certain spacing for supporting
the active as well as return side of the belt
 carry and train the belt.
 Idlers must be selected to properly protect and support the belt
and load to be carried.
 The type of belt idlers with in the series includes 20 degree

centers and capacities. and 45-degree throughing rubber cushion, belt training, flat
belt and return idler.
17 18

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Cont’d…
Cont’d
 Two types of idlers in belt conveyors
Straight carrying and return idlers; used for supporting active
side of the belt for flat belt and also for supporting the return
belt in flat orientation in both flat or troughed belt conveyor.
Troughing idlers; consisting of 2,3 or 5 rollers arranged in the
form of trough to support the belt in a troughed belt conveyor.

19 Fig. 7.3 Types of Idlers 20

Drives for belt conveyors

 Practically all belt conveyors are driven by an electric
motor directly connected to a speed reducer unit through a
flexible coupling.
Belt Conveyer Drive Arrangements
Selection of the type of speed-reduction mechanism can be
determined by preference, cost, power limitations, limitations of
the speed-reduction mechanism, limitations of available space,

 The belt conveyors are generally driven at the head end or desirability of drive location
A high-speed motor, which costs less and occupies less
pulley where material is discharged.
space, is preferred to a slow speed motor.
 The drive pulley is connected to the drive motor through
The following pictures shows some of the Belt Conveyer Drive
suitable speed reduction gear box and flexible shaft Arrangements
couplings

. 21 22

Cont’d… Cont’d…
.
Gear motor is directly Parallel-shaft speed reducer coupled to motor, and with
connected, by a flexible
chain drive, to drive shaft
coupling, to the motor’s drive
shaft provides flexibility of location and also is suitable for
Is a simple, reliable and
low speed high torque requirements.
economical drive
Spiral-bevel helical speed reducer, helical-worm speed
Gear motor combined with chain drive
to drive shaft — reducer, or worm-gear speed reducer, directly coupled to
 is one of the lowest cost flexible motor and to drive shaft
arrangements, provides additional
 is often desirable for space-saving reasons and simplicity
reduction, and is substantially reliable.
of supports.
Parallel-shaft speed reducer directly coupled to
The spiral-bevel speed reducer costs somewhat more than
the motor and to drive shaft —
is particularly well suited to large conveyors, is the helical-worm speed reducer and considerably more than
versatile, reliable, and generally heavier in the worm-gear speed reducer but
construction and easy to maintain.
is more efficient than the helical-worm and considerably
more efficient than the worm gear.
23 24

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Take-ups or belt tensioning devices

Allow for stretch and shrinkage of the belt due to variation of
 To make the belt move the endless conveyor belt need to be
temperature and atmospheric pressure
tightened so that sufficient friction force is developed b/n
It ensures that the
drive pulley
maximum tension in the belt is sufficient to prevent undue
 So Belts working under tension invariably gets elongated sag(un requaired drop down) between idlers
with time which needs to be taken up to maintain the desired tension in the belt in the back of the drive pulley is sufficient
tension in the belt which have a screw-type(mechanical) or a to permit such pulley to transmit the load
gravity type counterweighted take up unit also termed as belt
tensioning device.

25 26

Pulleys, Shafts and Bearings Pulleys, Shafts and Bearings

 At each end of the belt conveyor one large diameter pulley  The factors involved in pulley diameter selection include
is installed against which the belt turns and change the
directions, thus pulleys are called terminal or bend pulley.  amount of wrap,

 belt tension at the pulley,

 Drive is imparted to the belt by friction by one of the
 space available,
terminal pulleys called drive pulley.
 characteristics of the materials handled,
 Pulleys for belt conveyors are usually welded steel, drum  belt life expectancy,
types, for maximum strength, minimum weight, and for  shaft and bearing size and

resistance to shock during handling and operation.  size and ratio of reducer.

27 28

Typical Arrangements Typical Cross-sections

the belt Typical Arrangements a) Horizontal belt;

b) Inclined belt;

c) compound path with

horizontal; ascending and again
horizontal path

d) When space will not permit a vertical curve or when the conveyor
belt strength requires two belts
29 30

5

Typical Cross-sections
Flat Belts on Flat Belt Idlers:- especially used to
transport materials, which have steep angle of repose,
and they are useful when the material is to be discharged
at intermediate points by deflectors.
31
Cont’d…
Troughed Belts on 200 Idlers: the 200 trough permits
the use of the thickest belts so that the heaviest
materials and the maximum size of lumps as coal, ore,
soil and gravel can be carried.
It is most widely used cross-section for lump(piece of
solid material with no shape). 33
Cont’d…
Basic Data Requirements
Troughed belts on Continuous plate: they
convey many bulk materials in large quantities
than a flat belt. Preliminary Check
Covers are provided when handling dusty
materials.
35
4/11/2021
Cont’d…
Flat Belts on Continuous Plate: A continuous
surface supporting the carrying run of a belt is
devised for light, mildly abrasive materials
where smooth even travel is essential
32
Cont’d…
Troughed Belts on 450 Idlers of Equal and
Unequal length: they accommodate a large
cross-section of material than those operating
on idlers with rolls slopping 200.
34
Belt Conveyor Design Calculation
1. The material to be handled
2. Capacity peak or surge rate expressed in ton/hr
3. Path of travel
4. Feeding and discharge conditions
5. Operating conditions
6. Required life of installation
 Is the belt conveyor suitable for the material?
 Is the angle of inclination is within safe limits? etc.
36
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Cont’d
Capacity of a Belt Conveyor
 If the belt conveyor has an inclination α, then the
a.If the material to be conveyed is a unit load, capacity Q will be reduced by a factor p.
Q [tons/h] Q  pQ
Q  3.6qBv
where q = distributed load [kg/m2]
B = width of the belt [m] Cross-sectional Loading on Belt Conveyors
v = velocity of the belt [m/s]
b. If the material to be conveyed is in bulk Ac = 2 A f
load, Q [tons/h]. (B + 4) B 2
Af =
Q  3.6Av 110

where  = the density of the mat [kg/m3] Where A f = cross-sectional area of the material
A = the cross-sectional area of the material being on the flat belt [m2]
conveyed [m2]
v = Velocity of the belt [m/s] 37

Ac = cross-sectional area of the material on the

Belt Tension
troughed belt [m2]
The belt tensions, in addition to their effect on power
B = belt width [m] requirements they also influence the design and selection of
all component parts.

The assumptions used to arrive at the above formula

are a 20° inclination of rollers and angle of repose
(relax) of material to be 30°.

Loads on Drive Pulleys

40

We know that R =T-t. The relationship between T and t may be Number of Fibers
expressed
T After calculating the tension, T, it is possible to calculate the
 e  number of fibers in the nucleus of the belt
t
Where
T=belt tension at tighter side
t= belt tension at slack side T
μ = coefficient of friction n
α= wrap angle KB
where n = number of fibers
n = number of cords of the belt K = resistance of one fiber per
B = the width of the belt in meters unit width (5 to 7 kg/cm) and
B = width of the belt
t min  50nB
41 42

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Introduction
 chain Conveyors means a group of d/t conveyors used in
diverse applications, characterized by one/multiple
strands of endless chains that travel entire conveyor path.
 Chain conveyors employ single or double strands of
continuous chains wrapped around head and tail end
sprockets.

 Driven by one or Set of sprockets at one end and supported

by one or a set of sprockets on the other end.

 Materials to be conveyed are carried directly on the links of

the chain or on specially designed elements attached to the
43 44
chain.

Advantage and dis advantage of chain conveyors

The chain conveyor derives its name from the type of
dis advantage of chain
attachment, that is, apron, pan, or flight. Advantage conveyors
Material can be carried directly on aprons or pans or pushed in  Chain easily wrapped around  High weight
a trough by flights attached to the chain(s). sprockets of small diameter  High initial cost
The load carrying chain is generally supported on idle  Drive is positive i.e. no  Higher maintenance cost
sprockets or guidways. slippages b/n chain and  Limited running speed
The end less chain are kept by suitable chain tensioning device sprocket etc
at the non driven end.
 Chain stretch is also little
The units are generally operated by motor drives attached to
the head/drive shaft.
45 46

Cont…
Sample of chain conveyors

By MA 47 48
By MA

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Types of chain conveyors

The following are types of chain conveyors

Apron/pan conveyors
Cross bar/ arm conveyor
Chain pallet conveyors
Car type conveyor
Carrier chain and flat top chain conveyor
Trolley conveyor
Power and free conveyors
Suspended tray conveyor

49 50

Apron Conveyors
 Most common type of chain conveyors
 Consists of one or more strands of end less chain ,usually
link plate roller type running in steel guides.
The bed created by the aprons is used for carrying bulk as well
as unit loads.
Apron conveyors consist of a series of jointed overlapping or
interlocking apron pans on which the material is carried.

 Rollers insure minimum pulling effort in the chain while
roller guides (supported on the support structure of the
conveyor) carry the entire load of the material and chain
 Slow speed conveyors of 20 to 35m/min
They can handle abrasive materials that cannot be scraped
along a trough, and as the loading is readily controlled, it may be
used as a feeder.
As an alternative to a rubber belt, it can handle materials at a
temperature higher than 1500C that cannot be handled with

 The carrying surface of the conveyor is composed of a rubber.

serious of plates called apron 51 52

Typical apron conveyors Used to transport materials in two Cullet transport..\..\..\..\..\vidio\Chain Conveyor.mp4
Used as a vertical elevator directions

Cullet transportPace Line Roller Chain Conveyor.mp4

..\..\..\..\..\vidio\Apron Conveyor by PCK.mp4

53 54

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Types of Apron Conveyor

Depending on the nature of the material being conveyed we Corrugated apron conveyor: the most common type made of

have the following types of apron conveyors formed steel.

Flat space apron conveyors May be fabricated or cast from gray or malleable iron

Corrugated apron conveyor Front and rear edges beaded so that one overlaps the other to

Special types form a continuous bed or trough

Flat space apron conveyors: conveyor with rectangular shaped During turning of the chain over sprockets the apron ends move
flat steel wooden slat aprons with small gaps b/n them relative to each other without creating a gap for leakage of
Provide flat surface for conveying unit loads are called slat materials or jamming of adjoining aprons or pans.
conveyors as shown below Have different styles like
Style A
55 Style B 56

Style C e.t.c

Cont’d
Corrugated Apron conveyors • Style B provide force and easy discharge and consequently,

• Style A is used for horizontal and low incline 20-25 deg. low drop of material.

• Short pitches are used for feeders and pans & medium or long • Suitable for wide conveyors and can be used for inclined

pitch is used for conveyor. conveying up to 30deg.

• Suitable for bulk materials, including hot dusty, abrasive • Suited to handle lump material which should not be broken.

materials • Style C are used for large capacities of fines and lumps and
inclined up to 30 deg.
• They are suitable for use as feeding, picking, sorting and
lowering conveyors.

57 58

• Style D are of very strong and rigid construction.

Cont’d Special types: designed for special purposes and they are vrious
in number.
• Capable of carrying large quantities of material.
• They have good impact resistance under loading point E.g four component cast metal pans used for pig casting, sugar

• Style E are super capacity pans for handling crushed, fine, or mills

lump materials in a very large quantities. Cross bar/Arm conveyors: consists of a single or two strands

• Can convey as steep as 45 deg. of endless chain to which are attached spaced, removable or fixed
arms(or cross members from which materials are hung or
festooned.

59 60

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The arms may be replaced by shelves/trays to support Car-type conveyors

packages or objects to carry them in a vertical or inclined path
Consists of a series of small platform cars, propelled by an
Application
endless chain, running on a closed track.
Used for conveying and elevating or
Also called a pallet-type conveyor
lowering unit loads like barrels, drums,
May have vertical runarounds over sprockets having horizontal axis,
rolls, bags, bales, boxes etc Particularly used for carrying heavy as irregular shaped large objects like
For process applications such as molds in foundries coils for rolling plants e.t.c

dipping, washing, spraying, drying and

assembly.

61 62

Carrier chain conveyor: consists of one or more number of flat top chain conveyors: is a particular group of carrier chain
endless chains to which may be attached one of the many conveyors may be rolling or sliding type,
different attachments for the purpose of carrying unit materials or  Specially designed chain links or with flat plate attached to the
objects chain links so as to provide a continues smooth, level top surface
Have broad applications in particularly all fabricating and
to carry small articles like bottles, cans etc at high speed.
processing industries Mostly used in canning and bottling plants
Two types
Rolling type :chains are provided with rollers for minimum
friction,
Rollers are also used to support the objects while the chain used
as a connecting and propelling link for the rollers.
63 64
Sliding type: loads are directly carried on one or more chains

1. The force required to move the

Design Considerations of Apron Conveyors materials;
 In general, designing of an apron conveyor
can be considered as determining: F1  f g qmlm
Where, q m = weight of the material per unit length [kg/m]
 The maximum traction force, l m = the horizontal distance the material is
conveyed [m]
 The pitch of the chain and f g = friction coefficient.

 The stress on the shafts and on the wheels 2. The force required to move the moving
 The maximum traction force is a parts of the conveyor.
combination of the force required to move F2  f g qs ls
the material, the moving part of the Where, q s =weight of the moving part of
conveyor and the force required to the conveyors [kg/m]

overcome the level difference. ls

= the horizontal distance that
65 the conveyor is moving [m]

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3. The force required to over come the level Cont’d

difference.
5. After calculating the maximum force required,
maximum tension, T can be used to find the stress
F3   qm H on the shaft. The traction force R is equal to the
maximum tension T.
Where,
H = the level difference [m]

d 4. The force required to overcome the T

friction between the chain and the driving p
2db
gear can be calculated by: where p = the stress on the shaft[kg/mm2]
Increasing l m and l s in the expressions by 20 d = diameter [mm]
or 6m with respect to the bearing types, b = width [mm]

journal bearing or ball bearing respectively. T  R  F1  F2  F3

increasing H by 5%

Flight and Wide Chain Drag Conveyors

6. The power absorbed [kW]
 A flight conveyor consists of one or more endless propelling
mediums, such as chain or other linkage,
Tv
N  properly spaced scrapers or flights for moving material along the

102 length of a stationary trough.

where T = the maximum fraction force [kg]

v = velocity [m/s]
= efficiency (0.7 - 0.8)

70

Cont’d
Cont’d
Flight conveyor power required consists of three factors:  (I)+(II)+(III) where
I. The power required to run empty
conveyor 9.7  10 3
P (0.001WC LSFC  TL L FL  TH )
Plus FD
II. The power require to carry load over
horizontal distance
Plus
III. The power required to lift load

71

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Cont’d…
SCREW CONVEYORS
 Wide chain drag conveyors do not have flights as the open
links serve to move the material.  A screw conveyor or auger conveyor is a mechanism
 These conveyors operate at slow speeds generally 0.1 m/s or
that uses a rotating helical screw blade, called a
less.
 They are used for conveying abrasive materials like ashes, "flighting", usually within a tube, to move liquid or
coal or sand.
granular materials.
 In addition one typical application can be quenching hot
materials  They are used in many bulk handling industries.

 one of the oldest and simplest methods used for the

 ..\..\..\..\..\vidio\Apron conveyor Trial run April 4th 2014.mp4
movement of bulk materials.

73 74

For conveying fine grainvidio\Screw Conveyor.mp4

Here are some of the common samples of screw conveyors
Conveying dewatered sludge..\..\..\..\..\vidio\Shaftless Screw Conveyor
Applications from SPIRAC®.mp4

Herevidio\110 Ft Long Screw Conveyor

Mfg.By GMP Systech Engg.Pvt.Ltd..mp4

75 76

Shaft less spiral conveyor screws Arrangements of screw conveyor

For conveying large objects

The typical screw conveyor is shown above

The screw shaft if short (up to 5m) is supported at two ends but for longer
shafts(up to 40 to 50m) they are supported by bearing hangers at intermediate
points.
Long Screw Conveyor 77
The shaft may be solid or hollow.
78

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5.Hopper Cont’d….
7.Trough  which is formed by a helical blade attached to the
3.Cover plate
drive shaft 8, which is coupled to a drive 1 and
supported by end bearings 2,6 and by inner bearings 4.

 The trough 7 of the round-bottom shape is topped by a

 A u shaped trough generally covered at the top to avoid cover plate 3 with an opening 5 for loading the
pollution while the bottom part is circular matching the diameter conveyor.
of the screw
 A similar unloading opening 9 is provided in the
 Radial gap of 10mm to 20 mm is kept between the screw and
bottom of the trough.
the trough depending on the size of the screw.
 The movement of the materials is forced through the trough,  The loading and unloading points can be located
 by a rotating screw, 79
anywhere along the trough . 80

Conveyor Components b. The Drive Shaft, End Shaft and Coupling

a. The Conveyor Screw :screws of different  The drive shaft supports the conveyor screw section and
constructional features are used
keeps it in alignment.
 consists of spiral flying mounted on a pipe and is made
either right or left hand to suit the screw rotation and  The end shaft is located at the end opposite the drive shaft.
the desired direction of material travel.
 Couplings are used to connect successive conveyors screw
section when more than one section is necessary to make up
the total length of conveyor.

Typical Screw Configurations: (a) Helical Spiral (b) Ribbon Spiral

(c) Cut Flights 81 82

c. The End Seals Cont’d

The plate seal is an economical, effective sealing device,  Air purge shaft seals are arranged for attaching to
designed for exterior mounting between the end bearing and standard or special trough ends.
the trough end.  A constant air pressure is maintained to prevent material
 Split gland seals are designed for interior or exterior from escaping from the trough along the shaft.
mounting.
 The universal type of seal is arranged for use with waste
packing or with cartridge type lip or felt seals.
 Packing gland seals are effective means for sealing the
conveyor both internally and externally.

(a) (b) (c)

Various End Seals

83 84

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Typical Drive Arrangements

Cont’d
d. The Conveyor Complete with the Trough  With specialised design, the unit may operate at a slope or
and the Drive in the vertical position.
The trough is the enclosure in which the material
is confined and guided in its movement.  There could be many drive arrangements to meet the
A shaft mounted speed reducer makes a simple and practical limitation like space, type of drive, etc.
compact drive combination.

85 86

Cont’d
Typical Applications
Screw conveyors serve a wide variety of purpose in
many industries.

1. When the materials are extremely hot, cast screws and

troughs may be used or the screws and troughs may be
made of high temperature alloy metals.

2. If the materials are sticky or viscous, ribbon flight

screws may be the choice. Furthermore, special
coatings applied to the screw and troughs may also aid
Fig.10.5 Typical Drive Arrangements: (a) Vertical
(b) Horizontal and Vertical (c) Steep Slop the flow of the material.
87 88

Cont’d
Cont’d
5. When the materials are to be mixed or aerated, a conveyor
3. When extremely abrasive materials are to be conveyed they
screw of ribbon flights or cut flights or one of these
may require screws and troughs made of abrasion resistant
combined with paddles may be used to obtain the desired
metals or the screws may be provided with hard surface
results.
flights.
6. If materials are to be heated or cooled, while conveying,
4. When the materials are corrosive it may be desirable to make
they may require jacketed troughs arranged for circulating
the conveyor screws and troughs of stainless steel, Monel
heating or cooling media.
metal, nickel, aluminium, etc.
7. When contaminable materials are handled they may
require self lubricated bearings, screw and trough
89 construction which will eliminate pockets, creels, etc. 90

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Design Considerations
The lump size of the material determine the minimum size of the
 The trough is commonly fabricated from flat sheet from screw diameter D to be chosen
2 to 8mm thick. The screw diameter D is recommended to be at least twelve times
 The screw pitch t = (0.5 to 1.0) D. that for loads of uniform lump size and at least four times the
maximum lump size in case of un sized bulk materials.
 The selection of a screw conveyor basically depends on two
Conveyors handling heavy materials operate at around 50rpm and
factors
those designed to convey light loads, at up to 150rpm.
 The conveying capacity required and

 The lump size of the material

91 92

Cont….
The hourly capacity can be calculated by
The cross-sectional loading of a screw conveyor is given by
d 2 Q = 3.6 A v k tons/hr
A = where , k= is a factor introduced in designing inclined
4
Where,  = the capacity factor which take conveyors
account of the accumulation of v = the speed of the conveyor [m/s]
load at inner bearing  = specific weight of the material [kg/m3]
d = screw diameter Values of k corresponding the Inclination 
 (degrees) 0 5 10 15 20
Values Capacity Factor k 1.0 0.9 0.8 0.7 0.75
Material 

(slow flowing) Heavy-weight abrasive loads 0.125

(slow flowing) Heavy-weight mildly abrasive 0.250

(free flowing)Light-weight mildly abrasive 0.320

(free flowing)Light-weight non abrasive 0.400

93 94

The speed of the conveyor

tn where , t = pitch of the screw (lead) [m] From practical experience,
v= n = rpm of the screw
60 n = 60/ D for light non abrasiveload
n = 45/ D for heavy non abrasiveload
n = 30/ D for heavy abrasiveload

The power requirement in kW at the drive

shaft
The capacity formula can be rewritten, QL
N h  C0
 2 tn 367
Q = 3600 D  k
4 60
where , N h = power requirement for horizontal conveyor

 47  t  n  D  k   2 Co = friction factor

L = conveyor length [m]
95 96

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Cont’d Cont’d
And for sloping installation(inclined conveyor) Axial force, P [kg]

QH QL
Ns   C0 Mo where ,
P M 0 = the resisting moment
r tan   
367 367
N 0 = N h for horizontal conveyor
Where, = N for inclined conveyor
Ns
= power requirement for inclined conveyor s
H = level difference 102N o  60
Mo  r = radius at which the force P
Load per meter [kg/m] 2n is applied
r  0.7 to 0.8  
D
Q N0 2
q=
3.6 ν  975 kg  = reduced friction angle,
tan  = 
n
 = screw helix angle

97 98

The friction factor is adopted based on To be continued

experimental data.
Material
friction Pneumatic Conveyors
factor
Oscillating Conveyor
Flour, cereal, saw dust 1.2

Peat, Soda ash, pulverised coal, finely ground chalk 1.6

Coal (lump anthracite and bituminous, air dry brown), 2.5

rock salt
Gypsum, dry clay, sand, cement, ash, lime, moulding 4.0
sand

99 100

Pneumatic Conveyors Cont’d

 Pneumatic conveying is a method of transporting bulk materials  There are three basic system used.

in the form of powder, short fiber and granules over a pipeline
as a mixture with air or due to pressure of air.
 Air pressure is used to Convey materials through a system of
vertical and horizontal tubes.
 Pneumatic conveying is the process of transporting materials
with the help of flowing stream of air or gas.
 Suction or Vacuum System utilizes a vacuum created
in the pipeline to draw the material with the
surrounding air.
 The system operates at a low pressure which is
practically from 0.4-0.5 atm for light free flowing
materials
 Suction system eliminates dust at pickup sources.

101 102

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Cont’d
These systems are particularly suited to moving material from
multiple pickup points to a single location, the reason being that
the bulk of the system's expense is in the terminal end where the
receiver, rotary valves, and vacuum source are located.
Pressure-type System: positive pressure is used to
push material from one point to other
is ideally suited for conveying from one pickup location
to many discharge locations.
Generally, this type of system is more economical when
going from one point to several.

Operates at a pressure of 6 atm and above

103 104

A pressure system of this type generally conveys with a product-

to-air ratio of about 20kg of material per kg of air, or approximately
24kg of material/m3 of air (or 20 m3 of air/m3 of product).

Combination System (Push-Pull System)

 This is a system in which a suction system is used to convey
material form a number of loading points and pressure system is
employed to deliver it to a number of unloading points.

 Such installations are utilized when conveying over a long

distance is required.

105 106

Cont’d
Applications and Limitations an almost totally automated conveying with considerable
Pneumatic conveyors have many advantages: reduction of losses of material,
delivery of materials over a path capable of changing its improved labor conditions and minimum of human attendance.
direction in any plane,
The limitations of the system are
processing of the material simultaneously with its conveying,
 high power requirements (15kWh/t, 10 to 15 times higher than
an almost limitless number of loading and unloading points
mechanically conveyors),
served by a single system,
 rapid wear of equipment,
air and gas tightness eliminating dust nuisance and dust
hazards  the problem of dust recovery from the exhaust air

 inability to convey wet, caking and sticky loads.

107 108

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Design Considerations Cont’d

 In pneumatic conveyor calculations given are properties of
the material, required capacity Q tons per hour and the Lred   Lhor   Lv   Leqe   Leqv
configuration of the conveying pipe.

Required are: Where, Lhor = sum of lengths of horizontal sections

1. Calculated (reduced) conveying length, Lred
 Leqv = sum of lengths of vertical sections
[m]  Leqe = sum of lengths equivalent to elbows
 Lv = equivalent change over valves length
R0
= the ratio of bend radius to the inner pipe diameter
dp

109 110

Values of Equivalent Lengths for Elbows 2. Conveying air stream velocity, = [m/s]

Material R0 vair    1  BL2 red

Values of Leqv [m] at d
p Where,
4 6 10 20  = factor for the size of load particles
1 = specific weight of the load particles[tons/m3]
Powdered 4-8 5-10 6-10 8-10 B = factor assumed as equal to (2 to 5) 10-5, the lower
values being taken for dry powder materials.

Granular Homogenous - 8-10 12-16 16-20
Small Lumped Irregular - - 28-35 38-45 Values of Factor for the Size of Load Particles
Large Lumped Irregular - - 60-80 70-90

Material
Particle Size

The commonly used value for a two-way changeover valve
Powdered 1-1000(micron) 10-16
Leqv = 8m.
Granular Homogenous 1-10mm 17-20
Small Lumped Homogenous 10-20mm 17-22
Medium Lumped Homogenous 40-80mm 22-25
111 112

Cont’d
3. Weight concentration of the mixture, : Note: Graph (1): 1- for dry free flowing materials of high
specific weight (  1 = 2.5 to 3.2 t/m3), 2- for materials of a
lower specific weight (  1 = 1.8 to 2.5 t/ m3) but higher
moisture content and high abrasivity. Graph (2): for grain.


4. Air consumption, Vol [m3/s]

.

Q v
Vol   d p2 air
3.6 air  4

where Q = capacity of installation [tons/hour]

Graph Showing the Dependence of the Weight Concentration of
the Mixture  on the Reduced Conveying Length Lred
113 114

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5. Conveying pipe inner diameter, [m] d p

For pressure conveying system;
4Vol
dp  Lred vair 2
v air Pi  1   Pcs
dp

Where,
6. The required air pressure in the pipe,  = a factor; for pressure conveying systems,
[kg/cm2]  depends on the value of s
Lred v air 2
H air  dp
Pcs  and for suction conveying system:
104  = 1.5  10
7

Where, And for suction conveying system

 air = specific weight of the air
(average for a given vertical section).
Lred vair 2
Pf  1   Pcs
115 dp 116

Cont’d
 The plus sign before in equation is taken for upward, 7. The required air pressure of the compressor or
the minus sign for downward movement. air blower, [kg/cm2]
Pb  Pw  Ploss
Where,
Pw = working pressure ,
= Pi for pressure conveying system
= Po  Pf suction conveying system
,
 = 1.15 to 1.25 factor for losses in the intake
unit,
Ploss = pressure loss in the supplying air for
Graph Showing the Dependence of Factor on  compressors,
Ploss = 0.3 kg/cm2,
the Value of s P0 = atmospheric pressure = 1atm.
117 118

9. The required motor power, [kW]

8. The required capacity of the compressor LbVo
or blower, [m3/min] Nb 
60  102

d p2 v air  ' Where, Lb = theoretical work of the blower reduced to

Vo  Vol '  1 m3 drawn in during isothermal
4 compression [kgm/m3].
 = total efficiency of compressors =0.55 to 0.75.

where , Pb
 ' = factor for losses due to leaks = 1.1. Lb  23,030 P0 log .
P0
119 120

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Oscillating Conveyors
A vibrating conveyor consists of a trough supported by tined
springs and/or hinged links having a drive system.
Thus these conveyors are sometimes called oscillating
conveyors.
Oscillating Conveyor The vibrating conveyor consists of the following elements:
a) Watertight stainless steel tray riveted to a rigid mild
steel frame
b) Swinging arms
c) drive

121 122

123 124

Oscillating Conveyors Pattern of motion of the trough or load

Classification of vibratory conveyor 1. Reciprocating or inertia-type conveyors

Vibratory conveyors may be classified on the basis of 3 As the trough moves forward during its forward motion, it
considerations:
carries the material with it
1) The pattern of motions of the trough or load
2) Drive mechanism 2. Vibrating or oscillating conveyors
3) Frequency of excitation
The load is periodically thrown above the trough (jumps)
with the vertical component of the trough acceleration
greater than the acceleration due to gravity

125 126

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Frequency of Excitation
Drive Mechanism
According to the range of frequency of excitation of the
1. Direct mechanical type, use crank and connecting rod trough, the vibratory conveyor can be classified as
2. Single or double eccentric weight on a rotating shaft 1. Sub-resonant
3. Electromagnetic exciter using pulsed single-phase AC 2. Resonant
supply
3. Super-resonant system

127 128

Cont’d
Oscillating Conveyors Where = the magnitude of the movement of
the conveyor in time t.
Oscillating conveyors move materials in a uniform, A = maximum amplitude of the vibration
S
continuous flow by the upward and forward oscillating
k
motion of a continuous metal trough, mounted on   2f 
m
sturdy inclined reactor legs.
where k = rigidity and
The angle of inclination of the conveyor arm may vary m = mass

from 25 to 30 degree.

S = A sin t
129 130

Cont’d…
Basic Designs
 This conveyor is used for handling:-
Basic elements
 All granular free flowing materials
1. A trough supporting system.
 Hot, abrasive, fine, dusty, lumpy, stringy and other materials
2. The source of the controlled vibrating.
which are difficult to handle or where contamination or
Reviewing of the elements:
corrosion is a problem.
1. The trough is the only portion of the vibrating conveyor that
 In addition to conveying, it is used for
comes in contact with the material being conveyed.
 cooling, heating and drying
2. The base is primarily a means of mounting the conveyor and is
usually of a simple design incorporating structural steel
members.
131 132

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Cont’d
Types of Oscillating Conveyors
3. The trough supporting system's primary function is to control and
direct the motion of the trough a. Flexmount Oscillating Conveyors are used for light duty
applications. They have simple construction, remarkably rugged,
4. The drive is the prime element in a vibrating conveyor because it
compact and require minimum maintenance and attention.
is the source of the controlled vibration.
b. Coilmount Oscillating Conveyor are rugged, well reinforced
5. The reactor spring system can assume many forms including steel
and require minimum maintenance. The coil springs operate in
coil springs, flexible steel, rubber blocks, circular rubber to
the natural frequency range. They are used for medium duty
roids, and torsion bars.
service. The trough is supported by separate legs that are rubber
bushed at articulated points and do not require lubrication.

133 134

Cont’d Selection of Oscillating Conveyors

Torqmount Oscillating Conveyor are rugged,
i) Determining the trough width for the required
dependable and easy to adjust and maintain. They
capacity
are used for heavy and extra duty applications.
ii) Selecting the drive for the required capacity
Torsion bars fixed at one end and steel backed
rubber bushed at the other end, absorb the energy
of the trough movement at the end of the stroke at
all points of support along the trough length.

135 136

Advantages of Vibratory Conveyor Advantages of Vibratory Conveyor

 Hot and abrasive materials can be handled.  Low spillage of fines
 Cooling, drying and dewatering operation can be done  Controlled feeding and material alignment
during transport
 Heavy duty drive assemblies are fitted to all conveyors
 Scalping, screening or picking can be done
 Optional screening section can be built in for separation
 Units can be covered and made dust tight
of fines and sawdust
 Simple construction and low head room
 Optional fiberglass section for material detection can be
 Can be made leak proof
built into conveyor
 Low maintenance
137 138

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Limitations
Cont’d
There are few limitations, with today's
 The equipment is subject to high accelerations and high
technologies, to the successful application of this
reversing stress cycles; consequently, to achieve acceptable
class of equipment. Some materials that tend to fatigue life, the structures must be designed with stress limits
fluidise, or adhere to the feeder trough may be much below that considered good design practice for
more efficiently handled by other means. In structures not subjected to vibration.
addition, a dusting problem may occur at the outlet
of a feeder handling some dry, powdery materials,
and require special handling.
139 140

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