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1 CONTENTS Page number Chapter 1 Bulk material handling plants and conveyors 1 to Need for bulk material handling plant with conveyors 1 to Introduction to bulk material handling plant 2 to System description 4 to List of major equipment and structures for the plant 7 to 9 Chapter 2 Introduction to belt conveyor 10 to Introduction to belt conveyor Main mechanical components in a conveyor 10 to Belt conveyor function 11 to Conveyor-profiles (conveying-paths) Method of feeding/loading belt conveyor 13 to Method of discharge from belt conveyor 14 to 16 Chapter 3 Bulk materials 17 to Bulk materials Bulk density Repose angle Surcharge angle 18 to Abrasiveness Material size Other characteristics Material characteristic data (table-1) 20 to 24 Chapter 4 Belts 25 to Belts Carcass functions and types Covers functions and types 26 to Belt types Textile fabric belts 28 to Textile fabric multi-ply conventional belts 30 to Reduced ply fabric belts (special ply fabric belts) 34 to Fabric belt data for conveyor design 35 to Steel cord belts 36 to Steel cord construction Steel cord belt construction 37 to Steel cord belt characteristics and application Steel cord belt range 38 to Steel cord belt data for conveyor design Design requirements in belt selection 39 to Stiffness/load support Impact strain 39 to Belt tension rating 42 to Troughability Belt cover thickness 43 to 46 A-5

2 4.6.6 Choice of carcass type 46 to Belt selection procedure 47 to 48 Examples-1, 2, 3 & 4 49 to Note on energy loss / carry forward factor for a lump 59 to 61 Fabric belts table 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2f and 2j 61 to 69 Steel cord belts table 3a, 3b, 3c and 3d 70 to 73 Chapter 5 Idlers 74 to Idlers Idlers function 74 to Rolls (Rollers) 75 to Shell 76 to Housing Sealing Bearings 77 to Spindles Greasing Roll breathing 79 to Roll Quality Fixed frame idlers 81 to Troughing idlers (Trough carrying idlers) 81 to V - trough carrying idlers (2 - roll trough carrying idlers) Flat carrying idlers 83 to Impact idlers (Trough impact idlers) V - type impact idlers (2 - roll impact idlers) Flat impact idlers Flat return idlers (Single roll return idlers) V - type return idlers (2 - roll return idlers) 85 to Self aligning carrying idlers (S.A. carrying idlers) Self aligning return idlers (S.A. return idlers) 86 to Special purpose idlers 87 to Garland idlers 88 to Garland idler profile under load Garland 3 - roll carrying idlers 91 to Garland 5 - roll carrying idlers Garland 3 - roll impact idlers 92 to Garland 5 - roll impact idlers Garland 2 - roll return idlers 94 to Main reason for belt misalignment 95 to Misaligned idlers center line Off center loading of material 96 to Wind force Misaligned center line of pulleys Faulty belt carcass Engineering analysis of selfaligning action by idlers 98 to 115 A-6

3 5.6.1 Pivoted self-aligning idler (includes example-1) 98 to Inclined aligning force effect along conveyor width (includes example-2) 103 to S.A. force due to trough shape and gravity (includes example-3) 106 to Forward tilt for idlers (includes example-4) 108 to S.A. force due to bow - string effect (includes example-5) 112 to Rollers and idler- sets dimensions (includes table-4) 115 to Roller design (includes table-5 and example-6, 7 & 8) 119 to 123 Table - 6 : Rotating mass of one roller 124 to 131 Example-9 on breathing hole 132 to 134 Chapter 6 Capacity evaluation in system 135 to Capacity evaluation in system Guaranteed capacity Design capacity 135 to Examples-1, 2 & 3 for capacity calculation 136 to Notes on conveyor capacity (for load / forces) 140 to 141a Chapter 7 Belt width, speed and capacity 142 to Design for belt width, speed and capacity Functional requirements for belt width Necessary belt width for lump size 142 to Belt width for material - X Belt width for material - Y 144 to Other consideration to lump size 145 to 148 Table 7: Permissible maximum lump size (for belt width) 146 to Selection of surcharge angle (includes table-8) 148 to Recommended belt speeds (guide values) 151 to 153 Table 9: Recommended maximum belt speed in m /sec Necessary belt width for capacity 154 to Material cross - section on belt Cross - section on belt - 3 roll troughing idlers (for equal / unequal roll) - derivations 155 to Cross - section on belt - 2 roll troughing idlers - derivations 161 to Cross - section on flat belt - derivations 165 to Cross - section on belt - 5 roll troughing idlers - derivations 166 to Effect on cross - section by gap between rollers (includes table-10 & 11) 173 to Comparison of area, parabolic and circular arc (includes table-12) Reduction in cross section area due to belt bending radius Reduction in cross - section area due to conveyor inclination 175 to Reduction in cross - section area or conveying ability due to fill factor 177 to Conveyor potential (ability) for capacity 178 to Principles for selection of belt width and speed 179 to Use of table - 13, 14, 15, 16, 17, 18 and 19 for cross section area on belt 181 to Examples-1, 2 & to 188 Table - 13: Material cross section area (parabolic arc) for 3 roll idler 189 to 193 Table - 14: Material cross - section area (circular arc) for 3 roll idler 194 to 198 Table - 15: Material cross - section area (parabolic arc) for 2 roll idler 199 to 200 A-7

4 Table - 16: Material cross - section area (circular arc) for 2 roll idler 201 to 202 Table - 17: Material cross - section area (parabolic arc) for flat roll idler 203 Table - 18: Material cross - section area (circular arc) for flat roll idler 204 Table - 19: Material cross - section area (parabolic arc) for 5 - roll idler 205 to 206 Table - 20: Conveyor inclination factor 207 Chapter 8 Material behaviour on belt 208 to Material behaviour on belt for transverse load 208 to Liquid side pressure / force Rankine theory 212 to Active pressure / force 212 to Passive pressure / force 213 to Material side thrust on inclined face 216 to Rankine theory application to material on belt 217 to 221 Table - 21: Rankine factors Coulomb - Rebhann wedge theory (coulomb theory) 221 to Active force Fa per meter 223 to Passive force Fp per meter length of conveyor Effective force Fs on side roller, per meter length of conveyor 225 to Derivation of wedge slope β 226 to 234 Table - 22: Coulomb factors Method - 3 (Empirical method) 235 to Method - 4 (ISO formula) Load on middle roller (includes table-23) 237 to Concluding remark 238 to Belt edge clearance C at 90 % utility of material cross section on 3 - roller idler set 239 to 240 (includes table-24 & 25) Examples-1, 2, 3, 4, 5, 6, 7 & to 261 Chapter 9 Belt cleaners 262 to Belt cleaners External belt cleaner 262 to Single blade external belt scraper (cleaner) 263 to Double blade external belt scraper (cleaner) Skew multi - blade external belt scraper (cleaner) 264 to Cleaning force analysis 265 to Specialised external belt scraper (cleaner) 271 to Comparison between conventional and specialised blade scraper 274 to Other external cleaners 275 to Internal belt cleaner 278 to Pulley cleaner 279 to Scraper design parameters 280 Chapter 10 Belt tractive pull and power 281 to Belt tractive pull and power 281 to Symbols for engineering quantities 282 to 285 A-8

5 Basic engineering rules on friction 285 to Method adopted for calculation of the tractive pull at steady state Slope resistance, Fsl 287 to Slope resistance carrying run, Fslc 287 to Return run slope resistance, Fslr 288 to Material acceleration resistance, Fa 289 to Main resistance 290 to Rotational resistance of idlers 290 to Belt flexure resistance 293 to Material flexure resistance 294 to Basis for artificial friction coefficient of conveying, f 295 to Calculation of f for conveyor with positive power 296 to Calculation of f for conveyor with negative power 298 to Division of f into constituent coefficients (includes table-26, 26A, 27 & 27A) 299 to Reasons for earlier said + increment in f (includes table-28, Ex. 1, 2, 3, 4, 5 & 6) 303 to Idlers tilt resistance 315 to Tilt resistance by a roller 316 to Tilt resistance for 2 - roll return idlers 317 to Tilt resistance for 2 - roll carrying idlers 318 to Tilt resistance for 3 - roll troughing idlers (includes example-7 & 8) 320 to Forward tilt for garland idlers due to inclination (includes example-9) 323 to Skirt board resistance, Fsk1 and Fsk2 326 to Acceleration zone length La within skirt - board (includes example-10, 11, 12 & 13) 327 to Skirt - board resistance, Fsk1 336 to Skirt - board resistance, Fsk2 (includes example-14) 337 to Belt scraper s (cleaner s) resistance 339 to External belt cleaner resistance, Fce Internal belt cleaner resistance, Fci (includes example-15) 340 to Rotary nylon brush cleaner (external belt cleaner), Fce Rotary rubber blades cleaner (external belt cleaner), Fce 341 to Pulley cleaner resistance, Fcp Discharge plough resistance (includes example-16 & 17) 342 to Resistance due to related machine 347 to Plough feeder Travelling tripper (includes example-18) Reclaimer machine Fixed tripper Pulley turning resistance, Ft 349 to Belt wrap resistance around pulleys, Fw 350 to Conveyor running resistance summary Conveyor resistance summary table to This chapter and conveyor design 356 Example to 364 A-9

6 Chapter 11 Take - up devices 365 to Take - up devices Screw take - up 365 to Vertical gravity take - up 366 to Horizontal gravity take - up device 368 to Winch take - up device (fixed type) 370 to Stretching the belt for tension Winch take - up operation Application Principles for take up effect on belt tensions 373 to Floating take - up pulley (gravity force) 373 to Non floating take - up pulley 374 to Active winch take - up device 377 to Accidental fall of gravity take - up mass (includes example-1) 378 to Take up stroke (includes table-30 & 31, example-2) 381 to Rope and sheave system particulars for take up Sheave frictional resistance effect on take up force 384 to 385 Chapter 12 Drive units 386 to Drive units 386 to Electric motor Gear boxes 388 to Foot mounted worm gear box 388 to Shaft mounted worm gear box 389 to Horizontal foot mounted geared motor 390 to Parallel shaft helical gear box Bevel - helical gear box foot mounted 391 to Bevel - helical gear box shaft mounted 392 to Chain drive 393 to V - belt drive Mechanical power transmission efficiency of speed reduction mechanism (includes table-32) 394 to Flexible coupling 395 to Pin & rubber bush coupling Geared type flexible coupling 397 to Grid type flexible coupling 398 to Fluid coupling 399 to Traction type fluid coupling Traction type fluid coupling with delay chamber 400 to Three chambers traction type special fluid coupling Scoop type fluid coupling 402 to Fill controlled turbo fluid coupling 403 to Back stop (hold back) 404 to Pawl and ratchet type Differential band brake type 405 A-10

7 Free wheel type (Roller hold back and sprag type hold back) 405 to Hold back (back stop) mounting Guards Base frame Notes on drive units 407 to 408 Chapter 13 Belt tensions and conveyor design 409 to Belt tensions and conveyor design 409 to Minimum tension in belt 411 to Minimum tension for application of tractive pull to belt 411 to Minimum tension in belt to limit sag 413 to Pulley belt friction coefficient and wrap angle (includes table-33, 34, 35 & 36) 415 to Belt tension symbols Principles for calculating tensions in belt at various locations 419 to T 3 during steady state operation 419 to T 3 during starting / stopping of conveyor Calculation of tension T Belt tension T X at any point along conveyor 421 to Effect on belt tensions due to number of drives 422 to Drive distribution arrangement for conveyor 423 to Drive distribution based on reduction in tension alone 423 to Commonly used drive distribution (for economy, etc.) 424 to Notes on drive distribution in conveyor Take-up effect on tension calculation 427 to Floating take-up pulley (gravity take-up) 428 to Fixed take-up pulley (screw / winch take-up) 429 to Equivalent linearly moving mass of belt conveyor 431 to Equivalent moving mass for idlers, pulleys Equivalent moving mass for drive unit 432 to Material loading on partial length/s of conveyor Relationship among conveyor starting (braking) factors 434 to Starting factors relationship (for conveyors of + resistance during steady state) 435 to 437 (includes example-1) Braking factors relationship (for conveyors of + resistance during steady state) 437 to Idler spacing (includes table-37) 440 to Adjustment in value of conveying resistance to suit calculation purpose 441 to Belt conveyor of positive power Belt conveyor of negative power (regenerative conveyor) 442 to Belt carcass selection for longitudinal strength 443 to Safety factors for belt tensions 443 to Belt unit strength at joint Joint efficiency 445 to Belt strength selection (includes example-2) How to proceed with design 447 to Conveyor length coefficient-c 448 to 449 A-11

8 Design input basic quantity calculation 449 to Conveyor drawing / sketch with basic features 449 to Material load per meter length on belt, Mm kg / m Carrying side idlers rotating mass per meter length of conveying route. Mc kg / m 450 to Return idlers rotating mass per meter length of conveying route. Mr kg /m 451 to Volumetric conveying capacity design, I m 3 / sec Artificial friction coefficient of conveying f Belt mass per meter length, Mb 452 to 454 Table-38 Values of coefficient C (average) Design procedure for belt conveyor tractive pull and belt tensions 454 to Original design input: IP to Generation of design input:ip Generation of design input:ip to Conveyor design stage-i 456 to Conveyor design stage-ii 464 to Use of f s1, f s2, f b1 and f b2 for conveyor design 465 to Drive type-1, without fluid coupling 466 to Drive type-2, with fluid coupling 468 to 470 Example-3 & to Starting factors relationship (for conveyor of negative resistance steady state) 475 to Braking factors relationship (for conveyor of negative resistance steady state) 476 to Conventional values of belt line starting factor (includes table-39 & 40) 477 to Use of standards / codes in conveyor design 479 to 480 Example to The design capacity for load on conveyor 499 to 501 Example6 501 to Material stability on belt under acceleration / deceleration 518 to 520 Example to Tension diagram 533 to Plotting/depiction of tension diagram Type of tension diagrams 533 to Some tension diagrams 534 to 537 Chapter 14 Drive unit functional requirements 538 to Drive unit functional requirements Electric motor 538 to Conveyor load torque - speed curves (without acceleration) Ideal torque - speed curve of a prime mover Squirrel cage induction motor torque - speed curve 539 to Basic guide lines for drive / motor selection 540 to Type - 1 drive (without fluid coupling) 541 to Type - 2 drive (with fluid coupling) 543 to Calculation for starting time 545 to 547 A-12

9 Chapter 15 Pulleys 548 to Pulleys (includes table-41) 548 to Conventional pulleys (pulleys with plate diaphragms) 549 to Pulley construction 550 to Plummer blocks 551 to Rubber lagging (includes table-42) 552 to Pulley crowning 553 to Pulley behaviour under load (brief information) 554 to Pulley with turbo diaphragms 555 to Pulley construction 556 to Taper lock elements 557 to Other components of turbo diaphragms pulley External forces acting on pulley 558 to Pulley shaft design 559 to Basic information on forces, torque and bending moment acting on pulley shaft 559 to Theories on shaft design based on stresses 561 to Shaft deflection 566 Example: 567 to 568 Chapter 16 Conveyor frame 569 to Conveyor frame Frame for stationary conveyor 569 to Head terminal Tail terminal Bend-pulleys support Stringers Stands 572 to Decking plate 574 to Wind guard 575 to Belt cover Conveyor frame for shiftable conveyors 576 to Application 577 to Composition of shiftable conveyor frame 579 to Drive head station (DH) 580 to Return station / Tail station (RS) 584 to Modules (Intermediate stations) 585 to Approach bridge Intermediate feed station 587 Chapter 17 Super structure 588 to Super structure (Elevated structure) Conveying system needs super structures 588 to Items of super structure 589 to Design norms and requirements 590 to Super structure specification with respect to application 590 to Gantry (Open gantry) 591 to 592 A-13

10 Gallery (Closed type gantry) 592 to Trestles 594 to Houses for conveying system (Also includes some information on 595 to 601 springs and viscous dampers vibration isolation) Sheds 601 to Cross over 603 Chapter 18 Conveyor profile in vertical plane 604 to Conveyor profile in vertical plane Curvature effect on tension distribution within belt 604 to Nomenclature 605 to Concave curvature / radius 606 to Convex curvature / radius 608 to Transition length (includes table-43) 609 to 611 Example 611 to 612 Chapter 19 Introductory information on equipment associated with belt conveyor 613 to Introductory information on equipment associated with belt conveyors Feeders (belt feeders, vibrating feeders, apron feeders, and paddle feeders) 613 to Belt weigher 615 to Magnetic separators (suspension magnet, cross belt type and in line belt type) 616 to Dust control equipment (dust extraction / collection type and dust suppression type) 618 to Sampling system 619 to Unloading equipment (wagon tippler, truck tippler and ship unloader) 620 to Stockyard machines 621 to 625 Stackers 621 Reclaimers (side scraper reclaimer, portal scraper reclaimer, bridge type 621 to 623 scraper reclaimer, bucket- wheel on boom and bucket wheel on bridge) Blending / homogenization of bulk materials. 623 to Horizontal curved conveyor, introductory information 625 to Inward force (main), Fi 625 to Belt and material usual forces on idler; Fu 626 to Outward forces (main); Fo 627 to Stabilising force Fs 628 to Belt stability in horizontal curve 629 to Combined influence of forces along interface, to actually shift belt 630 to Principal design checks for belt stability and numerical example to 634 Horizontal curved conveyor application Cylindrical belt conveyor or (pipe conveyor / tube conveyor) 634 to 635 Chapter 20 Material discharge trajectory 636 to Material discharge trajectory at conveyor discharge pulley Free fall material motion, general rule Trajectory starting point location, from belt on pulley 637 to Case-1: [v 2 (R. g)] to Case-2: [v 2 (R. g)] < to 640 A-14

11 Example 640 to 643 Chapter 21 Travelling tripper 644 to General Construction 644 to Travelling tripper design 648 to Tripper travel resistance and travel drive power 649 to Frictional resistances at interface of tripper and belt 649 to Material lift resistance at tripper 651 to Travel wheel system resistance 652 to Miscellaneous resistances 654 to 655 Example to Concave Curvature Zone for Tripper 659 to Belt conveyor design to suit tripper Tripper concave radius 660 to 661 Example 661 to 663 Chapter 22 Foundation loads 664 to Foundation Loads General 664 to General rule for calculating foundation load. 665 to Foundation load depiction Static and dynamic loads Belt conveyor items foundation load 667 to Tail terminal Head terminal 668 to Bend pulleys support frame Stringer-stand frame 670 to Drive units 671 to Vertical gravity take-up Super structure 672 A-0.0 Addendum A-2.0 Chapter-2, flow division by two way chute 673 to 674 A-3.0 Chapter-3, friction coefficient between material and steel plate 674 to 675 A-4.0 Chapter-4, book includes amended table-2f. Its related information in addendum. 657 to 676 A-5.0 Chapter to 697 A-5.1 Idler diameter, pitch and stress strain in belt bottom cover 676 to 677 A-5.2 General information about rubber 677 to 678 A-5.3 Rubber stress strain characteristics 678 to 682 A-5.4 Usual method to find stress strain rubber block with example-5 / to 683 A-5.5 Belt strain while on roller / idler 683 to 686 Example-5/2, 5/3 and 5/4 686 to 693 A-5.6 Notes about rubber and stress strain characteristics 693 to 694 A-5.7 Belt sag approach angle to roller 694 to 695 A-5.8 Sag implication on belt stress strain 695 to 696 A-15

12 A-5.9 Notes about rubber and stress strain characteristics 696 to 697 A-6.0 Chapter-6, Variations in ship unloading rate due to sea level, fully loaded 697 to 699 ship, partially loaded ship, etc. and grab bucket unloader test rated capacity A-9.0 External scraper additional information 700 to 703 Example-9/1 701 to 703 A-10.0 Chapter to 704 A-10.1 Conveyor friction coefficient f, its variability and design consideration for it, installed power and consumed power 703 A-10.2 Information about idler diameter influence on f 703 A-10.3 Constituent of f 703 to 704 A-13.0 Chapter to 706 A-13.1 General note about this chapter 704 A-13.2 Drive efficiency, derivation and explanation 704 to 706 A-15.0 Chapter 15 Information about some materials for pulley and shaft 706 to 707 Pulley hub-shaft connection (keyed mounting), fitment tolerance table-46 & to 709 some information about turbo-diaphragm pulley 710 A-19.0 Horizontal curved conveyor application 710 to 711 A-19.1 Curved chute for feeding belt conveyor 711 to 714 Advertisements : Forward Section 1) ThyssenKrupp Industries India, Pune. 2) Phoenix Conveyor Belt Systems GmbH, Germany. 3) FFE Minerals India Private Limited, Chennai. 4) Voith Turbo GmbH & Co. KG, Germany. Advertisements : Rear Section 5) Mahindra Engineering & Chemicals Products Ltd., Pune. 6) Bulk-online, Germany. 7) Nord Drivesystems Pvt. Ltd., Pune. 8) Entvent Tools & Services, Chennai. 9) Concept Engineering Projects (P) Ltd., Pune. 10) Kali Material Handling Systems, Melakaveri. 11) Stallion Engineering Systems Pvt. Ltd., New Delhi. 12) Book on Belt Feeder Design and Hopper Bin Silo, Author - Ishwar G Mulani. 13) Man Takraf (India) Pvt. Ltd., Chennai. 14) Krupp Canada Inc., Canada. A-16

Geo. Robson & Co. (Conveyors) Ltd Coleford Road, Sheffield, S9 5PA Tel. +44 (0) Fax. +44 (0) Registered in England No.

Geo. Robson & Co. (Conveyors) Ltd Coleford Road, Sheffield, S9 5PA Tel. +44 (0) Fax. +44 (0) Registered in England No. Airglide Conveyors The Robson Airglide Belt Conveyor is a development of the traditional belt conveyor, but instead of carrying idlers it employs a cushion of air, being the means of supporting the loaded