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This is How to Convey Coal Skillfully

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Route Optimization

The route selected for the silo conveyors was tightly constrained by a number of existing industries occupying most of the land outside the port, Lakhigam village and a large road. The conveyors could not pass outside a 5 m wide corridor between the road and surrounding developed properties. Engineering horizontal curves like the two in this system is an iterative process. First, a rough profile of the conveyor is selected.

The tensions along the conveyor route are computed and used to determine the minimum horizontal curve radius that the conveyor can safely negotiate. The tension prediction must be accurate and requires drag prediction using rubber rheological equations (Nordell, 1996) and dynamic analysis (Nordell, 1984). After determining the belt tensions, a new route is selected with horizontal curves and tensions for the new route are computed. The process is then repeated.

High Speed Coal Conveying

Operating SC-1A and SC-2A at 7.5 m/s reduced the capital expense of the system and also the belt tension in SC-1A allowing it to bend through tighter horizontal curves. However, operating these conveyors at high speeds reduce the life of their belts compared to identical belts running slower. This is because most belt wear occurs in the loading zone. A high speed belt sees the loading zone more often than a low speed belt. Since SC-3 is much shorter than SC-1A and SC-2A it was designed to operate at 4 m/s so that the frequency of belt replacement on this conveyor could be reduced.

Since the speed of SC-3 is 4 m/s instead of 7.5 m/s, the belt width of SC-3 is 2,200 mm – far wider than the SC-1A and SC-2A. In addition to the increased width, the weight of the SC-3 belt is 59 kg/m, almost 50 per cent more than the weight of two other belts, which weigh 42 kg/m. Also, on this third belt, the linear weight of material is 476 kg/m. On the other hand, the SC-1A and SC-2A increase the speed while reducing the linear weight of material to 264 kg/m. Reduced linear weight reduces the belt tension necessary to control sag.

Furthermore, it also reduces the indentation losses and the tension required to lift the material. This reduces overall belt tension, which improves belt tracking in the horizontal curves. The narrower belt also shortened the idler roll length from 816 to 594mm reducing the weight and cost of the idlers. Additionally, it also reduced the width of the elevated gallery, cutting the weight, strength and space requirements for the gallery. These reductions further cut the capital investment.

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