BELT CONVEYOR ANALYSIS PROGRAM

From meters, to kilometers long. from kilograms to thousands of tonnes /hours capacity.
From kilowatts, to six Megawatts power demand.
For MINING INFRASTRUCTURE PLANNERS, DESIGNERS & ESTIMATORS
For POWER GENERATION operators , programers
For SELF EMPLOYED ENGINEERS, as time is money.
For CONTRACTORS and SUBCONTRACTORS who enter into highly competitive tenders and need to establish the correct costs of any
systems and, in multiple unit systems , need to be able to optimize for overall supply rationalization.
For ANY PERSON OR ORGANIZATION involved in overland material handling systems .
The program BC-V11.exe Include standard data for ConveyorBelts, Electrical motors , as well Permit optional inputs . It also permit
components rationalization in large project with multiple conveyors systems
The program is supplied wit a demonstration and training program file BCDEMO.dat
Nor the program, nor the demonstration file are copy protected and you are free to make as many copies as you may need. Subject to the
General Terms and Conditions.
TYPICAL OUTPUT FILE FOR A SMALL PROJECT." "

"

"

YOUR FIRM
BELT CONVEYOR DESIGN EVALUATION PROGRAM
PROGRAM REFERENCE: BC-V11

OUTPUT FILE No: BCDEMO-PP

DATA FILE No:BCDEMO.DAT

CLIENT OR SPONSORING FIRM

PROJECT REFERENCE
PROJECT COORDINATOR OR PM
PROJ/DES.ENG. NAME
CONTACT REFERENCE PHONE & FAX NUMBERS
LOCATION

YOUR CLIENT/PROJECT
THIS ITEM
YOU
YOU ?
9999 8888
THE WORLD

MATERIAL & SIZE mm3=

MATERIAL REPOSE ANGLE Deg & DENSITY kg/m3
MATERIAL ELEVATING ANGLE Deg:
AMBIENT TEMPERATURE deg C.MINI/MAX=
SYSTEM DESIGN SURCHARGE % & LIFE (HOURS)
IMPACT & TROUGH.IDLERS NUMBER OF ROLLERS & TROUGH.ANGLE:
RETURN IDLERS NUMBER OF ROLLERS & TROUGH ANGLE
:
IMPACT IDLERS CENTRE & ROLLERS DIA. mm=
TROUGH.IDLERS CENTRE & ROLLERS DIA. mm=
RETURN IDLERS CENTRE & ROLLERS DIA. mm=
BEARING IMPACT & SYSTEM OPERATION FACTOR (0.5 - 4):
NUMBER OF
PRIMARY DRIVE PULLEYS & MOTORS
DRIVE(S) % OVER RATING REQUIREMENTS:
DRIVE FRIC.FACT.& COUPLING EFF.%:
START TIME(SEC) AND BELT TENS.LIMIT % OP.:
BELT SURCHARGE ANGLE deg.=
>>> BELT TYPE:
STEEL CORDS BELT
WIDTH mm= 1800
PULLEYS >>>>
PULLEY FACE WIDTH = BELT WIDTH mm +
PULLEY
No:
2
3
4
5
6
7
8
9
10
11
12
SPECIFIED TAKE UP TENSION kN

PULLEY
DESIGNATION
HT SNUB PULLEY
HT BEND PULLEY
HT BEND PULLEY
DRIVE 1 PULLEY
DRIVE 2 PULLEY
LT SNUB PULLEY
TAKE UP PULLEY
LT BEND PULLEY
LT SNUB PULLEY
LT BEND PULLEY
TAIL PULLEY
0

140

mm.

NODE
REF.
27
29
31
33
35
3
8
7
9
15
17

BROWN COAL
-60
35
1200
18
2
45
20
200000
0
30
2
6
340
152
1800
127
3600
104
1.2
4
2
4
25
.25
90
200
135
10
TOP & BOTT.COVERS(mm)=FRAS + 8

BEARING CRS = PFW.+ mm. 200

DIAM.
mm
600
800
800
1500
1500
600
600
600
600
400
1000

CALCULATED INSTALLED TAKE UP

S U M M A R Y
NOMINAL CAPACITY
TOTAL LENGTH & LIFT
BELT TENS.LIMITS,STARTING TIME INCREASED FROM :
BELT OPERATIONAL MINIMUM STARTING TIME:
TOTAL MOVING MASS EQUIVALENT =
BELT CONVEYOR DESIGN EVALUATION PROGRAM

PAGE 1
DATE:07-03-2011

LAGGING
mm
12
12
12
12
12
12
12
12
12
12
12

TENSION IS : 81

+ 6

mm MAY NEED TO BE MODIFIED TO BEARINGS REQUIREMENT

WARP
ANGLE
45
90
100
200
200
185
180
90
90
25
185
kN
1000 T/H
1231.68 metres
200 sec TO:
-1 SEC. INPUT=

OUTPUT FILE No: BCDEMO-PP

1 m/s
-4.6 metres
200 sec.
200 SEC.
550726 kg.
PAGE 2

NOMINAL CAPACITY
1000 T/H
DESIGN CAPACITY : 1200 T/H
AT BELT VELOCITY OF : 1 m/s
SYSTEM TENSIONS NODAL ANALYSIS
(starting from T2 tangent point on last primary drive pulley)
<---------------- I N P U T
D A T A ------------------> <----------- O U T P U T
D A T A ---------------------------------->
Node
NODE
HORZ.RAD.
X
Y
WRAP
START.RUN.
LOADED RUN
EMPTY RUN
No.
REFERENCE
m.
m.
m
DEG.
N.loss
kN++
N.loss
kN++
N.loss
kN++
1 T2 INPUT
0
0
0
0
0
80.36294
0
80.36294
0
80.36294
2 RETURN BELT
0
1.5
0
0
61.85466
80.4248
61.47222
80.42442
61.47222
80.42442
3 LT SNUB PULLEY
0
0
0
185
736.1638
81.16096
731.6121
81.15603
731.6121
81.15603
4 RETURN BELT
0
6
0
0
247.4186
81.40838
245.8889
81.40192
245.8889
81.40192
5
0
0
0
0
736.1638
82.14454
731.6121
82.13353
731.6121
82.13353
6 RETURN BELT
0
6
.8
0
629.3259
82.77386
627.7826
82.76131
627.7826
82.76131
7 LT BEND PULLEY
0
0
0
90
736.1638
83.51002
731.6121
83.49293
731.6121
83.49293
8 RETURN BELT
0
0
3
180
1547.65
85.05768
1546.885
85.03981
1546.885
85.03981
9 LT SNUB PULLEY
0
0
0
90
736.1638
85.79384
731.6121
85.77142
731.6121
85.77142
10 RETURN BELT
0
298
10
0
17041.85
102.8357
16965.83
102.7372
16965.83
102.7372
11 RETURN BELT
13860
332
-1
0
13443.89
116.0516
13358.88
115.8685
13358.88
116.0961
12 RETURN BELT
13860
194.5 -2
0
7213.313
123.1232
7163.454
122.8905
7163.715
123.2598
13 RETURN BELT
15860
189.6 -4
0
6048.094
129.0448
5999.467
128.7638
5999.829
129.2597
14 RETURN BELT
13860
189.6 -4
0
6072.993
134.9664
6024.272
134.637
6024.829
135.2845
15 LT BEND PULLEY
0
0
0
25
736.1638
135.7025
731.6121
135.3686
731.6121
136.0161
16 RETURN BELT
0
3
-.6
0
-158.629
135.5439
-159.409
135.2092
-159.409
135.8567
17 TAIL PULLEY
0
0
0
185
2736.164
138.2801
2731.612
137.9408
2731.612
138.5883
18 TAIL END
0
1
1.2
0
633.9899
138.9141
633.5916
138.5744
633.5916
139.2219
19 BOOT
0
4
0
0
4803.684
143.7177
4793.853
143.3683
1017.374
140.2393
20 LOAD
0
180.2
.5
0
59317.47
203.0352
58962.29
202.3306
9052.745
149.292
21 LOAD
13860
189.6
4
0
75745.94
278.4688
75370.94
277.3903
11355.91
160.6479
22 LOAD
13860
194.5
2
0
69896.58
347.9649
69511.51
346.503
10661.66
171.3096
23 LOAD
13860
332
1
0
110480.3
457.5464
109821.8
455.4302
17085.53
188.3951
24 DISCH.POINT
0
303.5 -10
0
59357.07
516.9034
58758.54
514.1887
10108.81
198.504
25 HT HEAD PULLEY
0
0
0
200
736.1638
517.6396
731.6121
514.9203
731.6121
199.2356
26 EMPTY BELT
0
1.5
.3
0
217.6929
517.8573
217.2274
515.1376
217.2274
199.4528
27 HT SNUB PULLEY
0
0
0
45
736.1638
518.5934
731.6121
515.8692
731.6121
200.1844
28 EMPTY BELT
0
20
1
0
1460.364
520.0538
1454.27
517.3235
1454.27
201.6387
29 HT BEND PULLEY
0
0
0
90
736.1638
520.79
731.6121
518.0551
731.6121
202.3703
30 EMPTY BELT
0
0
-5
0
-2127.113
518.6628
-2128.635
515.9264
-2128.635
200.2416
31 HT BEND PULLEY
0
0
0
100
736.1638
519.399
731.6121
516.6581
731.6121
200.9733
32 EMPTY BELT
0
1.38
.4
0
260.5845
519.6595
260.1472
516.9182
260.1472
201.2334
33 DRIVE 1 PULLEY
0
0
0
200
266.0464
522.2714
260.1472
519.536
260.1472
203.8512
34 EMPTY BELT
0
4
0
0
196.8975
522.4683
195.6801
519.7317
195.6801
204.0469
35 DRIVE 2 PULLEY
0
0
0
200
223936.1
301.4102
222562.3
300.0473
64719.9
142.2049
FULL LOAD STARTING TENSIONS kN
FULL LOAD RUNNING TENSIONS kN
UNLOADED RUNNING TENSIONS kN

304.2991
223.9361
80.36294

302.9252
222.5623
80.36294

145.0828
64.7199
80.36294

OPERATIONAL DEMAND POWER

223.9361

222.5623

64.7199

kWH

ANCILLARY TAIL DRIVE POWER kWH

BELT CONVEYOR DESIGN EVALUATION PROGRAM

OUTPUT FILE No: BCDEMO-PP

PAGE 3

BELT SPECIFICATIONS:
BELT TYPE:ST2000 - COVER TYPE:FRAS - WIDTH: 1800 mm. - TP.COVER: 8 mm. - BT.COVER: 6 mm.
SPECIFIED BELT OPERATIONAL TENSION :KN= 540 SYSTEM TENSIONS OPER. & PEAK kN= 302.9252
BELT
BELT
BELT
BELT
BELT

ELASTICITY MODULI KN/m.=

THICKNESS mm=
UNIT MASS:KG/m=
RESERVE CAPACITY:
NET LOOP LENGTH m=

304.2991

550000
26
48.384
-100 % BURDEN : 333.33 kG/m
EDGE DISTANCE : 175
2497 m. ( INCLUDING VULCANISED SPLICES. )

FABRIC BELT MIN.CONCAVE RADIUS

STEEL BELT MIN.CONCAVE RADIUS

HEAD=
HEAD=

646
646

MINIMUM RECOMMENDED DIAMETER FOR HT & DRIVE PULLEYS:

MINIMUM RECOMMENDED DIAMETER FOR LT & BEND PULLEYS:
MINIMUM RECOMMENDED DIAMETER FOR LT SNUB PULLEYS:

m
m

TAIL= 172
TAIL= 172

m
m

mm (

MINIMUM CONVEX RADIUS = 17

MINIMUM CONVEX RADIUS = 87

128
m
m

1060 mm.
900 mm.
600 mm.

TOTAL BELT SHIPPING MASS (INCLUDING SPLICES BASED ON 10 TONS BELT SHIPPING REEL) = 120863 KG.
REMARKS: capacity of BELT to meet all operational parametres to be confirmed by SUPPLIER/MANUFACTURER
BELT SCRAPERS MINIMUM REQUIREMENT
HEAD PULLEY
PRIMARY SCRAPER ONE X 'H' TYPE OR EQUIVALENT AT -15 DEG. XX AXIS
HEAD PULLEY SECONDARY SCRAPER ONE X 'P' TYPE OR EQUIVALENT AT 200/400 mm PAST BELT/PULLEY TANGENTIAL POINT
TAIL PULLEY SCRAPER ONE 'V' PLOW TYPE OR EQUIVALENT FLAT AT RETURN BELT TOP
REMARKS:There are several valid proprietary belt scraper equivalents as well as custom designed/built alternatives.
SOME APPLICATIONS MAY REQUIRE SPECIFIC BELT CLEANING SETUP.
IDLERS REQUIREMENT & SPECIFICATIONS
IMPACT & TROUGH.IDLERS NB.OF ROLLERS :
3 AT 30 DEG.
RETURN IDLERS NB.OF ROLLERS
:
2 AT 6 DEG.
IMPACT IDLERS MINIMUM SPECIFICATION = HEAVY DUTY INPACT IDLERS REQIRED.
TYPE
---IMPACT
TROUGH
RETURN
TRANS.

CENTRE
mm.
340
1800
3600
1800

NUMBER
REQ.
14
682
339
4

ROLLER
DIA.mm
152
127
104
127

BEARING DYN.
DIA.
N.

50733
78780
26684
78780
IDLERS SHIPPING MASS= 45682 Kg. EXCLUDING BOLTS QTY= 4140
-------------------------------------------------------------------------------------------------------------------------

mm upper limit)

BELT CONVEYOR DESIGN EVALUATION PROGRAM

OUTPUT FILE No: BCDEMO-PP

PAGE 4

PULLEYS ASSEMBLIES
TOTAL: 12 PULLEYS & BEARINGS ASSEMBLIES:

AP

PROX. GROSS SHIPPING MASS = 48190

(*)kg>

PULLEY'S UNIT MASS FOR FAB.ST.ONLY EXCL.ANY FITTINGS

SHELL,END DISK'S THICKNESS,LOCKING DEVICES & BEARING'S ASSY.
PULLEYS SELECTION FOR: 1800 mm WIDTH
ST2000 BELT
ARE INDICATIVE ONLY AND ARE TO BE SUBJECT TO DETAILED DESIGN
PULLEY'S FACE WIDTH
mm= 1940
IN FUNCTION OF THE PARTICULAR FABRICATION METHOD AS WELL AS TO
PULLEY'S BEARING CENTRE
mm= 2140
THE SPECIFICATION OF THE MATERIAL EMPLOYED,AND OR THE FORM OF
PULLEY'S LOCKING DEVICES CENTRE
mm= 1765
CONSTRUCTION ADOPTED SUCH AS DEAD SHAFT , KEYED SHAFT , ETC.
SHELL & DISK MAX. ALLOWABLE STRESS MPa: 100
MINIMUM ALLOWABLE SHELL THICKNESS mm.
8
Note:Bearing's centres to be readjusted as required in function of Bearing supply
IF THIS PROJECT IS PART OF A MULTIPLE CONVEYORS SYSTEM, THEN PULLEYS RATIONALISATION MAY BE AN ECONOMIC

CONSIDERATION

DRIVE PULLEY'S TORQUE APPLIED AT EITHER OR BOTH ENDS OF SHAFT.

PULLEY
No:
1
2
3
4
5
6
7
8
9
10
11
12

TYPE
....

HT HEAD PULLEY
HT SNUB PULLEY
HT BEND PULLEY
HT BEND PULLEY
DRIVE 1 PULLEY
DRIVE 2 PULLEY
LT SNUB PULLEY
TAKE UP PULLEY
LT BEND PULLEY
LT SNUB PULLEY
LT BEND PULLEY
TAIL PULLEY

ALL PULLEY'S DATA BASED ON FULL LOAD RUN.

NODE
REF.

DIA.
mm.

LAG.
mm.

RPM
...

T1
KN

T2
KN

WARP
ANG.

TORQ.
KNm

SHEL
mm.

DISK
mm.

25
27
29
31
33
35
3
8
7
9
15
17

1200
600
800
800
1500
1500
600
600
600
600
400
1000

12
12
12
12
12
12
12
12
12
12
12
12

15.6
30.6
23.17
23.17
12.53
12.53
30.6
30.6
30.6
30.6
45.04
18.65

504
517
517
517
522
303
83
87
85
86
134
138

504
516
516
516
520
525
82
85
84
85
134
136

200
45
90
100
200
200
185
180
90
90
25
185

0
0
0
0
83.91
84.38
0
0
0
0
0
0

32
57
53
51
35
28
8
8
10
10
16
11

78
103
96
92
74
68
40
41
35
36
29
48

LOCK
DEV.
340*425
380*475
400*495
280*355
280*355
260*325
260*325
220*280
300*375

BEARING DYN
DIA. KN.
260
200
240
260
300
280
150
150
130
130
110
170

2924
1436
2433
2636
2825
2245
599
625
434
439
238
852

MASS
KG.
4852.5
5604.9
5744.11
5831.03
5680.18
4985.69
1985.58
1997.38
1866.49
1878.28
1803.43
2390.82

BELT CONVEYOR DESIGN EVALUATION PROGRAM

DRIVE(S) REQUIREMENT

OUTPUT FILE No: BCDEMO-PP

PAGE 5

MCC.RUNNING POWER DEMAND AT NOMINAL CAPACITY : KW= 190.9938

NUMBER OF FRONT DRIVE PULLEYS: 2

NUMBER OF FRONT DRIVE MOTORS: 4 * KW. 58.4226

SELECTED MOTOR(S):
MOTOR(S) FRAME
:
MOTOR(S) RPM
:
SYSTEM RELATIVE INERTIA 'J' Kgm2 =
START TIME=

4
D250M
1480
561
200 seconds

KW: 75

STARTING FACTOR : 101 %

GEARBOX SPECIFICATION
GEARBOX(S):
INPUT RPM:
OUTPUT STARTING TORQUE REQUIRED :
OUTPUT RUNNING TORQUE
:
DRIVE ASSEMBLIES SHIPPING MASS

4
1480
46 KNm
42 kNm.
1986

RATIO= 106 /1
OUTPUT RPM: 12.53188

(*)KG. * 4

EMERGENCY REDUCED DRIVE OPERATION

CAPACITY WITH ONE MAIN DRIVE ASSEMBLY REMOVED =

497

T/H

NON OPERATIONAL OVERFLOW PARAMETRES.

BURDEN TO BELT EDGE (0) CLEARANCE )
MATERIAL ON BELT: KG./M =
0
= 0 T/H.OVERFLOW CAPACITY
------------------------------------------------------------------------------------------------------------------------ANCILLARY TAIL DRIVE ASSEMBLY
TO BE FITTED WITH EDDY CURRENT / FLUID / OR EQUIVALENT COUPLING TO BE CONTROLLED BY PRIMARY DRIVE
TORQUE REQUIRED AT TAIL PULLEY :

SELECTED MOTOR:
MOTOR
FRAME:
MOTOR
RPM :

kNm.

0 KW
-0

GEARBOX RATIO:
0
INPUT RPM: 0
OUTPUT RPM: 0
OUTPUT TORQUE :
0 kNm.
------------------------------------------------------------------------------------------------------------------------IF BACK STOP IS REQUIRED THE STATIC TORQUE AT HEAD/DRIVE PULLEY :-48.12912 KNm
IF BRAKES REQUIRED, MAXIMUM TORQUE AT GEAR BOX INPUT = -1 kNm based on: 135 .% of belt maximum operating tension.
SYSTEM RELATIVE INERTIA 'J' Kgm2 = 694
MINIMUM
INERTIA
BRAKING
INERTIA
BRAKING

STOPPING TIME & MATERIAL DISCHARGE TIME(sec.)

STOP EMPTY
21.24583
STOP EMPTY
2.119873
STOP LOADED
25.28674
STOP LOADED
8.291883

MAT.(kg.)
4214.458
1381.98

MAT.(m3)
3.512048
1.15165

TAKE UP SYSTEM.
HORIZONTAL TAKE UP SYSTEM , FOR COEF.FRICTION OF :
REMARK : SPECIFIED TAKE UP TENSION:
FOR : 2 DRIVE PULLEY(S),MINIMUM TAKE UP TENSION kN =
FOR COUNTERWEIGHT ROPES SYSTEM OF:
COUNTERWEIGHT MASS , TONS =
OPERATIONAL TAKE UP PULLEY TRAVEL =
INITIAL TAKE UP PULLEY TRAVEL =

.25
0 KN.
80.36294
5
4.949326
189 mm
99 mm

-----------------------------------------------------------------------------------------------------------------------

BELT CONVEYOR DESIGN EVALUATION PROGRAM

SYSTEM LOADING ON STRINGERS AND FRAMEWORK kg/m RUN =:
MATERIAL FLOW CROSS SECTION m2 =

OUTPUT FILE No: BCDEMO-PP

PAGE 6

460
.3814128

TRAJECTORY COORDINATES FOR HEAD BOX/CHUTE DESIGN

COORDINATES X (horizontal) & Y (vertical) FROM HEAD PULLEY TOP CENTRE.(REF:'0').ALL DIMENSIONS mm.
(vertical neg. UP , positive DOWN )
REF:
1
2
3
4
5
6
7
8
9
10 11
12
13
X:
39
79
119
159
199
239
279
319
359
399
439
479
519
Y:
9
33
74
130
202
290
393
512
646
797
963
1144
1342
------------------------------------------------------------------------------------------------------------------------TRIPPER COORDINATES FOR FRAME DESIGN

14
559
1555

COORDINATES X (horizontal) & Y (vertical) FROM VERTICAL CURVE IP POINT ( 0 ).ALL DIMENSIONS mm: TRIPPER LIFT:-10000
COORDINATES FOR 100% BURDEN ON BELT:
ALL DIMENSIONS REFER TO U/S BELT
PROFILE (mm):BELT RADIUS= 765853
REF:
1
0
0
0
0
0
0
0
0
0
0
0
0
X:
0
0
0
0
0
0
0
0
0
0
0
0
0
Y:
0
0
0
0
0
0
0
0
0
0
0
0
0
TRIPPER STRINGER FRAME LENGTH: 0
------------------------------------------------------------------------------------------------------------------------RADIAL COMPONENT ON HORIZONTAL CURVED SECTION
horizontal curve either side of central alignment requires detailed check of the belt characteristics and supporting
structure with correct offset corrections and auto tracking devices
SECTION BETWEEN NODES: 10 & 11
RAD.COMPONENT IN N/metre run. 0 / 0
SECTION BETWEEN NODES: 11 & 12
RAD.COMPONENT IN N/metre run. 0 / 0
SECTION BETWEEN NODES: 12 & 13
RAD.COMPONENT IN N/metre run. 0 / 0
SECTION BETWEEN NODES: 13 & 14
RAD.COMPONENT IN N/metre run. 0 / 0
SECTION BETWEEN NODES: 20 & 21
RAD.COMPONENT IN N/metre run. 0 / 0
SECTION BETWEEN NODES: 21 & 22
RAD.COMPONENT IN N/metre run. 0 / 0
SECTION BETWEEN NODES: 22 & 23
RAD.COMPONENT IN N/metre run. 0 / 0
-------------------------------------------------------------------------------------------------------------------------

0
0
0