NAME

COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
CONVEYOR SYSTEMS

HENBAK MINE CRUSHING PLANT

CANDIDATE No

1114006I00103

ACKNOWLEDGEMENT
My regards are directed to all who actively participated in
facilitating and making this project a success. I would greatly
appreciate the help and support rendered by the lecturers at
Kwekwe Polytechnic in Electrical Department , your input made a
significant contribution in this piece of work.
Not forgetting my family and friends , you were always there for
me to help with all sorts of ideas and keeping my moral high
during the time.
Lastly , my regards goes to James Mapiravana, my husband to be
who always guide, help and care and not forgetting God above all.
To all the above ,I owe you showers of gratitude. Thanks once
again, always be blessed.

NAME

NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
CONVEYOR SYSTEMS

HENBAK MINE CRUSHING PLANT

CANDIDATE No

1114006I00103

CHAPTER ONE

INTRODUCTION
Zimbabwe s mining sector is growing at a faster rate and this
implies that there is need for crushing plants and conveyor
system projects to efficiently extract the minerals and processing.

BACKGROUND OF THE PROJECT

At Henbak mine Conveyor 1 ferries stones from underground

feeding Conveyor 2 on the surface. Conveyor 2 feeds the crushing
machine which is 100m away from the shaft . Motor 1 and 2 are
started manually , there are no emergency stop buttons along
100m conveyor . Consequently the operators may start Conveyor
1 first instead of Conveyor 2 thereby loading the stationary
Conveyor 2.

PROBLEM STATEMENT

Henbak mining crushing plant were used to be started manually.

The correct sequences of operation is crusher , conveyor 2 then

conveyor 1. The operator sometimes reverse the sequences

thereby loading the stationary crusher and or conveyor . This
triggered the researcher to design the circuit to correct the above
mentioned problem.
NAME

NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
CONVEYOR SYSTEMS

HENBAK MINE CRUSHING PLANT

CANDIDATE No

1114006I00103

AIMS OF THE PROJECT

To provide efficient , reliable means of starting without

interruption of other circuits.
To avoid damage of equipments and dangers to the
machine operators.

OBJECTIVES

To reduce accidents or dangers.

To reduce damage of equipments.
To design a control and power circuit.

LIMITATIONS
The time frame for the project will delay the production of

the company . This delay involved may lead to the denial of

the project by managerial team of the company.
The improvement of the crushing machine and conveyor belt
system is costful to the company.

DELIMITATIONS
As it is costful to the company but in the long run it will be

beneficial to the company to a larger extent.

Reduces accidents.
NAME

NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
CONVEYOR SYSTEMS

HENBAK MINE CRUSHING PLANT

CANDIDATE No

1114006I00103

Maximum reduction of equipments wear out.

Interlocked system reduces changes of interruption of the
system.

CONCLUSIONS

Sequencial starting is most efficient means of starting as for

conveyor belts system is concerned.

NAME

NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

CHAPTER TWO
LITERATURE REVIEW
INTRODUCTION

In this chapter the researcher focuses on the major

components that are being used at the Henbak mine crushing
plant conveyor systems. They consists of 3 phase induction
motors , contactors, stop and start buttons , overload relays
and cables.
In events of consultation and researches were made so as to
come up with considerable weight of the information .The
information was extracted directly and or indirectly from
authorized textbooks by different authors. The researcher also
made research as current technology and rules governing the
electrical body.
According to Engineer L Munemo who is Henbak mine crushing
plant engineer, who designed the previous conveyor system
circuits which have no interlocks, We as the students of

Kwekwe Polytechnic,we have carried out more researches on

the conveyor system sequencial starting method.We made
great use of the IEE WIRING REGULATION AND SAZ with the
aid of attached catalogues to suit the standards required.

Previously the Henbak mine has no sequence of starting which

causes damage to machineries . We impliemented the
sequencial starting method.
NAME
COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

NAME

NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

NAME
COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

NAME
COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

CHAPTER THREE
METHODOLOGY
INTRODUCTION

This chapter seeks to outline the procedures that was used to

collect information about the project and also define the methods
applied to come up with the relevant data which was used in this
design process .It also lays out the techniques that were
employed in this design , planning , structuring and execution of
this design project.

COMPONENT SELECTION

CONTROL BREAKER
Is a devices used to cutoff supply under normal or faulty
conditions .
BREAKER SIZE (5A)

This is the minimum breaker size which can be used on control

circuit because it does not draw more current
STOP BUTTON
Is a devices used to stop the circuit and it is normally close and
spring loaded.

NAME
COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

EMERGENCY STOP BUTTON

Is a stop button used to stop the circuit under emergency

conditions.
LOCKABLE STOP BUTTON

Is a stopping device used for safety reasons

START BUTTON
Is a device used to start the circuit and it is usually on normally
open conditions and spring loaded.
CONTACTOR

Is an electromagnetic switch which uses the electromagnetic

principle for energizing and de energizing.
CONTACTOR SPECIFICATION

Ui is the rated voltage and it is rated by the manufacturer.

Ui must range from 230V to330V.
THERMAL CURRENT (ITH)

This is the maximum current which can flow through the

contactor contacts without detiorating them.
POWER RATING

This is the rated or stated power a contactor can withstand.

NAME
COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

Ranges from 3,5KW to 5,5KW.

OVERLOAD RELAY
A device used for over current protection in the power circuit.
TRIPPLE MCB
Used for over current protection in the power circuit.(short circuit
currents).
For STAR DELTA it will be rated on electric motor full load
current.

For DIRECT ONLINE it will be rated on 1.5 x full load current.

ELECTRIC MOTOR SIZES

CRUSHER MOTOR (300Hp)
KW/Hp
VOLTAGE (V)
CURRENT (I)
FREQUENCY
POWER FACTOR
R.P.M
CONNECTION

NAME
COLLEGE

300KW
380V
394A
50Hz
0.8
1500rev /min
STAR /DELTA

NYAMAZANA TAFADZWA
KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

CONVEYOR 2(STRIKE CONVEYOR)

Hp / KW
VOLTAGE (V)
CURRENT (I)
FREQUENCY
POWER FACTOR
R.P.M

45KW
380V
60A
50Hz
0,8
1500 rev/min

CONNECTION

STAR /DELTA

CONVEYOR 01 (SARCIFICIAL CONVEYOR)

HP/KW
CURRENT
FREQUENCY
POWER FACTOR
R.P.M
CONNECTION
NAME

30KW
40A
50Hz
0.8
300 rev /min
STAR /DELTA
NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

CABLE SIZE SELECTION

The following formulas are used to calculate sizes of protective
devices and all supply cables.
FORMULAE
i)

for 3 phase supply

 3 V L X Pf

IB

IZ

ii)

G . A .T . S

Verifying Voltage drop

VD

=[(mV/A/m) Ib I] 1000

NAME

NYAMAZANA TAFADZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

Where this value has to be less than 2,5% of 380 for three
phase supply.

Where ;
IB

= Design current in amperes.

IZ

= Current carrying capacity.

IN

=Norminal rating of protection.

VL

= Line voltage.

PF

= Power factor.

= grouping factors.

= Ambient temperature.

NAME
COLLEGE

NYAMAZANA TAFADZWA
KWEKWE POLTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

= Thermal insulation.

= Sheathing.

CALCULATIONS FOR CABLES SIZES.

CRUSHER MOTOR(300KW)

3
= (300 000 ) 380 0,8

IB

=569,75A.

Therefore;

IN = 600A .

IZ = IN (G . A .T . S ) .
= 600 (1 30 0,75 0,725 ) .
= 36,8A.
NAME

NYAMAZANA TAFDZWA

COLLEGE

KWEKWE POLYTECHNIC

PROJECT TITLE
HENBAK MINE CRUSHING PLANT
CONVEYOR SYSTEMS
CANDIDATE No

1114006I00103

6mm2.(from table 9D1).

VD = mv/A/m I

(1000 ) .

= 6,2x10-3 56 9,75 100 ( 1000 ) .

=0,35V.

2,5% 380
=9,5V.
Therefore 0,35V is less than 9,5V.
Thus 6mm2 should be our supply cable.

CABLE SIZE FOR CONVEYOR 02 (STRIKE CONVEYOR).

IB = P

3 V

Pf ).

NA

=45 000 ( 3 380 0,8)

= 85,46A

IN = 100A .

IZ = IN

G. A . T . S
)

= 85,46 (1 30 0.75 0,725 )

= 5,2A. 4mm
2

from table (9d1).

Vd =mV/A/m Ib I (1000 ) .

=9,2 10
= 0,06V .

-3

85,46 80 ( 1000 ) .