| 2 1GUDETOss THE DESIGN OF TRANSFER CHUTES & CHUTE LININGS sy suooUjGug uope}a0ss ‘Bul He Mechanical Handilifig Engineers’ AssociationGUIDE TO THE DESIGN OF TRANSFER CHUTES AND CHUTE LININGS FOR BULK MATERIALS HJ. Taylor, B.Sc,C.Eng,M.I.Mech.E use, Artillery Row, London SWIP 1RT Il rights reserved.FOREWORD ‘Recommended Practice for Troughed Belt Conveyors’ ‘any years as an internationally recognised reference work coves it conveyor systems. This comp: tudy examines in greater detail the requirements for a means of transfer for loose Is between the individual belt conveyor flights Iso relate to chutes used in feed and discharge sociated plant. arrangements for interconnection of belt conveyor syste1 wi The work is intended to assist the chute and plant designer in his task and endeavours to indicate some of the pitfalls and offer guidance towards more effective chute design. 'BS2890 (Specification for Troughed Belt Conveyors), the definition for a chute is given as ‘A straight, curved or pen topped or enclosed smooth trough, by which materials are directed and lowered by gravity’. Preparation of this manual has indicated the need to broaden the concept of a transfer chute to embrace the many additional factors involved at the transfer point between belt conveyors. An attempt has been made to include some of these factors within this manual, The cliche that ‘there is no sul ice’ is very applicable to chute design; but experience can be an expensive tutor. It is hoped th: rovide some of the background infor against which the designer will enhance his understanding of the subject by critical examination of existing installations. ‘The scope of the study is intended to cover transfer chutes for the whole range of troughed bel in the MHEA manual ‘Recommended Practice’ i.e. for belts from 500mm up to 200mm wide yery diverse nature. Not all of the factors covered will be appropriate in every case and it will be apparent problems in handling 5000 tonnes/hour of heavy ore with 500mm size lumps will be very different from those eneountered in handling 20 tonnes/hour of a light granular product. The readers indulgence in these matters will be appreciated. The following Sections arise from original analysis by the author and are proposed as practical solutions: Section 7.0 Section 10.3CONTENTS Section 1.0. Classification of Materials to be Handled 1.1 Bulk Density 1.2 Angle of Repose 1.3. Classification 13.1 Lump Size 13.2 Cohesion 1.3.3 Other Properties 14. Table 1. Classification of Bulk Materials 2.0 Flowability of Bulk Solids 2.1 Bulk Density 2.2. Angle of Repose 2.3 Internal Friction 2.4 Wall Friction 24.1 Wall Friction Angle 2.4.2 Surface Cohesion 2.4.3 Time Enhancement of Contact Friction 2.4.4 Effective Wall Friction Angle 2.5 Testing for Wall Friction 3.0, Chute and Lining Materials 3.1. Chute Lining Materials. Table 2. 3.2. Wear to Chute Surfaces 3.2.1 Impact Wear. Table 3. 3.2.2 Abrasive Wear. Tables 4 & 5. 3.2.3. Details of materials tested in Tables 3, 4 & 5. 3.3 Wall Friction Angles. Table 6 3.3.1 Surface Roughness 34 Mild Stee! Carbon Steel loy Steels ion Resistant/Stainless Steel (12% Cr) Stainless Stee! High Chrome Cast Iron/Ni-Cr Tiles Clad Plate Rubber'Synthetic Rubber. Table 7. Polyurethane Ultra High Molecular Weight Polyethylene (UHMWP). Tables 8, 9 & 10. 3.4.11 Quarry 3.4.12 3.4.13 Be 8 3.4.14 Alumina Tiles 40 Operational Requirements and Design of Transfer Points 4.1 Transfer Height 4.2. Transfer of Belt Cleanings 43 in Material Flow Properties 44 mal OperationContents continued 5.0 Su 5.2 33 SA 6.0 70 7 72 13 14 1S 16 aa, 78 79 8.0 8 a2 83 9.0 ot 92 93 o4 10.0 10.1 10.2 10, 1.0 ud 1.2 13 Valley Angles Plates at 90° tes not at 90°. Table 11. Straight Chutes Turn Chutes Corner Effects and Fillets Discharge Trajectories Introduction Plotting a Basic Trajectory. Table 12 and Chart 1 Edge Material Load Cross-Section at Discharge Pulley. Table 13. Load Front at Pulley The Effect of Lumps Theory of Motion a Discharge Pulley Critical Velocity, High Speed Tr 784 Low Speed Trajectories Discharge Angle. Chart 3. Table 15 Plotting the Full Trajectory Collecting the Flow Foreward Collection into Chute Backward Deflection into Chute Side Entry Chute ‘Transferring the Flow Direct Vertical Drop Dump Chute Inclined Flat-bottom Chute “U’-form Chutes Crash-box Chutes 9.4.1 — Dimensions Chute Capacity and Flow Velocity Volumetric Capacity Cross-sectional Capacity ing Blockage by Bridging hate Incination and Material Velocity 10.3.1 Case 1. Straight Pat 103.2 Case 2 Straight Chute with Defected Bottom Section 103.3 Case 3. Curved ‘U’-form Chute 10.3.4 Examples, Case 1,2 and3 10.3.5 Velocity at Entry to Chute Discharging the Flow Backplate Chute Discharge Skirt PlatesContents continued Page 12.0 Chute Construction 9 13.0 Dust Control 81 13.1 Enclosures 81 13.2. Dust Suppression by Water Sprays, 81 13.3. Dust Extraction 2 14.0 Control Valves and Flow Diversion 87 14.1 Flap Valve Vertical Chute 87 14.2. Flap Valve - Inclined Chute 87 14.3 Flow Splitting 88 14.4 Doors 88 14.5. Flow Diversion Heavy Duty 88 14.6 Diverter Chutes 89 14.7 Radial Chutes ” 15.0 Safety Considerations a1 16.0 In Conclusion 2 REFERENCES (1) Amold, P.C. and Roberts, A.W. ‘Feeding of Bulk Solids from Bins. Seminar on Recent Developments in Design and Operation of Bulk Handling Systems, The Institution of Mechanical Engineers, London. September 1085. (2) Jenike, A.W. ‘Gravity Flow of Bulk Solids: Bul. 108, Utah Engng. Exper. Station, University of Utah, 1961. (3) Jenike, A.W. ‘Storage and Flow of Solids’, Bul. 123, Utah Engng. Exper. Station, University of Utah, 1964 (4) Hocke, H. ‘Wear Resistant Materials for Coke and Sinter Handling Plant. British Steel Corporation, Teesside Laboratories, Grangetown, Middlesbrough. Iron and Steel Intei December 1977. (5) Arnold, P.C. and Roberts, A.W. ‘The Geometric Design of Storage Systems for Bulk Solids: Seminar on Recent Developments in Design and Operation of Bulk Handling Systems, The Institution of Mechanical Engineers, London. September 1985. (© Mechanical Handling Engineers’ Association. Artillery House, Artillery Row, Westminster WIP IRT._ “Recommended Practice for Troughed Belt Conveyors’ 19861.0 CLASSIFICATION OF MATERIALS TO BE HANDLED The table of Bulk Materials (see 1.4) gives the classification for a typical range of bulk solids together with their approximate bulk density and angle of repose. ‘The terms used in this table are given in a descriptive or qu: requirements which may be necessary in the d precise determination of material low prope solids. 1.1 Bulk Density This should be determined for the loose bulk material as fed onto the chute or transfer point. Usually expressed in tonnes per cubic metre. 1.2. Angle of Repose ‘This is the slope angle which the surface of a normal freely formed pile makes to the horizontal. 1.3 Classification the characteristics of the materials which, in practice, considered necessary to use more precise values, the parties concemed should agree values appropriate to the particular case and a typical sample of material be provided for assessment and test. See Section 2. 1.3.1 Lump Size distribution an: now if the 3 Gissheaton | Descipson | __Size Range Vey Fine | Testhan 40 am Fine “20 pm‘o1 mm Tnmto3 mm Gaalgamaay | 3 mmo 10mm Targegramlar | 10 mmto25 nm 25 mm to 50 mm 50 mm to 75 mm Lumpy. 75 mm to 150 mm 150mm to 300mm Massive over 300 mm xlomlomm/olou|>1.3.2 Cohesion nce to the angle of repose of the material and it’s the more specific use of the term Surface Cohesion en in contact with a confining surface. See Section may be compared by nse, it should not be confuse ‘bulk solid opposing, Classifica Description 1 ‘Can be suspended in air and flows freely asa liguid 2 Free flowing, angle of repose less 30° 3 ‘Normal flowing, angle of repose from 30° 10 4s 4 Slow flowing, angle of repose from 45° to 60" 5 ‘Compacting, angle of repose greater than 60° 6 Non-collapsible, entangled, susceptible to arching, resistant to separation, Used as a descriptive likely flow behaviour. the 1.3.3. Other Properties Certain material properties may have a direct bearing come of these properties which may occur in mat ‘The following table sms and their transfer ease and safety handled by belt ‘Other Classification Description Oily, or Hable to react with rubber products High temperature Nomabrasive Abrasive Very abrasive Sharp edges Friable, easily degradable Mildly corrosive Highly corrosive Explosive or creating harmful dust Very dusty Inflammable Hygroscopic Sticky wee eer et eve ‘The foregoing classifications and nomenclature are based, where applicable, on ISO 3425.14 Table 1. Classification of Bulk Materials Bulk Dentiy | _Approtimate Angie of Respose Clasicaion Material aim Degrees Lamp | Cokesion | Osher ‘Alum (Lumpy) osno n ec | 3 1 ulversea) ors sas se | 3 t Alumina os 2 Bc | n ? ‘Ammonium C1 o708 10 wc | 2 Ammonium te oT pi 3 nxt, ‘Ammonium Sulphate ons 0 dp | 2 a Anthracite (See Coal) | Asbestos Rock ero | 2 po Shreddes sits 6 me ‘Ashes Coal Dry Fine 304s D ‘ nu Bry Coarse rc | 4 A WerFine saiss D ‘ a Wet Coarse Ro | 4 a Fy 2 ‘ ‘ > ‘Bagasse | 46 1 Baking Powder “ A 2 1 Barley 25 se | 1 in Barytes ~3 mim 35 sc | 2 a +3 mm to — 10 mm Fy D 2 a + 10mm to 75 mm x” src | 2 2 $75 mm to 180 mm H 3 a Basalt ~3.mm Bc 3 a $3.mm to 10 mm D 3 2 $10mmto~ 75mm sro | 3 2 35 mm to 150 mm | “H 3 2 Bauite Dry Fines Pa sc | 2 a ~F50mm sis era | 2 2 ROM. 3 wx | 3 a0) Beet Pulp Dry x « 1 Wee a % b Beets Whole ssi40 Ec | x 1 Bones (As Shipped) Bonemeal ac | 3 \ Boras — 3 mm sss we | 3 a $3.mm to — 10mm 5s D 3 a Piommto— 75 mm Savas re | 3 a 275 mm to 150 mm 0 H 3 a Brick Rubble 38 sro | 6 = Carbon Black Powder A 3 Carbon Petits Bc 1 fe Cement Portland Bulk » A v a Acrated a rt 2 Clinker 2 EG | 3 P Chalk ~3 mm uss A 4 a $3 mmto— 10 mm aus D ‘ a Si0mm~75 mm aoas crc | 4 = +75 mm to 150 mm “5 a 3 = Clay Dry Fines 3 D 3 > Dy 75mm Fe rc | 3 P Wet ~ 50 mm Er | 4 YBulk Density | _ Approximate Angie of Respose Classifcation Material si Degrees Here | comer | Over Coal Anthracite Fines 0.96 3 BC 3 tu Sized 09 2 D 2 a Coal Bituminous R.O.M. 08 38 EFG 3 fe Washed Sized 08 8 EFG 3 ie Untreated Slack 0708 rn D 4 s 0305 EFG 3 (kz Coal (Brown) Lignite 8 EFG 3 mz 6 A 6 1 Py D 2 i 26 D 2 1 Coconut Shell Broken EFG 4 1 Coconut Meat EFG ‘4 il Coffee Fresh Bean 2 D i 1 Roasted Bean D 1 i Coke Run of Oven cH 4 ars Sized EFG 4 ars Breeze aos D 4 Ps Calcined Petroleum EFO 3 pou Copper Ore As Mined EFG 2 P Crushed EFG 2 P (Copra Lump 20 EFG 2 1 Meal 35/40 BC 3 it (Copra Cake Lump 2» EFG 2 it Ground 30. BC M i Com Bar Shelled a D 2 Grits BC 2 Commeal 35 BC 3 Cottonseed Dry De-Linted 2 D 2 Dry Not De-Linted 35 D 3 Cake Crushed BC 3 Cake Lumpy ERG 2 Hulls BC 4 Meals 35 BC 3 Meats BC 3 Cayolite Lump EFG 3 Dust A 3 Earth Loamy Dry 35 BC 3 ‘Clayey Wet 8 BC 4 Feléspar Sends A 4 Screened + 3 mm to 10mm D 3 Lamp + 10 mm to ~ 75 mm EFG 3 [Lump + 75 mm to 130 mm H 3 Fish Meal BC 4 i Serap 6 i Flaxseed a BC 2 1 Frour (Wheat) A 2 psy 38 D 3 mp 2 BC 4 P Foundry Refuse Old Sand Cores ES EFG 3 kp ee . - -., ., pgs emeheannmiaanaeeeaexeaaeaeanaeaeaeaeaeaaeaeee aCUUUTUUUUUUUU UU Uv UU UU f Bulk Deny | _ Approninae Ane Respose Clasicaion Material tim Degrees Lump Cohesion aed | Fullers Earth Dry B BC 2 n pe | 2 in Be | 3 a 3 pe | 2 2 Gelatine Granulated | D 2 © Glue Fine ec | 2 2 Pearl 2 D 2 2 Gas Clie 2o1ss pv | 2 i Grain pent Dry Distes a | i | Dobrewers » | é fh Grate Screened ~ 10mm 0 p> | 32 P 510 mm 10150 mm 3 Bron | 2 , Gravel Bank Ran Wet 2 sc | 2 ? Diy (washed) 3 Er | 3 , sized Pebbles ” Ee | 3 . “cusneDry 3 ec | 2 tt Gypsum Da {orem st Acard 2 a | 3 Screened 3mm to ~ 10m © dp | 3 2 | Steud tm 0150 on ” ero | 3 : ee wo | 4 wwe Hops spent Wet 3% | Da ‘ 3 1 cashed ee x0 ec | 2 a Time Ore se] 2 ° iron & Stel Swart Machine vp | « | @ tron Ore (Depends on % Fe) a tron Ore Pets 2» eo | 2 a tron Oxide Pigment 0 a 4 1 Kaolin Clay 35 EFG 3 a Kaotn Tale 6 a | 4 a aed anenate ec | 4 1s Ores (Caen) 0 pe | 3 | mw Ons Be | 3 i Sulphate ‘ Lips Co Brown Lime Fine Crosed sna 6 sc | s 1 Hyerated ag 0 ao | 3 1 Hciated Plvroed O56 2 a | 3 w | pee 0s % eo | 3 1 Vigmerose Agietusat a ac | 2 a | Dest ian * ke | Cried rans # By} 2 . Linseod Cate Pea Sie os p> | 3 a Mel os u ge | 2 I Malt Dry Ground 03s ec | 2 er Diy wate os > | 2 u Weror Green 10 pb | é 1 Mea 08 se | 3 1‘Bulk Density | Approximate Angle of Respose Classification | Material aim? Degrees tarep. || Comeson: |] Oe Magnesium Chloride oss D ‘ p ‘Sulphate 1 Manganese Dioxide 13 = 2002 » EFG 3 > i D 2 > ians D 2 P 13 0.20.24 Ey BC 3 oo 030.35 BC i w Milk Dried Flakes ogno | Bc 2 1 Dry Powder 058 45 BC 2 1 Malted 0506 A 35 y ‘Whole Powdered 032 Bc 3 yy Mill Scale 22 46 : Mortar Wet 24 Be 4 ns Mustard Seed on BC 2 Nickel — Cobalt Sulphate Ore 1324 ERG 2 Oa 042 a D 2 \ Oats Rolled 03 D 2 ls Oi1Cake os EFG ‘ i Oyster Shells Whole 13 EFG 3 2 Paper Pulp 0.6.0 26 1 Peanutsin Shell 0.203 EFG 2 ke Shelled 0.60.7 D 2 i Peas Dried 0.708 D 1 nu Peat 0304 D 46 m Petroleum Coke (see Coke) Phosphate Acid Fertiliser 2% BC 2 & ‘Triple Super 5 BC 3 sus Rock Broken Dry 25130 ero | 2 2 Rock Ground 0 BC 3 2 Pitch as ere | 3 1 Polystyrene Beads BC 2 1 Potash Salts Sylvine BC 2 s Potassium Chloride Pellets D 2 1s Nitrate D 2 Sulphate BC 4 2 Pumice ~ 3 mm BC 4 > Pyrite Primary Crushed 35 Pa 3 pas Pelets 2 D 2 = Quartz Dust 8 A 2 > Screened ~ 10 mm 35 D 2 > Screened ~ 150 mm 35 erGH | 2 P | Rice Filled or Polished 20 Be 2 1 Grits BC 3 1 Rough BC 2 1 | Rubber Petits 35 ero | 4 1 ee Reclaimed 2 EFG 4 1 [Rye B Bc 2 1Bulk Density |__ Approximate Angle of Respose Classification Material tnt Dearees Lump | Cohesion | Other Salt Common Dry Coarse D 2 ns Fine 25 BC 2 ns Salt Cake Dry Fine BC 2 as Coarse 36 BC 3 8 Saltpetre 304s Sand Dredged Moist 45 BC 4 P Dy 38 BC 3 Pp Sand Prepared Foundry BC 4 P Sand Foundry Shake-Out 2 EFG 3 Pp Core a BC 4 1 Sand Silica Dry 2 BC 2 P Sandstone Crushed 0 EFG 3 P Sawdust 36 BC 3 P Sewage (Sludge) 30140 26 iis Shale Broken 0 EG 2 a Crashed 7 D 3 2 Sintertron 7 EG 2 P Lead » EFG 3 auy Slag Blast Furnace Crushed 0 D 2 P Furnace Granular Dry x0 D 2 P Furnace Granular Wet 4 BC 4 P Slate Dust 38 A 3 a Slate Crushed ~ 10 mum 8 D 2 a + 10 mm to 150 mm ErGH | 2 a Snow Compacted by Rain Fresh Fallen Soap Granules BC 2 ra Chips x0 D 3 k Detergents Flakes BC 3 © Powder BC 2 1 Soda Ash Briquettes 2 D. 2 1 Heavy 2 BC 2 a Light 37 A 2 a Sodium Bicarbonate 2 A 4 1 | Sodium Nitrate a EFG 2 1 Sodium Phosphate Sodium Aluminium Sulphate 31 | soybeans Cracked 35 D 2 ‘Whole 2108 D 2 32 EFG 3 D 2 237 BC 3 1 BC 3 u Spar (Fiuorsper) ~ 10 mm D 4 a +10 mm«0 150 mm EFGH | 4 a starch a BC 2 1 Steel Swart Crushed EFG 2 ikp Punching Scrap 38 36 P|e | Bulk Demin | tin? ‘Approximate Angle of Respose Degrees Classification Cohesion Other Sugar granulated Powdered Raw Cane Beet Wet Cane Knifed Sulphur Powdered Crushed ~ 10 mm (Crushed — 150 mm Taconite Pellets ‘Tale (Soapstone) Fine Powdered Screenings — 10 mm Sereenings + 10 mm to 150 mm Solid | Tatiow Titanium Sponge ‘Tobacco Leaves Dry Scraps Stems ‘Traprock Screened ~ 10 mm +75t0 150 mm ‘Trisodium Phosphate 7 Granular Pulverised ‘YVermiculite Expanded Ore Walnut Shells Crushed Wheat Wheat Cracked Germ Wood Chips - Dry Chips - Wet Shavings Zine Dust Concentrates (Ore Crushed Ore Roasted Oxide Heavy Oxide Light 0.70.8 ee 38 38 >>o E Rene WERE gouEN & RUNNY OU uNe ow gee gE ile kw. Pr wop- es ee Hor Note: ‘The classification symbols are explained in Sections 1.3.1, 1.3.2 & 1.3.3.2.0 FLOWABILITY OF BULK SOLIDS ‘materials in Section 1.0 are used in a descriptive or qu: well known properties of the materials. They do not define the properties precisely and are diffi Given prior experience of handling similar materials and observation of existing plants in operation, the general classification may assist in identifying the broad principles necessary for the design of a chute or transfer point. However, for the more difficult and cohesive materials it is essential that the flow properties of the materials are clearly understood and established if predictable operation of the transfer point is to be assured. An assessment and testing of the product being handled in its ‘worst’ condition is necessary both for the main stream flow and for the carryback or fines chutework. Wall friction properties should be established on representative samples to give the static and dynamic slip properties on appropriate contact surfaces including the Angle of Friction and any surface cohesion. In most handling systems, even with large ‘sized’ materials, the effect of handling will inevitably produce fines and testing carried out on the ‘fines’ will usually satisfy the situation for the larger sizes which will flow more readily. ‘The characteristics of a bulk solid which affect its flow are: 2.1 Bulk Density ‘This may vary dependant upon the extent of consolidation of the material. At transfer points, the material will usually be state following discharge from a belt conveyor terminal but may become consol up and stand over a period of time during stoppage of the system. Under consolidation or compaction the bulk density may increase, 2.2. Angle of Repose This is the angle formed by the sloping surface of the pile when a loose unconsolidated bulk solid is poured onto a horizontal surface Fig. 1. The angle may vary with moisture content, particle shape, size and distribution, cohesion, compaction and internal friction of the material. indicates the inclination at which the material will slip on itself under the conditions in which it is measured, usually either loose poured or ‘drained’ Its measurement is only meaningful with non-cohesive products. Such materials can be tested easily and give reproducable results. Materials which hold together when compacted, for example very fine powders, remarkable variations in repose conditions, from flushing like a liquid to completely overhanging to support an arch. Moisture is also a prime source of material cohesion and can make nonsense of repose angle measurements. Materials which invariably exhibit a consistant repose condi ‘may be classed as “free flowing’, and such angles used for pile or ‘drain’ calculations. Bulk materials which are cohesive may well form a specific angle of repose on pouring in a particular manner, but this has no relation to how the material may ‘drain’. Chutes which are required to han be designed on the basis of mater i tact surfaces. Flexible membranes of tough rubber, local steep wall contact points and the use of, low friction/good surface release properties are all useful techniques for accommodating the impact of a flowing stream of cohesive materials. ‘Whilst repose conditions offer a useful guide in assessing the self draining does not take into account the slip proj cstimation of transfer point layout and to those ins! acceptable. aingles to be employed in chutes, jon should be restricted to the roug ‘overdesign and site adjustment isMore correctly, consistant angles of stockpiles and the profile of mat ‘material is allowed to pile freely. stricted to the approximate determination of the contours in crash-box locations in chutes and at other points where ‘SEGREGATION OF LUMPS TO OUTSIDE ANGLE OF REPOSE 1. Freely Formed of particle sizes usually occurs when pouring piles of material, the larger particles are fines and tend to separate out to the outside of the pile, 2.3 Internal Friction ‘Much work over the Unless a transfer point includes hopperwork or enclosed chutes running full, the property of internal friction is usually not applicable to it’s design. For the majority of chutes and transfer points it is the Wall Friction prevailing between the bulk solid and the contact surface which determines whether the material will flow or not in open channels. friction angle — being the angle at which the bulk s Il begin to slide on itself when 1g onto the shearing surface is typically somewhat greater than the angle of repose, whigh is itself typically greater than the wall friction angle (see Section 2.4). 2.4 Wall Friction . 3 ‘This is the ability of the material to slide on a contact surface and will be influenced by the wall friction angle and any surface cohesion, consolidation or time related effects which may be in evidence. 2.4.1. Walll Frietion Angle ‘A sample of the bulk material is enclosed in a test cell, Fig. 2, and additional loading is applied to give a range of contact pressures reflecting normal surface loadings to be experienced in the application being considered. For each total surface load, the force required to commence and sustain slip is recorded and plotted, the resulting graph being known as the Wall Yield Locus. [APPLIED LOAD ww po co bel gece ees SURFACE BULK SOLID W = NORMALLOAD AT CONTACT SURFACE = APPLIEDLOAD + WEIGHT OF ID + WEIGHT OF CELL + WEIGHT OF BULK SOLID Fig. 2. Wall Friction ‘The slope of the graph indicates the Wall Friction Angle @, and any intercept with the y axis indicates surface cohesion. Fig. 3 illustzates typical wall friction characteristics. Tan @ = yw, the coefficient of friction for the material against the surface. Dry granular materials without cohesion will have a WYL which passes through the origin 10most wall materials, the WYL is slightly convex as show with increasing contact pressure. The graph is lues of F and W by the contact area of the test cell. in Fig. 3 and the wall friction angle ted as shear stress v normal stress by oS = tose sae eS 2 Se ie Sa (2) foe fowing mata {) moter with acace cohesion Fig. 3. Typical Wall Friction Characteristics the condition to sustain slip and the static wall friction angle the In the majority of transfer point app! ions, account must be taken of material flows coming to rest during stop periods and the designer must allow fc /ercoming the static frictional forces and any time related effects. 2.42 Surface Cohesion Interface effects between a damp or sticky bulk material and a contact surface strength opposing slip. A feature of this surface cohesion is that a force to cause sli direct loading by the material on the contact surface. The cohesive resistance to contact, to a cohesive bond the absence of any to surface area of ‘The cohesion of a material represents the ability of the particles to stick to other adjacent particles and to adjoining surfaces and will be influe a large degree by the moisture content although electrostatic, chemical and other inter-particle effects may all play their part. A perfectly dry granular produet tle or no cohesion. With many materials containing fine particles, the addition of moisture to the dry material tially increase its cohesion up to a maximum condi further addition of moisture will reduce the cohesion of the material an un ate! becomes a slurry. The effect of excess moisture is to act as a lubricant between the material and chute surface facilitating flow. See Fig 4. Mex. Coheton contr Stays Fig. 4. Variation of Cohesion with Moisture Content ~ Typical2.4.3. Time Enhancement of Contact Friction thermal or electrostatic influences. moist cohesive materials and tests to establish the tme test sample over a period and under consol from Amold & Roberts (1) shows the typical basis and after consolidation for 3 days. i i Norma Sse — KPa Fig. 5. Typical Wall Yield Loci for Moist Coal on Polished Mild St Plate 2.4.4 Effective Wall Friction Angle solid with wall friction angle @. mn Angle, Ge, represents the inclination of the , Fig. 6 (b), and Tan® e = ue, the effective Fig, 6 (a) illustrates a typical wail yield surface cohesion is taken into accout contact surface at which the material wi coefficient of friction for the material Normal Stress (N) = Related to thickness of bed of material Shear Stress {f) = Stress Promoting Slip Contact surf 7 ont: face Increasing bed depth Bulk solid Shear Stress ) Normal Stress (N) (@) (wr Fig. 6. Effective Wall Friction Anglecull e evident that the Effective Wall Friction Angle decreases with increase in normal stress winch in chutework is gene: the bed depth and density of the bulk solid. The Effective Wall Friction Angle can be very high for low of cohesive material ‘This explains why a thin layer of fines will often will enable flow to take place due to the reduced ma chute whereas larger material or an increase in bed depth all Friction Angle under the weight of the material sa j.from Arnold & Roberts (1) illustrates the considerably higher Effective Wall Fiction Angles which can occur when handling moist cohesive coal at low bed depths on a stainless stecl chute For non-cohesive wall friction angle isthe effective angle since the ws the origin and there ield-locus passes through be little variation with bed depth. vaca Wat Fcton Angle: Deprees 8 °. SS © c1 ez os o4 os 08 07 o@ os vo rath ~ mate Fig. 7. Typical Effective Wall Friction Angle for Coal on Stainless Steel 2.5 Testing for Wall Friction mal properties in the absence of other test of many transfer points where a measure of utes is of limited concern, For the more demanding are being considered to overcome operational problems, itis prudent various conditions of surface loading with environmental conditions € circumstances of use. Testing to measure the: carried out in Jenike type shear cell apparatus (2) & (3). It is however necessary to test on veal material of chute contact and over a distance of stip which allows steady state measurements te be seen) Jn fie shear cell apparatus for wal friction test, samples ofthe bulk solid in it's ‘worst’ representative condition foraonsnied and placed into an open bottomed circular test cell (approximately 85mm drametes) res ig ona horizontal sheet of the contact surface material attached to the work bench, The tex mars lightly consolidated and a floating top cover sample and, nal weights applied to give a range of contact pressures Fee aa (o.tne application (similar to Fig. 2). Shear force is applied to the cell by a contrelled steam deriee ons Eee (ansducer and values ofthe shear force required to commence and to sustain slip are eoonded ot pl cach total surface load. The resulting graphs give the Instantaneous Wall Yield Loci hy are ana dynamic rchiatetials which exhibit time related cohesion effects, the test sample with an applied weight is left to Ploted recut gi, abPropriste period before testing for shear force and normal force over the required range; the Plotied results giving the Time Consolidated Wall Yield Loci for instantaneous failure, Whilst the shear cell developed by Jenike is employed by a number of authorities for inv as anterear tari fange of particulate slid, itis het suited to the testing of fine powders of small art has inherent ions for measuring the shear properties of materials with robustly sized particles. methods have been investigated and are in use by a number of bodies, eit Headquarters Technical Department have developed an annular shear cell to suit Pare size up to 25mm. Also, the same authority has developed a refined approach to testing os ac reported ine, mith apparatus to accommodate materials with particle size up to Soma, These develaenean Teportedly, are giving satisfactory results. dn general, however, ‘fines’ cause the most adverse handling problems and in most systems some forms of rane ull generates fines which require to be handled, therefore testing of the smaller factions of a mited sige range bulk material is prudent. 63.0 CHUTE & LINING MATERIALS Chutes may be simply constructed from a single material or lined to give a sliding surface having the same or differing properties from the main chute construction material. ined for one or more of the following reasons:~ To facilitate repair or replacement of the sliding surface. ‘As a means of correcting the performance of an inadequate chute. To combat abrasive wear by increasing the wear resistance of the surface To assist in combatting impact wear, noise, dust or material degradation. . To assist low and avoid build-up ~ particularly with sticky materials. To protect the chute structure from chemical reaction or corrosion by the product being handled. | As protection from contamination or chemical reaction for the product being handled, e.g. in the Chemical/ Food/Pharmaceutical industries. ‘The choice of lining material will often be a compromise between conflicting requirements and must take into account the overall design and arrangement of the chute or transfer point. i “The selection of suitable lining material will also be influenced by the available methods of attaching the lining to the main structure of the chute. Note that the flow properties of a chute surface and its wear life can be improved substantially by liquid lub of the surface when this can be tolerated. e.g. water sprays are frequently used on mild steel chute surfaces Gravel processing plant. RnnnnAnhRAAnHRAARARAHRHRMRBHAARMRBRAMAAMRABABRBARABRAARABKRAAaRARAA3.1. Chute Lining Materials Table 2 lists a range of materials which are currently used as chute linings together with some of the characteristics of the materials. It should be noted that the characteristics may vary somewhat with the bulk solids being handled and the information given in the table should only be used as an approximate guide. Additional information on these lining materials is given in Section 3.4 Table 2. Lining Chart Key: Poor-, Good *. Very Good **, Excellent *** Sliding jing Mater ding | Impact | ‘Temperat, Low-Friet. piciesteataiia omsion | Resistance | Resistance ‘Quality Mild Stee! Low . > 7 = Carbon Steel Medium ~ > ~ = Low Alloy Steel Medium “ . = . Quench & Tempered Corrosion Resistance ‘Medium, 7 . - | ~ Steel ess Steel High ° : ve zs ~ 2B finish High Cr Cast Hien we ro = = Ion Tiles, L Clad-plate High oe ~ ” a Rubber High . = = = Polyurethane High vee = = : UHMWP Medium 7 - = we (Quarry Tiles Low . = > 7 Vitrified Tiles Low z = * Basalt Tiles Medium * * - * ‘Alumina Tiles High = > a 3 J3.2. Wear to Chute Surfaces I result from impact or abrasion ~ or, more usually, from a combination of both. At the point of intial impact of the material stream onto the chute surface the wear or damage to the chute surface is often il fact be the result of direct impact forces at 90° to the surface and gouging or scouring along the surface. Elsewhere, where the stream of bulk material slides along the chute contact surface, the wear developed will be ig abrasion and will depend upon the normal pressure atthe surface, the wall friction coefficient and the Despite the amount of research and investigation quantitative information available from field trials covering the wear it Getermined on a qualitative basis from experience in handling materials in various industries. fe resistance to abrasive wear of potential ished under laboratory conditions ive of the situation arising from stablished from time to time the re iboratory testing. The performance and compari vumstances and materials have often been reported as unrepres in-plant operation 3.2.1 Impact Wear .ges on an inclined surface. At the initial point of impact the stream ‘Impact occurs when a stream of bulk solid i "eetory from a belt conveyor head pulley, and impact wear can be velocity may be high, as with the discharge considerable. Fig. 8 shows a particle of the bulk material impinging on a chute surface at an angle of approach 61. and with approach velocity V1. The part ‘rebound with velocity V2 at an angle 02 the angle of rebound and rebound seioeity being dependant upon the coefficient of normal restitution between the particle and the surface material :pact component normal to the ze to the particle and the surface Je and the surface material. Wear at the surface will be a combination of two components: fi surface and, secondly, a scouring component along the surface. The re will depend largely upon the relative hardness and other properties of the pat -wise be dependant on these ‘The impact approach angle at which maximum erosion of the surface occurs wi factors. For a brittle surface material such as glass or cerami ‘occur when particles impinge at 50" to the surface due to the surface breaking-up and crack propogation. For more ductile or resilient surfaces, maximum damage may occur at impact angles from 15° up to 60° with reduced wear rates at very low approach fngles oF at 90°. It is well known that rubber will best withstand impact damage at 90° due to its resfience in absorbing the impact but can be subj iting and gouging at an impact angle of 45°. to severe wear by By keeping the impact angle as low as possible, and not more than 20°, impact wear will be kept under best control with most materials. V2 Mi ei 2 eee EM eae Fig. 8. Impact of Particle on Flat Surface Note: ‘Wear resulting from impact on a given surface can be many times greater than that rest the reduction in impact on a chute surface must be a prime consideration. Also, it follows that lining appropriate to resisting abrasive wear may not be suitable in the impact zone and a mixture of lining materials may be necessary to meet the differing requirements. for use Equally, the cost of lining material to meet the requirements of the impact zone may be. prohil jon away throughout the chute and a less expensive lining may be suitable for combatting wear from sfiding a from the impact zone.Published information by Hockell abrasion from field trials of potential terials under medium impact conditions. sinter was discharged by a conveyor head pulley through a height of 1.25 metres on toa cross chute whe at an angle of approximately 35° to 45° on the test surface. Relative wear was established by measuring the volume loss of a given area of lining material per 1000 tonnes of sinter passing. ‘Table 3 gives the ranking of the materials tested in resisting wear by medium impact together with comparative cost information at the time (1977). Comparative cost Unit Index Material cad aa 1 Cr-Ni-Mo martensitic white cast iron 3.72 0.53 2 Ni-Cr martensitic white cas 3.72 058 3.72 0.59 3.50 0.96 5.45 1.60 3.80 122 7.35 257 4.60 2.47 9 Low-alloy cast iron 2.50 1.48 plate, quenched and tempered No 3 1.30 1.35 IL En8 steel plate 1.00 1.00 12 Conerete No 4 Table 3, Ranking of wear-resistant materials subject to’ medium impact abrasion by blast furnace sinter Note: 1, The lower the index, the better wear resistant is the miaterial. 2. Further details of the mate 3. Cost comparisons made at th tested are given under Section 3.2.3 jime of the tests may not be relevant today. 3.2.2 Abrasive Wear Abrasive or sliding wear takes place where the id slides along the chute surface. The rate of wear developed will depend upon a number of factors including: the relative hardness of the bulk solid and the chute surface, the shape and size of the bulk solid particles, the wall friction coefficient, the material pressure at the chute surface and the sliding velocity. -comered particles — Iso be influenced ‘cording to many bed depth. The rate of wear if approximately proportional to (velocity) by the iding velocity, wear ‘The published information by Hocke/British Steel Corporation (4) also gives the results of field tests to establish comparative resistance to sliding abrasion of potential chute lining materials. These tests were made away from the impact areas on chutes handling (i) metallurgical coke and (ii) blast furnace sinter. The wear rate was established from the volume loss of the lining material per 1000 tonnes of material passing over a given arca of lining. Table 4 gives the test results indicating the ranking of the materials for wear resistance when handling coke. Table 5 gives the results when handling sinter. Comparative cost information at the time (1977) is also given. 7‘Comparative cost Wear Unit Index Material Index cos x cost 1 Sintered tungsten carbide 0.028 21.80 0.61 2 Fusion-cast alumina special 0.053 3:80 0.20 3 Extruded alumina No 11 ceramic 0.072 735 053 4 Sintered alumina No 10 ceramic 0.080 saa 044 5 Fusion-cast alumina O.115 6 Low alloy steel, QT No 7 armour 0.134 7 Cr-Ni-Mo white iron No 4 cast iron 0.179 8 High-chrome hardfacing 0.207 5.45 113 ‘9 High-chrome martensitic white east iron No 1 0.231 3.2 0.86 10 Ni-Cr martensitic white cast iron 0.240 3 0.89 11 Cr-Mn-Mo hardfacing 0.243 12 Low alloy steel, QT No 6 armour 0.286 13 13% Mn skin-hardened stee! place 0.307 3.27 1.00 0.326 iron No 2 0.328 ‘on No 10 cast iron 0.331 loy steel OT No 9 armour 0.335 0341 19 Chrome carbide hardfacing No 7 0.368 20 384% Cr-Mo cast steel 0370 21 Cast Basalt 0378 0.68 0.26 22 Plasma sprayed hardfacing 0.405 2 Acid-resisting cerami 0.413 24 Iron-based chrome alloy, cast 0.427 ate, quenched and tempered, No 1 0.460 0.463 0.470 0.476 4.60 2.18 0.488 0.45 0.74 30 Plasma sprayed hardfacing 0.515 steel plate, quenched and tempered, No 2 0.525 n 0.535 33. Low Cr cast iron No 5 0.571 31 Low-alloy steel plate, quenced and tempered, No. 3 0.665 35. Hligh-phosphorus pig iron 0.700 36 Low alloy steel QT No 11 steel 0.749 1.97 147 37 Concrete No 1 0.910 28 192% Cr-Mo cast steel 0.920 39 EnB steel plate 1.000 1.00 1.00 40 Plate glass 1.760 41 Solid rubber No 1 1.850 42 Conerete No 2 1.900 48 Solid rubber No 2 2360 1.63 3.85 44 Quarry floor tile No 1 4.780 46 Solid rubber No 4 4.800 47 Polyurethane No 1 4.930 48 Resin-based calcined bauxite 5.000 49 Resin No 5 5.200 50 Polyurethane No 2 6.670 51 Profiled rubber 6.880 52 Polyurethane No 3 6.900 53 Polyethylene No 2° 7.050 54 Quarry floor tile No 2 73350 55 Polyethylene No 3 PE 10.780 56 Polyurethane No 4 11.630 57 High-density polyethylene 14.000 58 Polytetrafluoroethylene 17.800 Table 4. Ranking of wear-resistant materials subjected to sliding wear by coke 18the longer wall be Note that there is no direct correlation between tables 4 and 5 since the tests were carried out on difrerem cnutes. ted that whe ining material is harder than the bulk solid, the harder the lining material, ife against sliding abrasion. generally ai Comparative cost Wear Unit Index Matestal Index __ cost x cost 1 Ni-Cr martensitic white cast iron 0.065 30 0.24 2 Cr-Mo-W-Nb hardfacing 0.079 3 High-chrome martensitic white cast iron No 1 0.115 3.72 0.43 4 Nodular graphite-based cast iron 0.137 3.50 0.48 5 Fusion-cast alumina special 0.172 3.80 0.65 6 Sintered alumina 0.173 5.44 0.94 7 Tungsten carbide hardfacing 0.192 11.00 211 8 Fusion-cast alumina 0.221 steel plate, quenced and tempered No 2 0.382 0.518 y cast iron 0.704 0.846 0.68 0.57 te, quenched and tempered No 1 0.952 14 High-phosphorus pig iron 0.953 15 En8 steel plate 1.000 1.00 1.00 16 Low-alloy steel plate, quenched and tempered No 3 1.336 17 Acid-resisting ceramic tile 2.030 2.265 2.490 4710 6.350 2 Silicon carbide ceramic No 3 8.470 23 Conerete No 2 10.320 24 Conerete No 1 18.000 0.30 5.40 Table 5. Ranking of wear-resistant materials subjected to sliding wear by blast furnare sinter Note: 1. The lower the index, the better wear resistant is the material 2. Further details of the materials tested are given below. 3. Cost comparisons made at the time of the tests may not be relevant today. 3.2.3 Details of the materials tested in Tables 3, 4 and 5:- Cast trons 1 2. . The low chrome cast iron (No. 5) has a nominal composit The Ni-Cr martensitic cas hardened to 500-650 Vicker The high-chrome martensitic cast iron No. 1 contains 2.8% C and 26% Cr and was hardened to 500-600 Vickers (47-53 RO), This material work hardens under medium impact to 700-800 Vickers (59-64RC). iron is a Ni-hard 1 type of cast iron containing nominally 2.8% C, 4% Ni and 2% Cr, (4T-5ORC). . High-chrome cast iron No 2 contains 2.72% C, 0.55% Ma and 27.3% Cr. ‘The Cr-Ni-Mo martensitic cast iron contains nominally 2.8% C, 19% Cr, 1.5%-2% Ni and 1% Mo. It was heat treated to 900 Vickers (67RC). The nodular graphite based cast iron was heat treated to 700 Vickers (59RC). The low-alloy cast iron contains 2.5-2.8% C, 0.4-0.7% Mn, 0.9-1% Cr and was hardened to 800 Vickers (64RC). The high-phosphorus cast iron was a pro} jetary Thomas iron, the third in the martensitic range. The sample tested contained 2.68% ‘Mo. Heat treated to 1200 HV. mn of 3.37% C, 0.30% Mn, 0.75% Cr and was heat \¢ composition of which was not available. ‘The Cr-Ni-Mo white cast iron (No. 4) C, 0.61% Ma, 21.7% Cr, 0.56% treated to 420-480 HV (44-46RC), Cr-Ni-Mo white cast iron No, 10 has a similar chemical analysis to (8) and is covered by BS4844 Part 3 rT)Cast Steels 1, 13% Mn steel is a cast steel of straightforward 13% Mn austet which can work-harden up to 550 HV (50RC) under heavy im 2, 3M0% Cr-Mo cast steel is a high-carbon cast steel containing 0.96% C, 0.93% Mn, 3.59% Cr and 0.3% Mo, liquid-hardened to about 550 HV (S0RC).. 3, 114% Cr-Mo cast steel is a low-carbon steel containing 0.4% C, 0.74% Mn, 1.54% Cr, 0.71% Ni and 0.37% Mo, ‘and was hardened to about 370 HV (37RC). 44, No 4 cast steel was a proprietary material imported from Germany. No details of the analysis were given but the ‘material was said to contain Cr, Ni and W. structure and about 200 HV (13RC) hardness, Rolled Steel Plate 1. Eng is a high-tensile carbon steel to BS970: 1955 specification containing 0.35-0.40% C and up to 19% Mn. Tis nearest American equivalent is SAE 1038. 2 Low-alloy steel plate No. 1 nominally contains 0.4% C, 1% Mn, 0.6% Cr, 0.6% Ni and 0.25% Mo, with @ supplied hardness of 420 HV (44RC). 3. Low-alloy steel plate No. 2 nominally contains 0.2% C, 1.2% Mn, 13% Cr and 0.25% Mo. It has an approximate hardness of 350 HV (36RC). 4, Low-alloy steel plate No. 3 contains nominally 0.15% C, 1.2% Mn, 0.8% Cr, 1.6% Ni and 0.35% Mo and is ‘quenched and tempered to about 330 HV (34RC). 5.. 13% Mn skin-hardened stee! plate is a rolled plate which is skin-hardened by re-rolling. 6. Armour plate No. 6 is an imported alloy steel quenched and tempered to about 510 HV (48RC) with « nominal ‘analysis: 0.24% C, 1.16% Man, 1.21% Cr, 0.08% Ni, 0.02% Mo. 7. Armour plate No 7 is a low alloy steel quenched and tempered to about 420-480% HY (44-46RC), The nominal anal said to be: 0.27-0.33% C, 0.5:0.7% Man, 1.3-1.7% Cr, 0.5-1.0% Ni, 0.30-0.45% Mo. 8. Armour ‘alow alloy steel produced by the BSC, quenched and tempered to 305 HV (30RC) with a nominal chemical analysis: 0.3% C, 0.65% Mn, 1.6% Cr, 0.75% Ni, 0.4% Mo. 9. Armour plate No. 9is chemically the same material as (8) but heat treated to 480 HV (46RC). 10. Low alloy steel No. 11 is a BSC produced stcel, quenched and tempered. Its nominal chemical analysis is: 0.17% C, 1.2% Mn, 0.5% Cr, 0.25% Mo, traces of Ti, V and Zr. Hardfacings 1. High-chrome hardfacing is a submerged arc applied hardfacing consisting mainly of chrome carbides. The nominal chemical composition is: 4.5% C, 3.5% Mn, 27-30% Cr, 1% Mo. 2, Ce-Mo-W-Nb hardfacing is an experimentallydeveloped hardfacing applied manually by gas, consisting of an eevee tof carbides, Is nominal composition is said to be: 5.3% C, 21% Cr, $.69% Mo, 1.9% W, 7% Nb, 1% v. 3, Tungsten carbide hardfacing i also applied witha gas flame, bur witha self-fuxing tubular ferrous welding rod filleg with grains of tungsten carbide. ‘The average deposit hardness can be up to 820 HV (65RC). 4. Sintered tungsten carbide hardfacing is not « hardfacing in the conventional sense, as it consists of hexagonal platelets fixed to a steel backing plate by soft or hard soldering, The platelets consist of tungsten carbide wit) 9 a cl binder, sintered in special furnaces, An approximate composition would be 92% WC, 6% Co, 2%% additive carbides. 5, Hardfacing No. 10 is a plasma-fused tungsten carbide sprayed onto a proprietary N-hard. Thickness of the coating was about 0.5mm, but no other details were supplied. 6. Hardfacing No. 11 is a chrome carbide applied in a similar manner to (5). 7. Hardfacing No. 9 is basically a chrome carbide based weld metal applied manually. Ceramics 1. The fusion-cast alumina is an alumina-zirconia-silica compound with a scratch hardness of Mohs. Its nom! Canposition ist 30% Als, 32% Z,On, 16% Sia, 1% Nan0, 0.5% Fess and 0.5% Ti0a, The erytallographic ‘composition is corundum, zirconia and a vitreous phase 2. ‘The fusion-cast alumina special is chemically the same material as (1) but is cast in a vertical rather than a horizontal mould. 5, Extruded alumina is a high-density non-porous high alumina formed by extrusion, for which the chemical ‘composition was not given. Hardness is 9 Mohs. 20 a ace aintGTUUUUUUUUUUUUUUUUUUUUUUvUuuUuUv uuu 4. Sintered alumina is a 90% sintered aluminium oxide material of high purty. Hardness is about 9 Mohs. 5. Slagceram is a Corporate Laboratories developed material, based on blast furnace slag and sand. In appearance and chemical analysis the final produc is similar to cast basalt. Scratch hardness is 8-9 Mohs, ie. between topaz and corundum. 6. ly occurring neo-voleanic rock with a melting temperature of about 1250 °C. When cooled -d conditions it becomes re-crystallised. The material is imported from Germany and a is a standard 150 x 150mm ceramic tile of a finer crystalline structure than the normal quarry 8 mn carbide ceramic No. 7 belongs to the family of silicon nitride-bonded silicon carbides. It ids and temperatures up to 1750 °C and is thus mainly used for those con 0.65% Als, 0.65% Fe203, 17.4% SisNg, 0.3% Cad. 9. Silicon carbides Nos. 2 and 3 are based on a special quality of silicon carbide grain. They are basically refractory materials but are also said to have good abrasion resistance under certain conditions. The typical composition of the fired material is: 89.5% SiC, 8.5% Si0>, 0.7% Al0s, 0.7% Fea0s 10. Quarry floor tiles Nos. 1 and 2 are standard 150 x 150mm ceramic flo. 11. Man-made rock is a proprietary composite mater ‘minerals like quartz, aluminium oxide and kaolin a conditions, produces a very hard and strong mat ns. Typical analysis . made by different manufacturers. based on selected granite particles, to which various \dded to form a system which, after firing under controlled Concretes 1. Concretes No. 1 and 3 are aluminous cement-based concretes with proprietary aggregate, supplied by different ‘manufacturers. 2. Concrete No. 2 is a proprietary concrete tile of which only the top 6mm is a wear-resistant surface. The ‘aggregate for the surface is a natural Bavarian stone consisting mainly of quartz and basalt. 3. Concrete No. 4 is an aluminous cement-based concrete with proprietary aggregate, with an addition of 2% by volume of wire fibres 25mm long by 0.4mm diameter. Rubbers 1. Rubber Nos. 1, 2, 3 and 4 are all sheets of grade A wear-resistant quality rubber supplied by different manufacturers, and varying from 10° shore hardness. 2. Profiled rubber is a grade A rubber with a saw-tooth profile, of 65° shore hardness. Plastics 1. Polyurethanes Nos. 1 to 5 are different grades of proprietary polyurethane in sheet or cast form, or asa two-part room temperature curing mixture 2. Resin-based cal calcined bauxite p 3. Resin No. 5 is an imported resin-based compound of which no details were supplied 4. Polyethylene No. 2 is a high density, high molecular weight, low pressure polyethylene. 5. Polyethylene No. 3 is a high density, high molecular weight product. bauxite, as the name implies is an expoxy resin-based compound, with an aggregate of cles. a3.3 Wall Friction Angles Wall Friction Angle of the chute lini this variation may not ies when handling bulk solid A may not exhibit these qualities t he same extent when handling bulk solid B. ‘There is a scarcity of published information giving values for Wall Friction Angles handled since these values are usually assessed from test procedures (see Section 2 individual job basis. ing materials v bulk solids mn specific materials on an However, the British Steel Corporation at their Corporate Laboratories have established test information on a wide range idslining materials and we are indebted to them for the information given in Table 6, which gives typical wall friction angles for a range of material combinations tested, For coniparison, the unconsolidated Internal Friction Angles forthe bulk materials tested are also given atthe foot of Table 6. The information given should be used only for guide purposes and tests should be carried out to confirm the values in specific cases if accurate prediction of chute performance is critical, ‘The angles given do not take into account the effect of wall cohesion for which an adequate additional allowance should be made on chute inclination. 2Table 6. Wall Friction Angles Wall Friction Angle (°) for Different Bulk Solids Coke | Sinter— |Iron Ore] Lime- Lining Material | Coal Vow, |Caleined Iron Ore] 65% F.| stone | Sand | Cement} Sugar | Grain | Flour Mild Stee! rusted 26 30 30 27 | 2529 | 24 | 733 32 2 30 Carbon Steel 26 30 30 27 | 25-29 | 24 3 2 2” 30 Low Alloy Steel 26 30 30 27 | 25:29 | 24 3 2 a 30 ‘Quench & Tempere: | Clad Plate 2 Stainless Stee! ws | 13419 | 22 | 21-24 | 1925 | 20 B 18 B 4 = 2B finish Corrosion Resist. Steel i High Ni/Cr Cast Iron Tiles Rubber ~ natural Rubber - synthetic | 27 29 2» a 28 a 22 2 18 26 Polyurethane UHMWP 3 | 226 | 2 20 6 a 6 16 2 Quarry Tiles: Vitrified Tiles 2B | 15-23 25 ” 16 2 Basalt Tiles W |__ Alumina Tites For Comparison Unconsotidated | Internal Friction | 50-55 | 40 40 ey 45 0 47 Angle (*) Note 1. Values provided by BSC Corporate Laboratories based on Jenike type tests using 95 mm dia, test cell. 2. All bulk materials tested were in a ‘fines’ category to suit the size of test cel ‘The values are approximate and typical only and represent instantaneous static wall friction, Dynamic values would be slightly lower but in many tests it was difficult to differentiate between static and dynamic values. ‘The values give the slope of the Wall Yield Locus i.e. excluding effects of Cohesion. Test procedure comprised: sample consolidation under 6.5 kg mass followed by constant strain shear force to produce movement at normal loads 1.5 kg, 2.5 kg, 3.5 kg, 4.5 kg and 5.5 kg. 3.3.1 Surface Roughness ‘The wall friction angle will be infiuenced by the condition of the contact surface ~a smooth polished surface gi ower friction angle than that given by a rough surface with a substantial variation according to the degree of ‘pol In many cases, a rough surface will polish with use over those areas where the material flows but itis on other ai less subject to material flow that build-up will occur. 8 Various extraneous features may also add to the surface con transverse weld lines, other local dist subsequent caking. These can all exhi nn with effect on wall friction, e.g. minor ledges, , surface changes duc to abrasion or corrosion and substantial increase in the effective wall friction angle or, where there is a Blip of the material will be against its own interns may be indented by hard gt high due to chute filling during stop periods. Under these 1d substantially above that which applies under normal we n instead of wall slip. Soft wall materials or comers of the bulk solid when contact sumstances, the effective friction angle may pressure when the chute is flowing. Rusting and corrosion of steel surfaces can lead to major flow diffi 1m and surface cohesion due to corrosion often leads to. standing time in contact with those coals conducive to es in coal handling installations where the 1p problems even alter 3.4 Lining Materials 3.4.1 Mild Steel Mild steel plate is the traditional material from which many cht of fabrication and forming into complex shapes with good struc be added to the chutework in appropriate wear locations to fa structure, sare manufactured being ducti trength at moderate price. Mi te replacement and avoid wear to the main ind offering ease Liners are usually fixed by countersunk bolts giving smoot improve material flow but are usually allowed to ‘work pol ines to the chute surface. They may be polished to in operation. d steel suffers from its inherent propensity to rusting and corrosion and is very prone to build-up of damp fines as outside the mainstream flow. Steep chute angles are required to counter this situation. Having Brinell hardness of approximately 150, mild stee! is only moderately resistant to impact and abrasive wear ‘and in heavy impact situations it is usual to employ bar or rail reinforcement on the sliding surface to promote captive up of fines as a cushion against the wear. The axis of the bars or rails is made in-line with the material flow to 3.4.2 Carbon Steel Carbon steel plate is available in a range of qualities (0.30%C to 0.50%C) offering improved hardness from 150 HB to 250 HB and hence better wear resistance than mild steel. The material is slightly more difficult to form and fabricate than mild steel and likely to cost from 25% to 50% more. 3.4.3 Low Alloy Steels, Quenched and Tempered ‘There are many branded abrasion resistant low alloy steels available offering resistance to both impact and abrasive ‘wear. These are mostly of low Nickel/Chromium/Molybdenum composition with hardness in the range 300 to 500 HB. These steels are consequently requirements than mild steel and w! the fabricated cost can be substanti ich more difficult to fabricate and form into the more complex chutework the raw material cost may range from that of mild steel plus 50% to 100%, ly more. In view of the difficulty and costs of fabri where its benefits can best be exploited at mi fixing by countersunk bolts or welded stud ion, the use of alloy steel liners is ofter t or on arcas where flat platework ited to flat impact areas ‘can be arranged with ‘The alloy steels offer similar friction properties to mild steel but are somewhat less prone to rusting and corrosive build-up 3.4.4 Corrosion Resistant Stainless Steel (12% Chromium) Proprietary brands of corrosion resistant/Martensitic stainless steel plate are available based on compositions ‘containing 12% Cr. These offer a competitively priced product for use in handling damp bulk materials where corrosion resistance is an essential feature in maintaining satisfactory flow. Material cost is in the order of 3 times that of mild steel. Hardnesses range from 200 HB to 400 HB, abrasion resistance — but these being more diffic increased hardness available in some brands giving increased form and fabricate — the difficulty increasing with hardness. 24These steels offer good flow, low-friction properties with resistance to corrosion and impact and abrasion resistance largely depending on the hardness. Fixing is usually by holes through the ining with bolts or welding to the chute backing. Alternatively, studs welded to the back of the lining sections can be empl 3.4.5 Stainless Steet Austenitic Stainless steel (17%-18% Cr) is available in a number of grades to suit the differing requirements of the industries in which itis employed ~ BS 1449 Grade 304 being available in sheet form in a range of thicknesses up to 50 mm and being suitable for most bulk material handling applications outside the chemical/food/pharmaceutical industries. BS 1449 Grade 316 stainless steel is available in similar sheet form and is an acceptable material for most food/pharmaceutical applications. For chutework, 2B surface finish is usually adopted, this being a dull buffed/polished finish available ex-1 platework or by mechanical buffing/polishing of the surface after fabrication. Stainless steel offers a low wall friction when handling many of the more difficult materials and inherently avoids problems from rusting and corrosion and, in the grades indicated, can be easily formed and fabricated into chutework form using modern manufacturing methods and machinery. Itsuffers however from its inherent cost— the raw material cost being some 5 times that of mild steel - an mostly limited to applications where thin linings are tolerable to meet low slip requirements and where abrasion resistance by comparison with mild steel is of benefit. is thus iproved Fixing is usually by countersunk bolts or welding onto the mild steel backing platework of the main chute structure but care needs to be exercised in accommodating countersunk fixings with thin liner plates. Proprietary composite lining sheets are ava th a bonded rubber backing offering the low-slip properties of stainless: ioning offered by the rubber backing at impact areas. This composit dng by countersunk bolts by indenting the metal 3.4.6 High Chrome Cast Iron Tiles /Ni-Cr Tiles s have been widely employed over many years as chute linings in works and mineral ore handling projects to combat severe wear by sliding abrasion. ‘These tiles usually (4% Ni, 2% Cr) have offered an effective and convenie: sliding abrasion whilst High Chrome cast iron tiles (25% Cr, 3%C) offer ‘moderate impact in addition to having a very high level of abrasion resistance. licd product to combat severe luc more suited to withstand Present day costs and the superior performance of the High Chrome Tile is currently spor ts adoption as a standard product for many applications since it offers both impact and sliding abrasion res Other cast iror High Cr tiles can be produced in almost any shape to suit specific applica adopted since these are available at more competitive price ‘off the sh ‘The standard flat tiles are available in a range of sizes from 150mm to 300mm square and thickness from 20 to 30mm. The tiles generally have one or two countersunk holes typically to suit fixing by MI6 bolts with inserts available for fixing by adhesive over the bolt heads to give a flush surface. Manufacturers say that Standard square tiles can be cut to fill chute corners etc. by sitting ab grinding disc and breaking the tile over packing pieces under a hydraulic press alternatively by slitting through by grinding. Wherever possible it is recommended that all chutes on a plant should be lined with a standard size stocking and repair. High Cr tiles have a hardness of 600 HV (equivalent 565 HB). The til frictional properties. Careful fitting flow situation by les will polish to a high finish in op3.4.7 Clad Plate Weld-clad stee! plate is available under a number of brand names for chutes subject to high abrasion and impact. Weld-clad plate is manufacturered by depositing a very hard layer of high Carbon Chromium iron on to a mild steel backing plate using a welding process. The composition of the deposit can be amended by the addition of alloying elements to the high Carbon Chromium iron and hardness is generally greater than 600 HB. During the welding process, 2 metallurgical bond is formed giving good plate, approxim: ng deposited with each lay‘ ‘two-layer deposit the wear resistance is improved due to a reduced layer deposits are a Manufacturers advise that the weld beads are made in runs approximately 35 mm wide which contain a number of transverse cracks. These cracks are randomly distributed being produced by solidification stresses and are limited to the hard face and do not represent a fault in the material. ‘The metallurgical structures of the hard surface are complex but in general consist of very hard carbides in a hard matrix varying with the alloying elements. ‘The wear resistance is very dependent on the composition and microstructure. late is available in standard plate sizes 14 mm thick being Smm thick hardfacing on 10mm thick mild of the plate is best carried out using plasma arc but it can also be cut using abrasive saw. The plate is very ‘0 machine but it can be ground and plates can be supplied by manufacturers with drilled and countersunk holes for bolted fixings. ‘The plates can be formed cold both with and against the cladding with minimum bend radius 5 x plate thickness depending on the configuration. Plates can be welded into position using the mild steel backing generally without pre-heat or special precautions Alternatively, stud welding can be applied to the backing plate. ‘The hardfacing has a similar corrosion resistance to stainless stee! in relation to its performance as a lining material ig process. The plate is not recommended for use in a corrosive i ‘0 reach the mild steel backing plate. The surface has good oxidation resistance. Clad-plate has good abrasion resistance with typical operating experience showing life expectancy over 5 times that of Carbon Steel (EN8). Laboratory wear tests show very much greater wear resistance but this is dependent on the abrasive media and the working conditions, Clad-plate is widely employed for chutework in steelworks handling ore coke and sinter and in mining and quarrying handling heavy robust ores. 3.4.8 Rubber/Synthetic Rubber Rubber is used extensively as a chute lining material throughout the minerals handling industry, both as a means of, ‘combatting impact and abrasive wear and also as a major factor towards noise reduction. ing materials are widely available in sheet or moulded tile form with edge strips and accessories to facilitate chute lining at inception or as a retrofit operation Natural rubber usually offers g materials are compounded from synthetic mater abrasive wear. Rubbers having a Shore Hardness of 60 are appropriate points and 80 Shore under severe sliding abrasion may give improved life. 1g and gouging at impact areas but most rubber ‘The ability of rubber to sustain impact wear is dependant on its resilience to cushion or absorb the impact and hence the thickness of rubber at the impact point and the direction of the impacting material is of importance. On a plain rubber surface, best resistance to impact damage is obtained when the impact angle is at 90° and approach angles of 30° to 45° should be avoided — particularly 45°, See Fig. 9. ‘The method of fixing the rubber lining in the impact area must be very secure. Experience indicates tht bolted fixings for plain rubber sheeting may fail in the impact area due to movement and stretching of the rubber with subsequent bulging away from the backing plate unless the rubber lining incorporates a bonded metal, perforated or ‘woven metal or fabric stiffening layer to hold the lining stable. 26NOT RECOMMENDED SLIDING Fig. 9. Rubber Linings — Application Rubber linings are available generally in sheet form up to 50mm thick with some proprietary linings incorporating bonded stiffening element. Moulded lining elements are available up to 150mm thick with proprietary clip-on fixing systems offering rapid inst tachment of rubber sheeting to the chute backing plate is ‘often carried out by countersunk bolts depressed iding surface of the rubber, but improved fixing is attained when the rubber incorporates a bonded stiffening element. Some proprietary brands of sheet or moulded rubber elements for use at the impact zone incorporate a profiled top surface in saw-tooth ‘stepped’ formation to overcome the impact problem with rubber when the approach angle is in the ‘forbidden’ range of 15° 50°. Table 7 indicates one manufacturer's recommendation for the typical thickness of plain rubber of 60 Shore hardness appropriate to the impact zone and to sliding areas of chutework. The values given should be treated only asa guide since the severity of the duty will vary with the nature of the bi being handled and the lining supplier should be approached for advice on the thickness appropriate to specific materials and the application. Table 7. Typical Thickness of Rubber Linings Impact at 50° to 90° WEIGHT OF LUMPS - Kg 3.0 Drop Height 0.1 03-10 10° 30100-30100 m 05 0 15) 2 S35 55 CSCS. 10 13200253555 5S Ow 15 O/H reat as PtH eas tte eH eet ett Bt) 20 2 % 35 55 55 80 88 6105105 25 Os Hi ag PE ott ian et totais ag 3.0 3% 35 55558 88 S180. 10 0 5 3 55 15 is 2 862535 5505 3 35 55 80 «105 105 ‘Thickness of plain rubber lining mm. Under test conditions, the ws ion angle for rubber when under contact from many bulk solids will show a lower slip value than the less re iaterials. The resilience of rubber, however, has the effect of preventing the build-up of fines even with cohesive materials thus aiding chute clearance. The cost of rubber lining can be quite significant in many applications since it needs to be adequately thick — particularly in the impact zone but life expectancy can be significantly greater than that provided by some metal linings. Rubber chutes are supplied by some manufacturers with an. open ‘space frame’ support applying the rubber as a lining material. This total design concept may offer greater resilien enabling thinner material to be used and may provide cost savings on the replacement may prove more difficult. in the impact zone mn but subsequent 73.4.9 Polyurethane xrethane elastomeric coatings and linings are widely employed in the minerals handling industry to counter both impact and abrasive wear and to provide a non-corrosive and noise attenuating surface. Polyurethane is a thermo-setting plastic material which is formulated in a variety of grades from liquid-mix chemical components which are cast or moulded into sheet or slab form in thickness to suit the application. The resulting product offers a tough smooth plastic material which can have the full resilience of natural rubber or be of graded hardness with improved wall-riction properties and abrasion resistance said to outlast some of the toughest rubbers in chute apy the linings may incorporat ‘chute surface in the same manner as rubber allic or fabrie stiffening to faci ings. te fixing by bolting methods to the ‘As with rubber, the softer grades (70 Shore) are used to counter impact abrasion and the material will usually offer best resistance to the impact damage when the approach angle is in the order of 90° to the chute surface. Approach angles of 45° should be avoided. Low angles of approach offer best resistance to sliding abrasion using the harder Suitable grades of material can be formulated to best match specific ‘that the most appropriate grade of material is to be achieved. table surface preparation, Polyurethane coatings can be applied or rebuilt on site by airless spray or methods but it is necessary to ensure the employment of suitably experienced and authorised applicators handle the sometimes toxic chemicals involved and to achieve the necessary degree of adhesion to the substrate surface. Inits cured state, Polyurethane as a chute lining material is non toxic and is available in food quality grades. It has good chemical resistance and offers good weather resistance being suitable for low temperature operation down to -50°C. Maximum operating temperature should be limited to approximately 50°C to 70°C, ‘The material in its cured state is generally considered as flammable but it may be made fire retardant with a small loss of physical properties. The material tends to melt and the products of combustion are generally considered to be toxic; the areas of application should be assessed with this in mind. ‘The material low-friction qualities when wet. For impact locations, a similar thickness to rubber is employed whereas in areas subject to thickness employed may be reduced to half the recommended rabber thickness by using the hard srades of Polyurethane. ing abrasion the rasion resistant 3.4.10 Ultra High Molecular Weight Polyethylene (UHMWP) ‘The use of UHMWP plastic as a lining material to overcome flow problems in bunkers and chutes has shown rapid growth in recent years. Many of the applications have been on existing systems where flow problems have been experienced or where problems have develoy inge in the type and nature of the product being hat Its success in these situ: considerable advant in low performance at re ing abrasion when handling appropriate products. ively low cost together with a high resistance to wear from s However, UHMWP is not suited to handling very highly abrasive materials such as coke or sinter nor to resist ‘gouging abrasion by impact. In impact areas, the UHMWP will abraid rapidly and alternative materials which offer impact resistance should be used. UHMWP is one of the wor considerable advantages when of plastic material which include it offers wer grades ughest known thermoplastics and compared with other pl ly applied as a chute lining material. It should not be confused wit igh Density Polyethylene, Low Density Polyethylene and PVC's ‘The main properties of UHMWP are:- low cost and can be readily cut and shaped to complex chute forms. = Good resistance to pure sliding abrasion — Low angle of friction. ~ _ Nilabsorbtion rate, repels water, giving non-stick properties which greatly assist the handling of damp and sticky cohesive materials — Lightweight 28 RANRAANRHRARHRAHRANAARANHRHRANHRAANRAANRANAANHRANHRANRANRA A= Chemical resistan temperatures. Av: naffected by inorganic chemicals up to 95 °C. Will maintain its properties at very low ble in food quality grades, — Reduces noise. Its limitations are:~ ~The material is not suited to withstand impact and will wear rapidly under impact conditions. It is not suited to handling very highly abrasive materials. The material is flexible and can distort under load unless adequately supported — It must be mechanically fixed to the chute backing ~ it cannot be satisfactorily bonded by adhesives due to its non-stick properties. — Asathermopla ill nt operate at temperatures in excess of 100°C and readily softens and melts at higher temperatures. Itis flammable and burns to give off toxic fumes and the potential fire hazard has to be considered against its application. The use of naked flames or welding equipment must be avoided. = Its coefficient of expansion is 10 times that of mild steel but t applications. is not a problem in most chute lining UHMWP is available in sheet form usually in standard sizes 2m x Im, 2.4m x 1.2m, or 3m x 1.2m with thickness up to 200mm. Linings for chutework are generally formed from sheet of minimum thickness 6mm to allow satisfactory fixing plus additional thickness dependant upon the extent of the anticipated wear. Extruded profiles of the material are available and it is produced in slab form, rods and special sections. grades and, sinc for the duty. In being a pure whi le. Other grades incorporate fillers or ad s or reconstituted material usually being employed cost which may lessen the performance and give rapid wear. By the use of additives, e.g. glass spheres, it is possible to improve the abrasion resistance. Table 8 shows one manufacturers laboratory test results which indicate the relative abrasion resistance of their various grades of UHMWP based on their weight loss when abraided in a sand slurry. Table 8. Comparative Abrasion Resistance ‘Comparative UHMWP - Grade aogier 100% Virgin White 1.00 Reclaim 1.04 110 135 141 100% Virgin material Glass filled O61 Table 9 gives the results of a further series of tests by the same manufacturer to illustrate the resistance of UHMWP to pure sliding abrasion by comparison with a number of other lining materials. The tests were carried out under laboratory conditions by abraiding samples of lining material in a sand slurry and determining the volume loss. Table 9. Relative Volume Loss of Lining Materials When Abraided by Sand Slurry ‘Spec Relative feed Sewty Volume Loss UHMWP ~ 100% Virgin White 0.94 7.00 UHMWP — with Glass spheres 0.98 oes Carbon Steel 745 160 Stainless Steel 7.85 550 PTFE 226 5.30 High Density Polyethylene 192 6.00Fixing of UHMWP linings should be arranged wi staggered in ‘brick’ formation on large areas. ensure a negative ledge or zero ledge across the fhe major sheet length in the direction sheets joints should be carefully butt or scarf jointed and trimmed to e of flow. ‘Adequate fixing of UHMWP linings to the chute backing is essential if successful performance is to be achieved Incorrect or insufficient number of fixings is the most common cause of failure. The preferred method is to use countersunk head M8 or MIO screws set into the lining with spring washers and cadmium plated nuts on the underside of the chute backing plate; alternative methods may be needed when access to the backing plate is difficult. ‘The fixings should be pitched at not more than 200mm around the periphery of each sheet and steel platework backings should be treated prior to lining with a rust inhibiting compound which will also assist in preventing ingress, of material behind the lining. ‘On large areas, intermediate fixings should be made at not more than 300mm pitch. only a small size fixing screw is recommended ing of a covering plug when the fixing is below the is limits the size of the exposed head and ing surface ‘The top leading edge of the lining should be protected by a stainless steel capping strip. ‘The superior flow properties of UHMWP are il strated by the manufacturer in comparative terms by Table 10 Which shows test figures for coefficients of frictio Table 10. Coefficient of Friction Tests Materials Static Cooent Mild Steel on Mild Steel 0.30 to 0.40 Wild Siec'on UBMWP | 0.15 1 020 UHMWP on UHMWP- 0.20 to 0.30 3.4.11 Quarry Tiles Quarry tiles are used for chute lining applications where a low cost product is required offering resistance to abrasive wear in the absence of impact. Quarry tiles are available from many sources offering a more robust but less refined structure compared with vitrified tiles. Typically they are available in thickness 12mm or 19mm. These tiles offer a low-cost ‘cement or epoxy mortar is suit material to counter abrasive wear in situations where fixing by an appropriate le, Hardness is typically about 5 Mohs. the tiles offer a smooth surface with a fairly low-slip value but subsequent wear and the mortar fil les can detract. les are utilised in applications where low friction is required combined with t duty applications and where fixing by an appropriate mortar is suitabl s. 1g abrasion resistance in ey are not suitable for Vitvfield tiles are low grade ceramics fully sintered and vitrified by kiln giving a glass-like surface. Hardness usually approximately 5 Mohs (Diamond = 10 on the Moh scale. 30Fused cast Bas les have been widely used to combat abrasive wear in hoppers and chutes over the past 40 years. Basalt occurs as a hard natural mineral rock; its processing, smel developed largely in West Germany based on the dense Basalts availabl at 1250 °C and cast into moulds with subsequent tempering and control nd casting into tile form having been the area. These are crushed and melted cooling to refine the structure. ‘The tiles have composition mainly comprising nearly 50% Silica and 15% Alumina together with Oxides of iron, calcium and magnesium. They have a very dense, fine and uniform structure with density approximately 2.85 kg/dm3 ‘and hardness approximately 8 Mohs (Diamond = 10 on the Mohs scale). Basalt tiles have nil water absorption and high chemical resistance except for Hydrofluoric acid. Following installation, the tiles become ground and polished in operation with very low friction properties. Static nn angle depends on the bulk material being handled but usually lies in the range 15° to 25° whilst the dynamic mn angle may be less than 15°. in a wide variety of shapes and sizes, flat or curves k but thicker tiles up to 80mm are sometimes used for areas subject interlocking edges. i, usually 30mm or can have scarf or work is carried out by specialists to ensure the use of correct mortar and that satis l performance poter the Basalt tiles is to be realised. Steel cappings and edging led linin are employed to Basalt tiles are particularly suited to withstanding sliding abrasion as an economical wear resistant material. Under impact conditions, the surface may be subject to erosion and alternative materials should be employed. 3.4.14 Alumina Tiles High Alumina Ceramic Tiles are widely used to combat sliding abrasion in hoppers and chutes where a measure of impact resistance is an added requirement. The product is particularly suited to the coal industry for chutework handling coal and shales but the thickness of the tiles must be made adequate to suit the degree of impact which they have to withstand. High Alumina Ceramic is a tough wear resistant material having a composition usually from 85% to 95% into a fine powder with binders, processed by extrusion, casting or pressing into tile shapes les offer a very dense and homogeneous structure in the best qualities with density approximately 3.50 kg/dm3 and scratch hardness approximately 9.0 Moh (Diamond = 10 on the Moh scale). The tiles have nil water absorption and high chemical resistance. Alumina Ceramic should not be considered as a particularly low-friction lining material, manufacturers state a wall friction angle approximately 29° but this may vary with the bulk material handled. Under wet conditions the slip properties improve. ‘Alumina tiles are available in a range of sizes, flat or curved, usually up to 200mm square. the range from 12mm to 25mm but thinner tiles are available. The tiles are available wit hole to facilitate fixing, ess is normally in ferlocking ends and a ied out with plai ed fixing on the hol and edging strips are employed to contain the tile by using an epoxy resin adhesive mortar or by bedding on a with the bolt head protected by a ceramic cap. Steel cappings ining. Care must be exercised over the choice of ceramic ti is recommended that the installation work is carri to ensure that itis correctly matched to the application and to achieve the full performance potent ‘Small ceramic tiles bonded to a rubber backing sheet are available offering the advantages of the product in sheet form to suit the lighter duty applications. 314.0 OPERATIONAL REQUIREMENTS AND DESIGN OF TRANSFER POINTS ‘Transfer points between belt conveyors or between belt conveyors and associated items of a process plant must: 1. Collect the total discharge from the feed conveyor or plant item. 2. Contain and direct the product flow. 3. Ensure continuous transfer of the product without blockage. 4. Control 5. \¢ free fall of the product to minimise impact wear, noise, dust generation and product degradation, Ensure the directed discharge of the product to suit the requirements of the receiving conveyor or plant item. Not all of these factors over-riding factors may be e' vill need to balance the most important fa requirements for access for inspection and be evident on every inst and their relative importance will vary. Additional be a compromise in meeting all the requirements and 10 account the effects of impact and abrasive wear and the jing replacement. Attention to meeting these requirements will involve the following five steps: 1 2 outline geometry to achieve the required flow cay transfer and enclosure requirements. 3. ing materials, methods of fixing, n of ‘crash box’ principles in heavy duty ‘material in dead areas and pockets. 4 the transfer point geometry and assess the loading imposed on platework and structural supports ~ ig into account the dynamic effect in deflecting the mat loads should the chutes become full at plant shut-down or 5. Design and detailing of the transfer poi stream when in operation 10 blockage. che excess dead In pursuing these design stages, specific attention should be given to the factors outlined below in 4.1 through 4.4. 4.1 Transfer Height In a conveyor system necessitating the use of transfer points, the plant layout and the height necessary to give effective transfer should be assessed in detail at the early design stage. Too often, the plant layout and buildings are allowed to dictate the transfer point requirements resulting in chutework having to be incorporated with excessive drop - with all its attendant problems. The opposite situation — having a transfer point with insufficient transfer height for effective chutework ~ can, of course, be equally or more embarrassing. 2vvuvuvvUuvUvU VEU aaa aaa aaa aaa aa Fig. 10 shows a typical situation where transfer between floor levels of a transfer tower is allowed to dictate the conveyor transfer height whereas effective transfer might well be achieved at reduced height by a modification of the supporting structures. ‘Thansren face Stoam. as Fig. 10. Typical Transfer Tower It is a good maxim never to elevate the feed conveyor discharge by more than the minimum height to effect satisfactory transfer. Remember that elevation of the feed conveyor absorbs additional power. One metre of excess elevation will require an additional 1kw of power to run the conveyor for every 300 tph of material transported and, ‘with modern systems sometimes handling many thousands of tonnes per hour, the power absorbed at the transfer can be substantial. Any additional power absorbed due to excessive transfer height will be dissipated as additional impact, abrasion, degradation, noise and dust generatjon within the transfer point. 4.2. Transfer of Belt Cleanings The collection and transfer of the droppings from belt cleaning devices on the feed conveyor can present a major problem nnsfer point which should not be underestimated. With belt cleaning scrapers adjacent to the may well be possible to the main chute or to provide a separate ‘fines is purpose. Note that the belt cleanings are lt to handle than the mainstream flow and may require steeper chute inclinatio 1g t0 avoid build-up. Any ‘When the feed conveyor belt cleaning devices are set back along the conveyor away from the discharge pulley, separate transfer arrangements may be necessary for the droppings. Small screw conveyors, scraper-chain or reciprocating tray conveyors are frequently employed for this duty. 4.3 Variation in Material Flow Properties Possible variation in the flow properties of the material being handled must receive adequate consideration. Few plants handle a single consistent material over the whole of their working lives and, indeed, many plants have to be designed to handle a variety of materials of differing characteristies during their working day. ‘The characteristics of the product may vary with its method of processing or transporting prior to the transfer point. The product may release inherent moisture due to degradation or receive additional moisture due to change in ‘weather conditions or processing, Few materials are homogeneous and consistent prior to processing to the stage of a finished product and adequate consideration must be given to ensure that the transfer point will handle the material in its worst condition without flow blockage from build-up or bridging from large lumps. 4:4 Transitional Operation ‘The geometry of the transfer point must allow for start-up and shut-down of the conveyor system. The transitional trajectory of material from the feed conveyor must be catered for and the capacity of the transfer point chutework ‘must accommodate over-run of the feed conveyor when the system is stopped, possibly in emergency. 3B5.0 VALLEY ANGLES In dealing with a hopper or chute, the angle of the inclined backplate — or bottom plate ~ down which the material is to fiow, is important; but a further aspect must be considered. A hopper or chute must have sideplates and where the bottom plate meets a sloping side the intersection is at a lower angle to the horizontal than either plate. The slope of the intersection is called the valley angle. ‘The valley ang! angle which must di st be sufficiently steep for the material to flow if the hopper or chute is to clear and it is this te the inclination of both bottom and side plates. 5.1 Plates at 90° For two sloping hopper plates, set at 90° in plan view, the slope of the valley angle is given by the formula Cot C= VGobA + Cot?B where C = Valley Angle A = Inclination of back plate B = Inclination of side plate All angles measured from the horizontal ‘The nomogram (Fig. 11) gives values for the valley angle for this arrangement of plates with the plates set at 90° in plan view. A (slope of one plate) 60° gs 70° 20°90" Les lalesuld o 45 ¢ 32 34 36 a % ‘ i 45 ot ss ae? i 28 26 28 a fati B (slope of the other plate) ! 2 o ; so 60° gs 1 argo t 7 2 a oy Las ecatssciealisll Fig. 11. Valley Angles for Plates at 90° It will be scen from Fig. 11 that the valley angle can be increased by making the sideplate more vertical, along the slope of the ides where flow down the chute ‘backplate. Thi will not be subject to the effects of a reduced valley angle. 345.2 Plates not at 90° For two sloping plates set at an angle other than 90° in plan view, the general formula for valley angle becomes: PLATES [ee 7 ATS0° corA Fig. 120. Fig. 12b. Fig. 120 FLATER! Plan View - Acute Plan View - Obtuse Plan View — Special Case; ‘Angle Angle No Valley Angle Fig. 12. Valley Angles for Plates NOT at 90° Application ofthis general formula gives a reduction in valley angle as @ is reduced below 90°, i.e. when the plan angle between plates is acute (Fig. 12 a). The se of acute angles should be avoided since there is substantial risk of material bridging between the plates in Wn to the reduced valley angle. Even with the plan angle between plates at 90°, intersection of plates which form a valley angle to he assist flow. good practice to include a flat or curved fillet at the leviate the bridging effect of material in the corner and thus When the angle 0 is increased above 90”, i.e. when the plan angle between plates is obt angle will increase up to the point where the intersection in plan n, the valley angle will be a maximum and the same as the slope of the backplate ‘A. Further increase in angle I decrease the valley angle. 12b), the valley Table 11. Valley Angles for Plates at Various Horizontal Angles vi ie Slope of Slope of fc hiansate Horiz. Angle Backplate | Sideplate Horiz. Angle © between plates © when Valley A B o s 0 10 im 15 | AneCmA 30 30 16 Baas 6 2B 7 45 0 mw 6 2B 30 29 125 0 B 6 w 30 29 a 110 8B 2% Bw 29 30 28 25 100 90 % 9 3 29 26 2 90 45 45 6 M35 38 4 43 = 6 2 7 AL 44 45 44 125 5 7 ad 45 44 40 105 90 a 44S 44 4 35 90 0 60 a 7 5 54 56 58 - 5 9 4ST 59 60 59 120 90 Sa ey. 57 31 90 5 75 2 6 69 n B “ = 90 J ea pe B co) 90 Note: All angles in degrees. 35iso the valley angle C, are measured from the horizontal plane, also angle @ is s the variation in valley angle over a range of plan angles for the two lley angles correspond with those given in Fig. 11. 1 also gives the plan angle for the special case when the inters ig. 12 c.) and the valley angle equals the slope of backplate ‘A’ n between plates lies along the slope of ‘The valley angles applicable to chutes are sometimes more difficult to identify compared with those met hoppers. 5.3 Straight Chute th a straight chute of trough form the inclination (angle A) of the bottom plate material flow (Fig. 13). 1 the deciding factor for 2. Rectangular ¢."U' Form A Alternative Cross Sections Side Elevation — Straight Chute View on X. Fig. 13. Straight Parallel Chute ides or be of ‘U’ form does not ereate a reduced valley angle providing the chute sides are straight and parallel along their length. angle along the tapering portion. giving a throttling of the material flow when running full, but the reduced valley angle will give a tendency to cause blockage. Any tapering of chutework should thus be carried out very gradually and a check made to ensure that an adequate valley angle is maintained since throttling of the material flow requires the flow stream to deform internally with extra pressure and drag on the sidewall. Ideally, such changes should take place in vertical or very steep sections of chute with all but very free flowing mate: h a divergent chute, there will also be a reduced valley angle — but the flow will tend to follow the slope of the bottom plate and be less affected. qe Reduced Valley Angles Side Elevation — Chute with Taper section View onX Fig. 14. Straight Converging Chute 365.4 Turn Chute If an attempt is made to develop a fiat bottomed inclined chute to turn the flow of material through a substantial angle in plan view (Fig, 15a), itis evident that the outer sid ‘create reduced valley angles and that the bottom plate will have to be built in segments with tapered ‘steps’ (vertical or steeply ineli geometry. The chute will become a series of short straight chute segments with the mate each section - the result often proving unsatisfactory in operation in addition to the compl to achieve the required jon has resulted in curved chutes being developed — generally of ‘U' form in cross section —and curved in give a smooth flow of material through a curved path (Fig. 15b). (a) Flat-bottomed Turn Chute (b) Curve‘U'-Form Chute s along the chute base length of the chute centreline and the vertical drop over this length. Note however that the flow path of material down a curved ‘U’ form chute may not follow the valley angle and allowance must be made for this feature since the flow path may be at a lower incli 1e and is thus at the is usually necessary to employ a developed section at the feed end to connect from a “U-form of the chute. Fig. 16. This connecting section may also be tapered the pulley down to the width of the chute. This developed section will give rise to i careful attention to ensure satisfactory flow. Fig. 16. Connecting Section to ‘U’-form Chute 376.0 CORNER EFFECTS AND FILLETS ‘The effect of surface cohesion (See 2.4.2) is frequently displayed by build-up in the sharp corners of flat bottomed chutes where the material has a relatively large contact area but little mass to generate slip, Fig. 17 shows a flat bottomed chute with 90° corners, inclined at an angle of @ to the horizontal. If Mis the mass of material build-up per unit len; stress resisting slip and p the bulk density of the mate: ‘one comer, R is the radius of build-up, Cs the cohesive then: Cohesive resistance to slip = 2 R Cs per unit length. Frictional resistance to slip = Mg Cos @ Tan @ where © = wall friction angle. (neglecting the effect of the sidewall). Force generating slip = Mg Sin 8. Build-up will occur up to the critical radius at which the net force generati this critical radius. Mg (Sin © — Cos © Tan §) = 2R Cs slip exceeds the resistance to slip, and at 268 ie, R= ——__2 ___ eect ~ (Sin @ ~ Cox © Tan since M = p RFT) Radius in metres Cohesive stress in Newtons/m? Bulk density in Kg/m? 9.81 BOR R = Radius of cohesive build-up. Chute inclined at 6 to the horizontal. Wall Friction angle of bulk solid 6. Fig. 17. Inclined Flat Bottomed Chute with Vertical sides ‘The problem of corner build-up by fine cohesive material in flat bottomed chutes may be alleviated by sloping the chute walls outwards to give obtuse corner angles or by introducing corner fillets. These may be either flat or curved into the corners. The appropriat: up if the we of fillets can be determined by calculating the critical radius R for the potential corner n angle and cohesive stress values are known for the bulk solid being handled. A curved 38 Se cee ee ee a eefillet applied at this critical radius should then eliminate the problem. Alternatively, a flat fillet located as shown in Fig. 18 can be employed, but this will be somewhat less effective since minor corner effects will still be present. R = Critical Radius for comer fillet Alternative Flat Fillet Fig. 18. Chute Corner Fillets Example: ‘A typical moist coal ‘fines’ may have wall cohesion Cs = 100 N/m? and bulk density = 800 kg/m? Wall friction angle against a mild steel chute at low bed depth = @ = say 40° ‘Chute inclination angle = say 60°. Bes 2s 2 (1 ~ 2) (Sin © ~ Cos © Tan 9) ie. R= —__00_ 0.266 metres 800 x 9.81 x 0.215 x 0.446 For a fine limestone where density = 1600 Kg/m*, having the same value of surface cohesion, the required fillet radius would be: R = 0.133 metres.6.0 CF aSECTORIES ischarged over the end jectory. The curvature of by the velocity of the and its direction of travel at the point at which it leaves the uad the acceleration due to gravi ion of chute _ad wearing plates, depends upon the shape of the trajectory which must be predicted as accurately as ole. ‘A number of pk ications give established path of belt conveyor discharge trajectories dicates that the actual will often differ from the predicted plot. correction factors have resulted in methods achieving better compliance in some cases but with ts elsewhere. thods for predicting t! In order to achieve improved cre in prediction of the trajectory plot, it is recommended that a clear understanding of factors affecting the geometry and dynamics of the material at the conveyor discharge pulley is established. Some of the factors which may affect the geometry are outlined in Sections 7.3 through 7.7 whilst the subsequent Section 7.8 covers the dynamics of the load stream motion at the pulley. Tables and charts are given with these Sections to facilitate calculation and plotting of the trajectories and it is recommended that users of the method establish careful comparison between the predicted trajectories and those achieved in practice so that they might assess the relevance of the geometric factors to the accuracy requirements of their predictions. Note that the method given in this manual for plotting the trajectory path is based on a step-by-step approach so that users will become aware of the importance or otherwise of the factors involved and will be better placed to assess any feed-back information from trajectories achieved in practice. ing a basic trajectory for a particle is given in Section 7.2. It should be noted that this method ig from a horizontal reference line so that the same method will apply to all circumstances, tes adjustment and replotting The method also fa Step-by-step instructions for plotting the full trajectory are given in the final Section 7.9. a i a nme aeee a i ee ee ee a eTLOLS SSS SS SS SCOOT TT w ww ewww eww wwwse 7.2. Plotting a Basic Trajectory In Fig. 19, ata given instant, P is a particle about to traject away from the discharge pulley circuit with velocity, Ve, in the direction of the base-line. Fig. 19. Plotting a Trajectory If the particle is unsupported by external means, it will be subject to the effect of gravity giving a vert downwards acceleration of g m/s?, and, disregarding any effects due to air resistance, the particle will move trajectory which can be plotted using Base-line Components and Vertical Components. a Ve , when this is known, ‘convenient to construct ly from a horizontal reference line. ‘The Horizontal Component represents the distance tra led by the particle horizontally during a given time interval. The Verticle Component represents the distance travelled by the particle vertically under the influence of gravity. ‘Table 12 gives a series of Horizontal and Vertical Components based on time increments of 0.05 seconds which is usually appropriate for plot tories at belt conveyor speeds. Horizontal Increments may be read off Chart 1 based on Belt Surface Speed, V m/s, and the load stream approach angle to the pulley, a. (The angle ais shown on Chart 1). Note that the base-line may be inclined, horizontal (and coincident with the horizontal reference line) or declined. See Fig. 20 To plot the basic trajectory: (see Fig. 20) 1. Set down the position of the particle at the point from which it trajects and draw a base-line projecting direction of travel. Also, from the particle, set out a horizontal reference line. 2. Check the belt surface speed approaching the discharge pulley (V m/s) which may be +ve or —ve depending upon whether the conveyor t's approach angle to the pulley (a) dor declined. Refer to chart 1 and read off the Horizontal Increment in millimetres. Note that this increment represents the horizontal travel of the particle for an 0.05 second time interval and equals 50 x V x Cos a. . Along the horizontal reference line, starting at the ii ition of the particle, mark off a series of points (at ‘an appropriate scale) with distance between the points equal to the Horizontal Increment. Draw a series of parallel vertical lines through these points to intersect the Base-line and projecting vertically downwards from the Base-line for a suitable distance. ‘Number the verti particle. |. From each intersection with the Base- 12, lines at their intersection with the Base-line, starting at zero at the initial position of the lay out on these vertical lines the Vertical Components from Table Note that Vert ‘Components co: Join up the points established by the bottom of the vertical Components with a smooth curve to give the path of the basic trajectory for the particle. & 1 Component ‘0° (zero) is at the spond with the numbered intersect ial position of the particle and the other Verticala.Inclinded Horizontal Increments 50 Ve mm. Ve mis Vertical Components Base-line and Horizontal b. Horizontal Horizontal increments 50 Vh mm. Lt Ve mig 01 reference line ‘Vertical Components Horizontal reference line _ 273" pe Repo c. Declined Fig. 20. Plotting the Trajectory 2 Vertical Components,vuvvuUvUvuUuUuUUUUUvUv ue ee ee eee Table 12. Trajectory Components Plot Time Horizontal Point Seconds Component mm. 0 0 0 0 1 00s 50 Vb 2 2 2 50 Vb 49 3 ee 110 4 e 196 5 307 6 441 1 ol 8 785 9 9 993 10 10 1226 u u 1484 2 2 1766 B B 207 4 4 2403 1s 15 2159 16 16 3139 7 v7 3544 18 18 3973 19 19 405 20 2» 4905 a a $408 2 2 5935 Note: 1. V mvs = Belt surface speed at 2 a= Load stream angle of app 4 interval 0.05 seconds. Ptey Bopetech ‘gic “I + 2g 255 4 al termite ke mie score oe 20° * * a ae at vy wo . oe 8 aoa : ag 10° . * Ho7.3 Adjustment to Direction of Travel for Material Approaching Discharge Pulley 7.3.1 Pulley Height and Belt Sag In most cases, the general belt line of the feed conveyor at the discharge pulley approximation for the direction of travel of the belt conveyor load on reaching the pulley. For improved accuracy in determining the discharge trajectory, however, adjustments should be made to take account of the with respect to the belt line approaching the p is may be affected by: (a) pulley position rel troughed idlers over the transition distance and (b) belt sag. ll give a sufficiently close ‘The discharge pulley is often set 1/3 ot more of the ¢ at the bottom of ‘ough depth above the general be the trough which can affect the approach line to the p by as much as 2°. Belt sag over the transition distance can well add an additional inclination of 1° or more on level or inclined conveyors - whilst on decline conveyors the effect of belt sag could alter the approach direction by as much as 4° ‘The combined eff ‘ing these adjustment pulle trajectory above that which woul 21. This will mainly affect those cases where the material trajects imm conveyors. approaches the weyor, sec Fig. Adjusted trajectory “S a: | =: << =a / t ~ Adjusted belt-ine ‘at approach to pulley Fig. 21. Adjustment to Approach Angle 7.3.2 Belt-Bdge Material correction of the approach angle given in 7.3.1 is clearly a generalisation for the majority of the is carried by the flat centre section of the troughed belt. A further adjustment is required for supplementary material at the belt edges. Material at the belt edges will approach the discharge pulley over the transition distance at differing angles which will be dependant on belt width, idler trough angle, pulley position relative to the idler belt line and the position of the material relative to belt width. the effect of this is to reduce the trajectory throw for the edge material in high-speed trajectories where the load front does not pass round the pulley. This effect is shown by the typical ‘kidney’ shape of the impact area where a high-speed trajectory contacts a chute surface, see Fi. 22 ral material pasedine for centtal mato Base-tin S#8e-line for edge material ' Cross Section XX Fig. 22, High-speed Trajectory ~ Typical Cross Section 447.4 Load Cross Section at Discharge Pulley With a troughed belt conveyor, the belt flattens over the transition distance to the discharge pulley and the material tends increasingly to slump laterally towards the belt edges as the belt flattens at the pulley (Fig. 23). Here the load cross-section shape approximates to the segment of a circle for a free flowing granular material. For lumpy and cohesive materials, the load shape will retain a higher profile. The cross-sectional area of the load at the pulley is equal to the average cross-s ‘roughed portion of the conveyor. For granular mat load cross-section at aives the height of the load profile jonal area of the load on the ie pulley as Fig. 23, Table 13, alues given in Table 13 relate to a belt conveyor handling a full cross-sectional load of material and rads will have reduced values. C = 0.058 + 25 Belt Width mm Fig. 23. Load Cross-Section at Discharge Pulley Table 13. Load Height at Discharge Pulley h values (mm) Surcharge ‘Type of Angle ce Width aa ee Belt Width Degrees | 400 500 650 800 900 1000 1200 1400 1600 1800 30° Three equal roll io | 40 48) «6179S 13215170206 troughing idlers 20 |56 6 79 122 145 173190216264 96, 25 163 70 89 114 137 162 190 216 244 295 35° Three equal roll 10 | S38 66 ©=« «8107.32.55 183 208-229-279 ‘roughing idlers 2 | 68 79 9 129 155 185 213 261 «272330 25° | 76 «86 107 «(137 «168 198-230 262295353 45° Three equal roll 10 | 66 6760694 «119147178200 229-259 310 troughing idlers 20 | 74 86 104 137 168 198 230-262-292 356 2 (79 of 112 145 178 21 246 «277-312-376 Flat 10 165 19 2 2m 6M 4 6 3 5B 3 36 «SL ls BBB 55 60) 85102112135 1467.5 Load Front at Pulley Section 7. es details of th ie in close proximi cross-section at the pulley for a free flowing granular material that much of to the belt surface but that the bed depth may be quite significant for the wider Previous methods for plotting discharge trajectories have assumed a radial load front at the point of trajectory from the pulley. However, since particles of free flowing material will become subject to trajection when their weight is no longer supported by the conveyor belt or by other material on the bel suggested that a Vertical section be adopted as the most relevant load-front from which the trajectory should be plotted, (see Fig. 24), il PP rY ) Fig. 24. Vertical Load-Front at Pulley 7.6 The Effect of Lumps In Fig. 23 giving the load cross section at the discharge pulley for granular materials, the radius R from the pulley axis to the belt carrying surface will approximate to the position of the centre of gravity of small granular materials or fines laying at the belt surface. This radius is used to determine the underside boundary of the discharge path. When the product contains larger lumps which may ride on the belt surface, an assessment of lump size should be made to establ mn of their centre of gravity relative to the belt surface and the boundary radius of the lump from ‘The location of the centre of gravity of lumps at the belt surface may be used to establish the discharge path of the lump centre of gravity. The underside boundary radius of lumps is then scribed beneath the centre of gravity path to establish the underside boundary of the discharge path. This underside boundary for lumps will lie somewhat below that for a granular or fine product. Fig. 25. Lumps at the Discharge Pulley 46‘Tune upper boundary of the discharge path is determined for granular materials from the vertical load height at the discharge pulley. For a product containing lumps which may ride at the upper surface of the belt loz gravity of the lumps may again be assessed and used to determine the centre of ‘upper boundary radius is then scribed above the centre of gravi discharge path. This upper boundary for lumps wi n of the centre of y discharge path. The lump path to establish the upper boundary of the somewhat above that for a granular product Additionally, with lump products, the lumps may have to ride further out to pass over the pulley and larger lumps riding at the top of the load stream will ricochet and tend to discharge over a wider path. For this reason, with large lumps an allowance of 50% of the lump size is often made outside the upper boundary when fixing the position of chute covers and impact zones, (see Section 7.9, step 8, Figs. 29 and 30). 7.7 Load Stream Approach Velocity & Direction at Discharge Pulley ‘he load stream carried by the be! I be conveyed at belt speed and will meet the pulley sm at this point and the particles and lumps contained lent to belt speed, V mis. ta tangent point. in the load stream The direction of travel of the load stream at the instant of reaching the tangent point at the pulley will be affected to. minor extent by flattening of the load stream over the tra tance but for practical purposes will be in the same direction as the approaching belt with adjustments for belt sag, pulley height and belt edge considerations (see 73), The direction of travel of the load stream at the approach tangent poi see Fig. 24. For belt conveyors with plain covers, the approach angle, a, through zero to ~20°, ay be: Il normal horizontal or declined, within the range of +20° ‘The belt speed should be calculated from the rpm of the discharge pulley: 2RN Belt speed = TE mis. where R = radius from pi N= RPM of pul 4”7.8 Critical Velocity and Point of Trajection 7.8.1 Theory of Motion at the Discharge Pulley ‘Consider the discharge pulley in Fig. 26, with a small spherical particle in contact with the belt surface at the tangent point ‘A’ where the approaching belt first meets the pulley. ‘The approach angle, a, may be on either side of the verticle centreline of the pulley depending upon whether the belt has an inclined approach or a declined approach ~ see alternative dotted-line. Fig. 26. Motion at the Discharge Pulley ‘At Approach (point A). If the particle has mass M, tangential velocity V, and lies at a radius Re from the pulley axis, MV" (i.e. Cer Re ‘The force acting on the particle (due to its mass M) towards the centre is Mg Cos a. Mvs Re require a force towards the centre of igal Force) if the particle is to follow a circular path around the pulley. If the force towards the centre Mg Cos a is greater than the particle will follow the circular path around the pulley. Mv? Re If the force towards the centre Mg Cos a is less than the particle will traject away from the pulley. ‘The force towards the centre Mg Cos ais jst equal to MY wen thevelocitys at crite! value, Ve known ax the Critical Velocity and Cos oc = YS eRe. or Ve = Vg Re Cos a If the approach velocit ject away from the pulley at pulley to point B, at which it ts away from the pulley. At Discharge (point B). Neglecting any influence from frictional contact with the belt surface, the Horizontal Component Vh of the velocity will remain constant as the particle travels round the pulley, and Vh = V Cos a. Vh Cos © ‘The exit velocity of the particle at point B, Ve = ANTNNHAHANARAHRANHRAARAANHRAHRHANRAANRANRANANRAHRANHRAARANRAA ANAThe particle will traject at point B when the tangential velocity at this point is critical in relation to the discharge angle, ©. i.e. when Cos @ = Ye" _ __Vh?_ BRe Cos@ gRe 2 34 [et or Cost@=—Y cote, and Cos @ = *4/ V2 Cost sRe zRe ie angle ©, some aut assume that the particle will adhere to the belt surface as , in which case @ is given by the formula, Note: In determining the dey travels around the 2 cos © = BRe 4 [V¥? Coe « ‘The effect of adopting the proposed forumula Cos @ = > \/¥" oe eRe is to lift the departure point higher up the pulley, thus giving a higher trajectory which corresponds more closely with ed situation in practice. It also ref of the particle under gravity as it moves down the discharge side of the pulley. 78.2, Critical Velocity Dependent upon the effective radius ‘Re’ from the pulley axis to the centre of gravity of Joad particles or lumps in contact with the belt surface, and to a lesser extent the approach angle a, there is a critical velocity, above which the load stream will traject immediately it reaches the pulley circuit at the approach tangent point. ‘This Critical Velocity, Ve = Vg Re Cos a . (See 7.8.1) ‘Values of the Critical Velocity, Ve, may be read off from Chart 2. Alternatively, for more immediate reference, approximate values for the Critical Velocity for a range of pulley diameters are given in Table 14. Table 14. Critical Velocity Critical Velocity, Ve mis Pulley Dia. ‘Approach Angle Horizontal tor +or— v 10° 2° 200 1.05 1.04 1.02 250 116 113 315 1.29 125 355 137 133 400 144 1.40 455 133 1.48 500 1.60 155 610 1.76 va 630 1.79 174 760 1.96 1.90 800 201 1.95 s15 215 2.09 1000 2.24 217 1060 231 224 1220 2.47 240 1250 2.50 243 1370 262 254 1400 2.64 256 1600 2.82 274 Note: The table is based on belt thickness 12.5 mm and fine material in contact with the carrying surface. ive. Radius ‘Re? = Pull Diemeter +25 mm 497.8.3 High Speed Trajectories ‘When the load stream approach vi 1¢ load stream trajects immediately it reaches the pulley circuit and the bas \jectory is projected as an extension of the di travel of the belt contact material. See Fig. 27. These trajectories are defined as ‘High Speed’ trajectories. DT Ae ‘lpn = Soe ae Fig. 27. High Speed Traject © Camere 7.8.4 Low Speed Trajectories ~ Discharge Angle ‘When the lo: discharge side: In all cases when the load stream follows round the pulley, the velocity of its constituent particles will increase under the effect of gravity as the particles follow down the discharge side of the pulley. The horizontal component (Vh) of the initial vel Temain constant if the effect of frictional contact with the belt surface is neglected. See 7.8.1. Note that Horizontal Velocity Component, Vh = V Cos a where: a = Load stream approach angle to pulley. See Fig. 28 V = Initial velocity of load stream entering the pulley circuit ‘The load stream contact materia begin to traject away from the pulley on the discharge side when the angular position of the belt at an angle © with the vertical centreline from the pulley axis and when: Cos @ = * \/¥°C08* 4 were Re = Radius from pulley axis to the centre of gravity of belt contact material, gRe Metres and g = Acceleration due to gravity = 9.8.1 mis? the discharge the vertical centr ted in this case as the tangent to radius ‘Re’ from the e of the pulley. See Fig. 28. for more immedi belt speeds. ‘Values for angle @ may be read off from Chart 3. of © are given in Table 15 for a range of pulley reference, approximate values These trajectories are defined as ‘Low Speed’ trajectories i.c. when the load stream passes round the pulley before trajecting. 1 between high-speed and low-speed trajectories is at the « Ve. At this particular : | purposes, the same trajectory path will be established by following either the high-speed or the low-speed method for setting the trajectory base-line. Note: At very slow belt speeds, there isa limiting situation at which the bed depth of material on reaching the pulley will shear over the pulley edge at an angle approximating to its angle of repose. This i of particular note on slow speed feeder belts but consideration of discharge trajectories under this circumstance is probably irrelevent. 50Is VvUuUUUUUUUUUUUv Ue ee EU EU UU or SWpORA won 7 eH, s/s on AudoiaA [e049 sz oz st or soo 4 oF eo Ie ot [Loe Looe ot ys eS souoroeless peods YBIH. 9%, BAIS Boao sy ul earRoGW OF ay stan os" oo | oe | 0? “e uous a8. | 8 souorgslesy pods mo7 On16 eoue six ut seniooIen oot ost es) st ot oY @ OF saaiDap ‘70 ‘ai0uy yoworddyIM ad Fig. 28. Low Speed Trajectories Table 15. Discharge Angles Discharge Angle © degrees Pulley Belt Speed m/s Dia. - mm. @ « a « | « @ or=10° 20° | =10 20° | 10" 20" | or-10" 20" | o-10" 20? | O10" 20" 20 | sz 54 | is) 2 | 1.03" 101 | 20 | 35° 57 | 25 30 | Laat 12 | 3s | 58 59 | 33° 36 | 27 124 355 | 509 61 | 36 39 | 135" 132° 4oo | 6t 62 | 39 © 42 |_ naar 139" 4s | 62 3 | 41 44 [10 Laat so | 63 64 | 43 46 | 7 | ase sae oo | 64 66 | 47 49 | 26 © 31 | 173" 1.70" 60 | 65 66 | 47 «049 | 2732 | 176° 7B 70 | 6 67 | so 52 | 33 37 |_193* 1.89" soo | 67 8 | st 53: | 3538 |S Lugar sis | 68 69 | 53) 55 | 38 41 | 37 24 | 242" 2.08% 1000 | 69 = 70 | S456 | 48 | 2 | 221 216° tooo | 69 = 70 | 55 57 | to | 25 2B | 228" 2.23" m0 | 7 m1 | 57 58] 44 47 | 30 34 [24a 239° ws0 | 7 om | 57 99] 4 47 | 3034 1 Loar Bo} nm 2} 8 | 4 9 | 33 37 | 4 a | 2ser 2539 woo | 2 72 | 8 6 | 47 49 | 3 37 | 16 © 2 | 260% 255° oo | 2 mi] @ a} o s| 7. | 3 2 | 278 273 Note: 1 «= Approach Angle to pulley which may be +-ve for inclined approach, zero for horizontal approach, or =ve for declined approach. The table is based on belt thickness of 12.5 mm and fine material in contact with the carrying surface. ie. Radius ‘Re’ = Pulley Diameter + 25 mm * The values shown to the right of the zig-zag line are the belt speed a which the discharge ange isa minimum and is equal these * speeds are approximately equal to the discharge trajectories may be plotted by following the trajects immediately it reaches the pulley circuit. Velocities given in Table 14 and the assuming the load stream 2Approach Angle, o<, degrees Angle of Discharge,©, degrees 40 35 30 25 20 15 100 40 choot i 48 800: 750: 700: 650. = 600. sso ! Effective 500 Radius Re | gomm 50 Velocities in ATA AAT High Sp 350. = a AAA Ge 250 VI Bas at 160 100 | so 0 N | 005 1.0 15 2.0 25 3.0 Approach Velocity — V mis. give ies Chart 3 Low Speed Trajectories, Pulley Discharge Angle7.9 Plotting the Full Trajectory 1 2. 5 Lay out the discharge pulley to a suitable scale and set on the belting thickness passing round the pulley with its corrected approach angle (see 7.3). Draw in the height of the load stream at the pulle (see 7.5). ‘Check the radius ‘R’ from the pulley axis to the carrying surface of the belt. R = pulley radius + belt thickness. Knowing the pulley speed, N rpm, calculate the belt surface velocity ‘V’ at the pulley, 21RN a Note that ‘V’ is approximately equal to belt speed and that the load stream veloci at belt surface velocity, i.e. load stream velocity = V mis (see 7.7). (ee 7.4) and the vertical load section at the tangent point iV mis . Where ‘R’ is in metres. the pulley is assumed to be Refer to chart 2. Note that R is approximately equal to the effective radius Re for fine mat the Critical Velocity, Ve at radius *R”. Compare the load stream velocity If V is greater than Ve (by more than 5%), Section 7.8.3. Follow Fig. 29 and draw in ‘the tangent point at approach 20, Section 7.2. Also from this tangent point, draw in a horizontal reference line and plot the basic trajectory for small material in contact with the belt surface, see Section 7.2. This will establish line A in Fig. 29. Note that if V is only marginally greater than Ve (within 5%), the load stream may i the pulley circuit, but depending on pulley radius may load front will traject immediately it reaches the pulley. See -speed trajectory ba the pulley. Note that thi as a projection of the belt carrying surface from ‘angent point corresponds with point ‘P* in Figs. 19 & © SPS tar ata Fig. 29. Plotting the High-speed Trajectory 34If V is less than Ve, the load front will follow round the pulley before trajecting, see 7.8.4. Refer to chart 3 to determine the angle of discharge from the pulley. Follow Fig. 30 and draw in the base-line for this low-speed trajectory as the tangent at the belt surface at the discharge angle. Note that this tangent point corresponds with poi ig. 20 (c), Section 7.2. Also, from this tangent point, draw in the horizontal reference line and plot the basic trajectory for small material in contact with the belt surface. See Section 7.2 and Fig, 20 (c). This will establish line A in Fig, 30. Note that for the slow-speed trajectory, the basic trajectory is followed by all small granular material in contact with the belt surface and it is not necessary to plot a supplementary trajectory for belt edge material Hetzer terres Une Oo a at ig a Low-Speed Trajectory 55see 7.5 Fig. 24. This vertical height pulley circuit as a vertical load front and traject as step 6 for high or low speed trajectories respectively. Set off above the basic trajectory line ‘A’ a vertical distance ‘h’ on each vertical plotting line. Join up the points with a smooth curve to give the upper boundary of the load stream trajectory. See Figs. 29 & 30, line ‘B’ ies ‘A’ & ‘B’ represents the discharge path for small granular it jad stream converges along the trajectory path as the speed trajectories, the supplementary b small granular material at the belt edges. 8, Check the effect of lumps on the discharge trajectory, see 7.6 and Fig. 25. From the belt surface, assess the vertical height to the centre of gravity of belt contact lumps ‘a’ and the radius the path of above the envelope on the underside of the lump ‘ra’ Also the centre of gravity of belt contact lumps through thi basi trajectory line ‘A’ (or trajectory line) on each vertical plotting line, From these centre of gravity positions, scribe ares representing the Jump underside radius join up these a ‘a smooth tangential curve to give the lower boundary path of the lumps. See line ‘D” Fig. 29 and line “C’ Fig. 30. In similar manner, set out the centre of gravity path for the upper lumps by plotting dimension ‘b’ above the basic trajectory line on each vertical plotting line and from these positions scribe arcs representing radius ‘rb’ Agai these arcs with a smooth tangential curve to give the upper boundary of the lumps. See Fig. 29 and line ‘D’ Fig. 30. ing dimension ‘a’ ver th high-speed trajectories for belt-edge lumps, above the supplement Note that the upper boundary of the lumps may be extended by ricochet against other material in the load stream and by rotation or rolling of the lumps. ize and the pattern of the discharge trajectory ith the belt surface may have to lift as they pass 0 le boundary of the lumps back towards the basic trajectory the upper boundary. for these reasons, a margin of 50% of ine for the trajectory path. See line ‘F” Fig. 29 and line ‘ upper lumps lowed above the upper pi ind method proposed for plotting discharge trajectories is based on the assumption that the bulk solids ave discreet particles of a free-flowing nature, fluffy materials, very high belt speeds, a mixture of large lumps and fines, damp cohesive materials or excess ‘may alter the upper and lower limits of the material path. Lumps riding near the top of the material at the discharge pulley will be thrown further from the pulley as indicated in step 8 above. I cause light and fluffy materials to spread vi lly and laterally as they are being discharged and er the trajectory path. Excessive moisture also cause the material to spread. Allowance should be made accordingly when applying the result of the plotted trajectory. Sa a a ce a a8.0 COLLECTING THE FLOW ‘Assuming that discharge of the feed conveyor is at a terminal pul shown in Fig, 31 with three material discharge areas: 1. Main discharge trajectory he free discharge will usually take the form 2. Underspray of fines from pulley 3. Fines from belt cleaner The proportion of material discharged at the three 10% be dependent upon the characteristics of the handled, belt speed and belt surface. Hi speeds, dry granular materials and low-stick belt ive a higher proportion of discharge in the main stream whilst sticky materials with a higher fines wa c /\ Fig. 31. Discharge at Terminal Pulley ont cusawer t, contain and transfer s. Jements of the discharge ~ either as a combined will be influenced by the type of material handled, its discharge velocity and the conveyor inclination/de the discharge pulley. TThe first step in the design of any transfer point is to predict this trajectory as accurately as possible — but the prediction at best is likely to prove only a rough approximation. The chute, therefore, must accommodate fairly wide variations in the path of the main stream fiow and should have facilities for adjustment or trimming of the flow. The chute must also cater for the start-up and shut-down situation when the throw of the tory will disappear. ‘The design should aim to the flow smoothly without crea achieve . the impact angle against chutework should be kept turbulence and wherever possible in order to thin 20°. Based on the arrangement for the flow, traditional methods of transfer by gravity chute have developed into three broadly grouped types shown the following sections. 8.1 Forward Collection into Chute This is perhaps the most logical way to collect and direct the main stream flow — but it usually leaves the problem of separate collection of the belt cleaner fines. For in-line transfer, the chute may be of simple flat bottom construction or incorporate a curved bottom plate to assist centralisation onto the receiving conveyor. Fig. 32 however, the forward collection chute is of specialist construction formed from segmented “U More usuall receiving conveyor, See specialist knowledge and experience of the mat very careful prediction of the discharge trajectory and friction angles between chute ig and material in order to maintain controlled flow without blockage. 37ATOR CURVED separate Berra Late FINES EotuzcTIon PAN Fig. 32. Simple Line Straight Chute Fig. 33. Forward Collection Curved Chute red with a rubber sealing strip - possibly spring loaded ~ to avoid be est suited to low speed discharge trajectories where the impact an, intaining the position of the chut slope angle. A dead zone exists where the chute is not swept by the discharge stream and build-up of fines in this area can lead to chute blockage. Chutework of mild steel construction is p ly vulnerable to build-up due to ity to corrosion and lining materials with non-corrosive, low f is problem. ‘ontrolled flow with, knowledge of chute construction and experience of, 8.2 Backward Deflection into Chute ‘The fines fall-out beneath the main discharge and from the © py emin beta Fig. 34, Backward Deflection 58A better solution, however, is to employ an adjustable defiector pulley to collect and direct the flow of the if the geometry wi constructed to withstand the forward thrust ofthe trajectory and should be formed in a trough section t fiow and may be built in angled segments or curved along its length to direct the flow. The deflector universally adjustable so that it might be set on pl arranged by suspending the deflector-plate from a pivotted cross bar to allow adjustment to its position relative to the discharge pulley. Horizontal angularty is provided by adj See Fig, 35. Given sufficient adjustment, the deflector-plate chute can be used quite effectively to turn the material in the to feed onto a receiving conveyor directly beneath. Care needs to be taken, however, t0 speed of the receiving conveyor is not too great and that the horizontal angle through which the material flow is tumed does not generate a reverse velocity against the direction of belt travel. Fig. 36. FEED t ' l {epessns Fig. 35. Adjustable Deflector Plate Fig. 36. Plan View on Adjustable Deflector Plate A very effective transfer can be achieved with the addition of a centralising reception hopper with sloping backplate on the receiving conveyor. 8.3 Side Entry Chute With the side entry chute, the chute is formed as an inclined trough either flat bottomed or ‘U shaped - directed ine with the receiving conveyor, the chute being loaded from one side by the . the trajectory of the feed conveyor discharge is arranged to impact Eauscrion PONT collecting chute or backplate of the receiving conveyor by one of the methods shown in S 59‘Very specialised designs of side entry chute have been introduced within the underground coal mining ‘where the problem of transferring at 90 degrees is widespread. These are based on a deep “U" shaped chut with the receiving conveyor but with its central plane inclined to the vertical, arranged to capture the trajected flow ‘on the curved platework and feed this backwards and down the incline of the chute to the receiving conveyor. Fig, 38. Adjustment of the chute is provided to allow trimming of the installation in situ Itis of note th lope angles for a chute fabricated in mild steel arranged as Fig. 38 with the rear end having valley angle of 70° to prevent bt the discharge end at 35° 10 45°, to handle ROM coal are typically ‘up and the chute curved through to ine and a separate fines chute is incorporated ign can be concentrated on achieving the best cleanings — often by means of a separate fines ‘The chute lip is for belt cleanings. flow pattern for the conveyor unit. just beneath the discharge has been adopted so that sam flow with separate 20° ahwax impact ANGLE (CHUTE ANGLE TO SUT Fig. 38. Curved Side Entry Chute9.0 TRANSFERRING THE FLOW the flow from the feed conveyor discharge pul generally form a continuation fro based on the total integrated requirement for , See Section 8.0, transfer of the flow down the ion, transferring and discharging the flow. The design selected for transferring the flow through a vertical height which the flow must be directed and other goemetric limitations of th imposed by the product being handled, be di sted by the plan angle through ‘ogether with the requirements Low capacity installations (upto 1500 tph of material density 0.8 Te/m!) will be more tolerant to the use of sliding chates giving a minimum of dust-make and product degradation. On high capacity installation unlikely that degradation of the product wil handling the product since here design must concentrate on efficient handling, considered as a major factor in ection and uninterrupted flow. ‘The chute options available for transferring the product are 9.1 Direct Vertical Drop Dump Chute With direct vertical drop, the ‘chute’ will act simply as containment for the product and prevent scatter and emission of dust. This may be an acceptable method for low density materials where there is limited drop and the material does not have to be protected against degradation and dust make at the bottom of the chute. Direct vertical chutes are also employed as ship-loading and road transport loading spouts (often in telescopic form) for containment of product and dust with the falling material impinging directly on to the pile building up in the vessel. Elsewhere, vertical drop chutework is more usually associated with ‘crash-box’ installations where the impact of the falling material is controlled and directed. See 9.4 below. 9.2 Inclined Flat Bottom Chute Here, the chute can be readily and cheaply fabricated but, with a flat bottom to the chute trough, its application is largely limited to simple in-line transfer or as a reception chute feeding in-line of aveyor with defiector plate or crash box collecting from the feed conveyor. Attempts to negotiate flat-bottom chutes around Food belt No, 1 convey) Fig, 39. Crash-Box and Straight Chute Belt Transfe: 6comers rarely meet with success in handling bulk mater applications, the flat bottom of the chute trough will reac ‘without bends will inherently suffer less wear. 39 shows the principle of employing a crash-box. lect the belt scrapings from the feed conveyor but conveyor discharge further over the crash-box with a deflector plate to re-direct the impact area. See Fig. 35 in Section 8.2. a straight chute, Note that a separate fines chute is used ¢ this by positioning the feed tream flow backwards into ‘This arrangement combines the cushioning effect of a crash-box with the bridging effect of the chute. By comparison with a curved chute, in addition to the ease of lining and the lesser wear suffered by a straight ‘chute, the slope angle of the straight chute may be steepened to ensure flow with the more dificult sticky materials ‘without fear of side spillage from more free flowing materials. In this respect, the slope of a curved "U" form chute is Critical and if to cater for more difficult materials the slope is made too steep then free flowing materials may spill or lose direction by travelling further up the sidewalls of the chute, ‘The combined effect of crasl fall conditions and is on! ‘and chute is understood to reduce degradation by some 65% compared with free less effective than a curved chute. When using f 1m chutes, attention must be given to the potential for build-up of fines in the corners of the chute, particularly if the product is cohesive in nature. The situation can be eased by sloping the sidewalls of the Chute outwards to avoid right-angle comers or by introducing fillets into the corners. These should be curved, preferably; see Section 6.0 on ‘Corner Eifects: Attention must also be given to ensuring satisfactory valley angles on convergent sections of chutework. See Section 5.0 9.3. ‘U’ Form Chutes ‘The use of ‘U’ Form Chutes has developed as a consequence of the call for smooth continuous flow chutework capable of directing the flow around corners and with the minimum of product degradation and dust-make. ‘The concept is usually applied t from the feed conveyor discharge minimum slope to direct the flow requirement based on forward or backward colle xed ‘U’ form chutework forming a smooth channel ‘controlled manner on to the receiving conveyor. ‘A large diameter pipe, if capable of being bent to the correct path, clearly would offer a most satisfactory chute ‘and, in this respect, the °U’ form chute aims to simulate the lower half of a pipe but with the advantage that the pipe diameter may be varied along its length to suit the configuration requirements. ‘The photographs in Fig. 40 show typical examples of curved “U" form chutes. It is of note that this form of chutework demands very specialised attention to design and construction skill together with a detailed knowledge of the flow properties of the materials being handled. “Application of such chutes is most appropriate to the handling of single products of regular free-flowing materials but the ‘as a basis for chute design has been developed to a substantial extent for the handling of run-of: ‘materials in both underground mining operations and surface handling plants. See Section 8.3, ‘Side Entry Chi ‘The use of “U’ form chutes has been applied over many years in the form of open spiral chutes as an anti-degradation/anti-dust means of filling silos and bins. Use is usually limited to applications with moderate throughput where abrasion is not too severe since the addition of linings is restricted by the expense and difficulty in fixing to the complex form of this chutework, 9.4 Crash Box Chutes ‘The ‘Crash-box’ (sometimes referred to as a ‘dirt-box’ or ‘rock-box’) has traditionally been employed in heavy duty mining applications as a means of absorbing impact of large lump materials after falling through substantial eights and itis now accepted in a wide Variety of industries. Indeed, in many industries where heavy ores 1¢ use of a crash-box at impact is considered to be the most effective and economical method of impact abrasion on chutework and is often found to be the only method of countering the effects of withstandi impact. 2Fig. 40. ‘U’form Chutework 6‘The principle of the crash-box is shown in the various diagram: free material inged to impact on a dead poc! Id-up to form a si and the subsequent impact of the material stream is cushioned by the pocket of ‘The angle of the retained material in the crash-box is usually assumed to be at its angle-of-repose but this can only be taken as a rough measure of ion in practice and initial design should always be based on providing in facilities for adjustment 1e best compromise may be achieved when the plant is in operation to assure satisfactory flow in addition to containing the impact Application of the crash-box is particularly relevant to heavy duty and high capacity systems where it may be the only practical method of accommodating the very substantial levels of impact and abrasive wear which may be evident but it can be applied with success on a wide range of applications. By comparison with a direct vertical drop dump chute on to a receiving conveyor, the use of a crash-box has been assessed to reduce degradation of material by almost 50% and the wider adoption of this simple device is becoming more evident Due consideration must be given pocket of materi differing grades \e dead to handle application however, since the crash-box has the disadvantage th pptable contamination of the product if the conveyor system ‘The crash-box is not suited to handling very cohesive materials such as small damp coals. 9.4.1 Dimensions »wing extract from the MHEA Manual on Recommended Practice for Troughed Belt Conveyors tion of crash-box chutework in high capacity installations with guide dimensions High Capacity Installations ~ Coal, Lignite, Abrasive Ores is a most exceptional installation if one has to consider degradation along wi Further, in high capacity conveyors the height between them at transfer points is at least 3.6m hence, due to the sheer weight of the mass of the material. itis essential for the crash box to be down close to the receiving belt with only a short curved back plate spout or chute down to within 50 to 80 mm of the belt. This crash box and spout should be arranged parallel to the line of the receiving belt. At the discharge point there is a choice of methods. ‘The first is to arrange an adj forward movement material lands centrally on to the bed of materi deflector plate against which the trajectory of the material impinges, all irops vertically without touching the walls of the enclosing chutework and in the crash box (Fig. 41). Seraings chute) Fig. 41. Right Angled Crash-Box Feed Chute 6 Raannnninhnrnri fi nHnHRnhnRhRKR RHR ARH AKRHRARAHKRHRRARAHRARARAHRAARA‘A second method is to have a second crash box to receive the discharged material at a suitable height and distance from the discharge pulley commensurate with the belt speed and trajectory. Again, from this crash box, the material flows vertically downwards without touching the enclosing chutework and lands centrally on to the bed of material in the second crash box (Fig 42), then flows out down the short spout on to the receiving belt. Both these methods suit in-line, right angled or any other angled junction points: ‘The crash boxes, as previously mentioned, have to be large enough to provide sufficient depth of bed so that: = it provides a reasonable cushion to help absorb the kine! = the slope of the bed of material should be arranged so that it finds it own angle of repose which normally varies from 40° upwards depending on whether the material is free flowing or sticky, has lumps with a percentage of fines, or is all fines. energy of the material ‘The outgoing eiige of the erash box should have a 100 mm bottom plate of the crash box should be bolted on to the back a that some adjustment can be made to the outgoing edge to suit differing ‘flowal variable moisture content. This is especially so with fine ores. the same material with a ssreaates Soto ae Fig. 42. In-Line Crash-Box Feed Chute Other approximate leading guide dimensions of crash boxes are shown in Fig. 43, Both methods, when designed properly, are efficient and effective, the two crash box method being slightly more complicated t has practically no wear and therefore mimimum maintenance. The deflector plate method has the advantage be positioned at a variable distance from the discharge pulley and, in addition, can be adjusted in its angular position to suit a particular material or application. However, it fakes a tremendous pounding and wear from abrasive materials and consequently may need to be lined with wear resistant material. Rests of tow Fig. 43. Typical Crash-Box - Guide Dimensions 6510.0 CHUTE CAPACITY AND FLOW VELOCITY 10.1 Volumetric Capacity ‘The volume of the transfer chute must be sufficient to contain the over-run of material from the feed conveyor when the conveyor system is stopped. ‘The amount of over-run method of sequence interlocking draw-off from the chute by the out- through the transfer chute must does not occur. of the feed conveyor, whether it Wg, and the nnveyor from the transfer chute since this will affect any f the stopping parameters of the conveyor system ensuring that over-flooding of the transfer chute Also, sequence starting of the conveyor system will be necessary to ensure chute clearance before the feed conveyor restarts. 10.2 Cross Sectional Capacity ‘As shown in Section influence of gravity onc ad stream discharging from # jectory path falls below the oF feed conveyor locity under the inal discharge height from the pulley. ‘The dimensions insfer chute must be sufficient to collect the load stream and to ensure continuous flow of Chute blockage may occur due to: (i. Mechanical bridging by large lumps. (ii) Choking or bridging by a cohesive arch due to insufficient cross section, mn, corner effects or cohesion of material during Avoidance of these problems requires attention to the chute geometry and to its governing dimensions. 10.2.1 Avoiding Blockage by Lumps ‘To avoid mechanical interlocking or jamming of lumps within the chute, it is recommended that the cross sectional dimensions of the chute at any point should be arranged so that the dimension between containment walls inthe flow area is at least 2% times the major dimension of the largest lumps. This recommendation should satisfy those cases where the chute is handling sized material or the product contains a significant proportion of large sized lumps. For those cases where the chute is to handle only the occasional large lump, and ikely to be in isolation from other lumps of similar dimension, a reduced dimension between containment walls of 2 times lump size may be appropriate. 10.2.2 Avoiding Blockage by Bridging ‘The dimension across the chute between the side walls must be sufficiently large to avoid forming a cohesive arch across the chute following a stoppage of the conveyor system when static material builds up in the chute. pressure. Readers are referred to papers by Arnold and Robes “Draft code of practice for the design of hoppers, bunkers and silos 19% "for further information on this To avoid this situation arising within transfer point chutework, it is recommended that chutes be designed and dimensioned to operate as an open flow channel, any covers or enclosures being positioned well above the anticipated maximum bed-depth of the material. See Fig. 44 6dd id i te ee ee ee ee ee nanuns wor 2h wea x LUMPSTE chute cross secrion Fig. 44. Chute Dimensions mnal area of the chute should be at least 4 times the the feed conveyor the chute running only ¥ full under normal conditions ~ and ‘minimise the chances of the chute becoming full during plant stoppages and to avoid the likelihood of a cohesive arch forming should the chute become temporarily To avoid bridging from wall-to-wall of the chute, there must be an adequate ratio of chute width/bed depth; this, ratio varying with the form of the chute cross-sectional. Fig. 45 indicates thé proportions usually accepted as good practice. a4 4 ~p > ¥ Fig. 45, Chute Proportions 10.3 Chute Inclination and Material Velocity Flow must be ensured by handled and the chute Materials) ing the chute at a sufficiently steep angle which will depend on the material being irface. (See Section 2.0 on Material Flow Properties and Section 3.0 on Lining For good practice, where material is already sliding on the chute surface, itis usually accepted that the minimum valley angle should be at least 5° to 10° greater than the static wall friction angle for the material in its worst condition. plus an allowance to counter surface cohesion which may typical i ther 20° or more for difficult further allowance of 5° ‘maintain flow. o7provided to ensure clearance of material away from the impact area (see Section 10.3.5 and Se convenience the chute may be continued throughout its length at this enhanced inclination. ‘These features, necessary to ensure that the material will commence to flow from the static condition, wi excess slope which will accelerate the material giving it an increasing velocity as it flows down the chute straight-line chute of constant width, the bed depth of the material will decrease along the chute as the veloci increases. This increase in velocity may be quite substantial. ‘There is little published information relating to the calculation of flow velocity for bulk materials in chutes and the limited information available is of complex nature. Simplified methods are proposed in the following cases to assist designers in assessing approximate values from which they might better judge the chute parameters. ‘The cases are based on material already sliding on the chute surface at a known initial velocity. lination angle = 8, sliding veloci ler an element of the material, mass M, ing on the chute. The force along the chute surface due to gravity acting on the material, F = M g Si sete mene v? ing Down a Straight Chute I be due largely to the friction on the bottom plate for a flat bottomed projected area of the chute bottom for a°U'- form chute, i. neglecting any drag from the sidewalls for a straight chute, the resistance to sliding down the chute, R=MgCos@xu where = coefficient of friction (dynamic) between the material and chute surface. ie. R= Mg Cos © Tan where 0 = effective wall fri ‘The net accelerating force along the chute, P= F — R ie. P= Mg (Sin © ~ Cos © Tan) But, from the increase in energy, where S = distance travelled along the chute. M pxs= Mwz-vay 2 2g (Sin © — Cos © Tan 8) S + VP tion angle (dynamic) and u = Tan 9. sand equating for P gives V2 = or V2 = V2g (¥ — XTan ) + VF where Y = vertical drop along chute X = horizontal projection of chute length ¥ & Xin metres, Vi & V2 in miso. 2 = 9.81 ms? 10.3.2 Case 2. Straight Chute with Deflected Bottom Section Straight chutes which ‘level receiving conveyor. Fig. 47 iboth types but arrangement assist in minimising wear by giving a smooth transition through the deflecting section. Arrangement (b) will give rise to more turbulent flow of material, depending upon the severity of the angular changes, with a measure of increased wear on the surface and reduction in flow velocity. Fig. 47. Straight Chute with Deflecting End A detailed analytical approach to determine exit velocity involves considerable and complex calculation. The following simplified analysis is proposed as an approximation which should give satisfactory results for practical purposes. 1. Along the straight section of the Chute, A, use the formula from Case 1 to calculate the flow vel entry to the deflecting section B 2. Along the deflecting section B, use a s exit using co-ordinates X2 & ¥2. ity, V2, at i formula to Case 1 to calculate the equivalent velocity Ve at chute ie, Ve = V2g (¥2 — XI Tan) + VE This leaves a correction to be made to the velocity to cater for the defiection of the flow, see Step 3 on. 3. Calculate the average velocity throught the deflection - V24Ve 2 Va and hence the velocity correction Ve from formula Ve = 2 Va Sin Eran 6 where & = Wall friction angle (dynamic) for the chute surface. B = Angle through which chute deffects. 4. Calculate the corrected exit velocity V3 = Ve — Ve. Note: 1, The analysis for Step 3 is based on the approximate velocity change normal to the chute bottom = 2 Va sink and hence the resultant normal reaction on the chute bottom based on rate of change of momentum = Ms x 2.Va sind where Ms is the mass flow per second. ‘The drag force along the chute bottom perpendicular to the resultant normal reaction = Ms 2 Va sin Tan which equates to the rate of change of momentum in this direction ie. Ms x Ve = Ms 2 Va Sin tan g Ve=2vasin8 tan 9 where Ve = velocity change due to deffection = velocity correction 2. Repeated successive correction for exit velocity will give improved accuracy to the calculation but is considered inappropriate in view of the approximate nature of the method.Case 3, Curved ‘U’-form Chute there are no corner effects to initiate build-up from cohesive materials and a slightly less mn is tolerable compared with a fiat bottom chute, ‘U-form chute may be constructed at constant width throughout its length to facilitate fabrication but at bend med by the outer wall, The resulting reduction in velocity and ll may promote overspill unless the chute is made sufficiently his type of chute is described as a ‘lobster back” chute by a number of authorities in view of the resemblance to the shape of the lobsters shell. designed *U'-form chute is highly regarded for its ability to contain and direct the flow of material - In meeting this latter with that flowing around the outer w: necessary. of the bend. Some adjustment or trimming of the loadstream at exit may be be seen that the fabrication of curved *U'-form chutes requires specialist skills in preparing the developed of platework to form the complex shape of the chutework in addition to the high level of design and draughting expertise involved in their application, ‘The complex nature of the chute limits the choice of lining materials. The flow pattern of material down the chute will be of complex nature and itis difficult to consider a direct analysis, for change in velocity along the flow path but a simplified method may give a suitable approximate assessment. If the chute comprises straight sections and a curved section, as shown in Fig. 48, the change in velocity along the straight sections can be assessed according to formulae given in Case 1 ie. V2 = V2g (YI — X1 Tan 8) + VE 2g (Y3 — X3 Tan 8) + V3? and V4 = ‘Along the turn in estimate of the flow path has to be made and hence an adjustment to the is section. Hence co-ordinate Y2 giving the drop and X2 giving the horizontal projection developed length of the flow line, $2. chute of the Fig. 48. Curved ‘U'-form Chute 70‘The apparent effective exit velocity from the turn section, Ve3, neglecting any reduction due to the turn, may then be assessed from a similar formula: Ve3 = Vig (2 — X2 Tan 6) + VE and hence the average velocity through the turn: Va= V2+Ve3 2 Considering the turn section in the horizontal plane, and assuming that the chute is at constant slope, 2 Average Horizontal Velocity component, Vha = Va x XZ If the approximate horizontal radius of the tum along the assumed centreline of the flow-path = Rt, then Centrifugal Force, C.F., on the sidewall due to the turn is given by: M Vat? Rt CR= where M = mass of material in turn section s2 = Ms x 52 where Ms = mass flow per second is x whe pe ‘The drag on the sidewall due to the horizon D=CE x Tan § where 6 = effective w: Ms S2 Vah? Tan 8 Va Rt surn, D, is given by ion angle for the chute. ie D= Equating: Rate of change of momentum = Sidewall drag ‘Ms S2 Vah? Tan 6 Ms X Ve = where Ve = velocity correction VaRt = loss in velocity due to sidewall drag at the turn ieVe | = Sa Vat X2 Tan 6 ‘Va SP? Rt or é Ve = Va Tan 9 2 SR Knowing Vo, the corrected velocity at ext from the turn, V3, can be calculated from V3 = Ve3 — Ve Note: ‘The above analysis is clearly a very rough approximation based on a number of assumptions but it should offer simple method of assessing “guide” values for the flow velocity. Again, repeated successive correction for exit velocity will give improved accuracy to the calculation but would be inappropriate in comparison with the method. 10.3.4 Examples Example Case 1 Consider the typical situation for a straight chute 2.0 metres long, If the effective dynamic wall friction angle @ = 25° (Tan 8 = 0.466) ‘and static wall friction angle =35° allowing for possible cohesion, plus 5° lus, for safety, sf Make minimum chute inclination, @, 45° and Y = 1414m X= 1.414 m If material velocity entering the chute, V1 = say 2.0 mis Velocity leaving chute, V2, = V2 x 9.81 (1414 — 1.414 x 466) + 4 4.3 mis nExample Case 2. Consider the chute from Case 1 extended by a curved deflecting section from chute inclination 45° down to 15° where the curved section is at 2.0 metres radius giving co-ordinates Y2 = 0.5, and X2 = 0.9m and fi = 30°. Entry velocity to curved section V2 = 4.3 mis from Case 1 above. Equivalent velocity at chute exit 2g (2 — X2 Tan 6) + VE V2 9.81 (0.5 — 0.9 x 0.466) + 4.2 0 = 448 ms Average velocity along cure Va = Y2-£YE = 4.39 mis Velocity correction Ve = 2 Va Sin-B Tan 8 = 2 x 4.39 Sin 15° x 0.466 2 = 105 mis Exit velocity from chute V3 = Ve ~ Ve = 4.48 — 1.06 = 3.42 mis Example Case 3. Based on Fig. 48, for the turn section of the chute, if Turn Angle 6 = 75°, entry velocity of material V2 = 2.0 mvs, chute valley angle © = 40°, effective wall friction angle § = 25°. Assess, or guess, the probable flow line for the centre of the material path along the chute, hence the horizontal radius of the material path Rt = say 1.75 metres. From the chute geometry, determine the horizontal developed length along the flow line, X2 = say 2.1 metres, the vertical drop along the flow line, Y2 = say 1.65 metres and the slope length, $2 = say 2.6 metres. Determine the apparent exit velocity from the turn section, ignoring the effect of the turn: Ve3 = 2g (¥2 — X2 Tan) + VE 2.1 X 0.466) + 4.0 ua Average velocity through tur, Va = Y2+Ve8 20 54:14 _ 5.07 mye xz Velocity correction for turn Ve = Va Tan § 2 a S2Rt = 3.07 x 0.466 21 26 x 175 = 1.98 ms Exit velocity V3 = Ve3 ~ Ve = 4.14 — 1.98 = 2.16 mis10.3.5 Velocity at Entry to Chute :pact angle and will rebound or ‘he wear pattern at entry to a y ing a series of wear bands progressively reducing in severity as a steadier flow pattern develops down the chute. See Fig. 49. The extent of the mat coefficient of normal re depth of the mate e chute wear should be employed I rebound at chute entry n between the bulk mates Low impact angles at Il depend on the approachi \d the chute surface and wi minimise the disruption impact angle, «, and the bbe dampened by the bed the flow pattern and the If the velocity of the approaching stream is V mis, the component of velocity along the chute will be VCos «. The impact component of the velocity, VSin a, will be destroyed in the ensuing cascading flow and, disregarding any secondary effects in this area, the reduction in velocity along the chute due to impact will be VSine Tan@ from consideration of momentum. ‘The resulting velocity along the chute, V1 = V(Cosa ~ where @ is the ws ee Tan) Fig. 49. Flow Pattern at Chute Entry For a 20? impact angle and with typical wall friction angle of 25°, the resulting velocity along the chute calculates out at approximately 80% of the approaching stream velocity. If the formula V1 = V(Cos « ~ Sin « Tan 6) is further examined, it will be seen that the vel be reduced to zero when along the chute will Tan «= Tan 6 Ifthe wall friction angle is again taken typi pact angle a = 65° ity along the chute will be seen to reduce to zero, B11.0 DISCHARGING THE FLOW In discharging the flow on to the receiving conveyor at a transfer poi following parameters: the chutework must aim to meet the )) To feed on to the receiving conveyor in its direction of travel ii) To ensure that the load stream is in a cent ‘To minimise impact on to the receiving belt. 'v) To ensure as far as possible that the velocity component of the material stream in the direction of the receiving conveyor speed ~ hence minimising wear on the belt covers and the power demand in to belt speed The importance of each of need to be assessed against the particular merits of each installation since they may not cases, e.g. in handling a lightweight granular material the effect of importance and the design may only need to concentrate on directing the load in a centralised stream to avoid spi Wherever possible, the chute discharge should be arranged to run in-line with the receiving conveyor bel Alternatively, the receiving hopper on the conveyor should be arranged with a sloping backplate act terminal part of the transfer chute down which the material will slide in the direc should only be omitted on the most simple of transfer stations where arrangements such as may offer a convenient and acceptable method on horizontal conveyor systems handling. gr moderat speeds. Fig, $0 illustrates the nature of direct belt-to-belt transfer with comments in the implications. -belt transfer wr products at ing some of incline on to horizontal conveyor The horizontal component of the feed ve t wi impact decrease. (b) In-ine on to Inclined Belt. Relative to the receiving bel the velocity in the and may be unaccept: {c) Side-on to Inclined Belt. nt gi a Fig. $0. Direct Transfer11.1 Backplate As an improvement to direct transfer, is usual to incorporate a collecting hopper on the receiving conveyor with feed is directed. This may not always be convenient with side feed and under these circumstances the use of direct transfer should be limited to horizontal conveyor systems on less onerous duties. The photograph in Fig. 51 shows a typi a sand and gravel qu: arranged onto a sloy material back beneat have to be extended to accommodate the side feed. y where direct transfer is, side feed, a deflector plate is often used to bring the e backplate. The length of the backplate may With a flat backplate, centr jon of the feed on to the receiving belt is not always successful with the material frequentely snaking down the plate. An improved arrangement is given by making the back of the hopper in conical form or as a curved plate. nsfer Point at a Sand & Gravel Quarry with Discharge on to Backplate of Receiving Hopper ers 10 resist abrasion —such as tiles or one reasonable percentage of Jumps mixed in fines through on to the back pl the bed of fines which cushion Another method of prolonging the material builds up on a ledge, for of a hopper from abrasive materials is by a crash box. In this form the is own angle of repose, and then flows over itself, down on to the belt, 1611.2. Chute Discharge The better situation using chute discharge in-line on to the receiving bel strated in Fig. 52. (91 a Soro Cre with oe utes to cea fond Sed rate nose! ot um (0) Fie Stn crate ‘at ah Scherge ona Fig. 52. Chute Discharge Arrangements rm cross section will generally provide good centralisation providing the feed length is sufficient. Alternatively, a flat bottom chute may be developed at the discharge end into ‘U’ form to centralise the load stream. * Fig. 52 (a). If this proves inconvenient, a flat bottom chute should be arranged with a ‘fish-tail’ end since this encourages discharge towards the centre and also allows small material to discharge beneath the larger lumps thus providing a cushion against impact. Fig. 52 (b). ‘An improved arrangement is given by incorporating Vee plates between a flat bottom feed chute and skirt plates on the receiving conveyor, see Fig. 52 (c), but care must be taken wit angles formed to avoid build-up. This latter arrangement wiil also enable the terminal bottom edge of the chute to be sealed down to the receiving belt with a rubber strip whereas the ‘U’ form chute or fish-tail end cannot itself be sealed and is usually terminated about 50mm above the belt. Fig. 53 shows the use of a crash-box to cushion the material impact prior to the chute discharge leg whilst Fig. 54 illustrates the use of a grid to cushion the impact of large lumps on the receiving belt. This latter arrangement is only suited to clean products where blockage of the grid/grizzly bars is unlikely. Fig. 55 illustrates the use of a crash-box ledge on the feed chute to counter wear from an abrasive product. [ peemeeeamertmees remertat cl ott || Sepasotmamen tee | Sithionthe impact fom ume Spacing iechoros End Fig. 54. 1Loading chute Loading skirtboards Tail pulley Fig. 55. Use of ‘Crash-box’ chute leg to counter abrasion Note: The rubber covers of a receiving bel be subject to impact damage, the extent of which may depend very substantially on the angle of approach of the ipacting lumps - sce Section 3.4.8. jeneath the feed chute or feed hopper, detailed consideration of the relative approach angle assist in minimising wear on the belt covers. Heavy impact on the sloping sides of the should be avoided. opening outward where the hoppe be more than 2! imension of uniformly sized lumps, when th percentage of the natural flow. Where lumps are occasional and fines are mixed, the ‘the maximum lump size. represent a considerable throat may be made twice 11.3 Skirt Plates To retain the load on the belt after it leaves the loading hopper or chute and until it reaches belt speed, skirt plates are necessary. tes are usually an extension of the sides of the hopper or chute and extend parallel to one another, ids of the belt width. The length of skirt plate is a function of the difference between the material Ww speeds the skirt plate should be at least two or three times the i for each 1 mis belt speed. The lower edges of the skirt plates are posit 30mm above the belt and t ce should be uniformly increase 6Omm. The gap left between the skirt and the belt surface should be sealed by a rectangular rubber strip clamped to che outside of the skirt plate (strips of old conveyor belting must never be used for this purpose as they cause damage (0 the belt cover). higher speeds it should be 1 When heavy loads are being conveyed it is good prac construct another shallow 120mm high ski ly 50mm outside each of the main skirts and welded to them and then a rubber strip is clamped ‘This arrangement relieves the outward pressure the rubber strip and makes for a better seal, providing the rubber strip is maintained pressing to leave off the rubber strip from the skirt plates and ‘The height of skirt plates must be suficient to contain the material volume as itis loaded on the belt, but where there is a percentage of lumps mixed in the load then the height must contain them, thus a height of one third of the belt width is a reasonable one. B ee oe a kt ls ee keke Akh KR ke ee eh eek le ew ee ee[~TUUOVUUUUVUVUUUU UU UU 12.0 CHUTE CONSTRUCTION d from plate materials ~ most frequently from metallic materials such as ‘and supporting members. Plate thickness needs to be adapted to an the chute isnot fitted with ightweight chutes extending in dimension up to about 2.0 metres in it materials such as wood chips, plastics, fine coal or similar products may be rk, replaceable length and suited to handling constructed in 3mm thick plate Similar chutes to handle run-of-mine coal on conveyor belt systems up to 900mm wide or heavier materials such as sand and gravel would be constructed in a minimum of 6mm platework whilst chutes for heavier ores and rock handling are more usually fabricated from 8mm, 10mm or 12mm platework For very heavy chutework handling heavy ores with large d lumps, the construction may well extend up to the use of 20mm thick platework with stiffening and impact grids at impact locations. Chutes are frequently made in sections with flanged and bolted joints to facilitate both the initial fabrication and subsequent handling and site installation, losed, the chute should incorporate observation apertures with hinged covers located away from the flowing ‘material and sited to allow observation of the flow and any developing wear at critical areas of the installation, The apertures should be limited in dimension or protected with fixed bars to prevent entry of personnel. ‘On large installations where the removal of covers for maintenance may prove inconvenient or impractical, access panels may have to be provided in the covers to permit entry to be made by maintenance personnel. Under these ircumstances, the addition of pairs of small apertures located in the chute walls at intervals along the chute will enable cross bars to be inserted to assist in the internal handling of lining materials and the attachment of rope ladders ete Careful attention needs to be given to the size of lining sections employed to ensure that these can be manually handled chutework for replacement purposes through restricted access. Some users specify 40 Kg as the maximum weight of a lining plate to facilitate manual handling into position. ‘The running surface of the chute oF lining must be kept as smooth as possible to avoid the generation of turbulence in the flow stream. Transverse weld ps or imperfections, or uneven fiting of lining tiles must be avoided since they all promote disruption of the flow pattera with erosive wear, possible build-up of fines and distortion of the flow path.13.0 DUST CONTROL Depending on the material being handled, requirements, dust control measures atthe t belt conveyor system. environmental situation of the transfer point and the operating fer point may be necessary to ensure satisfactory performance of the In its simplest form, dust control may involve nothing more than attention to enclosure of the transfer point chutework or the use of water sprays where these are tolerable to suppress the creation of dust. Elsewhere, the use of dust extraction equipment may be necessary at the transfer point enclosure 13.1 Enclosure Where enclosure of the tra carried back to encase the headpulley and a rubber cur of the load stream on the belt and wi ‘oceasional excess load or lumps. The underside of the in running belt so that the let aperture to the enclo: transfer point, the enclosure should extend along the outgoing belt by approximately loading point with sealed skirt plates to the belt and the exit aperture again Kept as smal ‘ubber curtain to accommodate the load profile on the belt. See Fig. 56 Fig. 56. Enclosure of Transfer Chutes 13.2 Dust Suppression by Water Sprays The use of water sprays for dust suppression has developed largely in the underground coal mining industry where the suppression of dust from the ventilating air stream in underground tunnels and workings is of paramount importance to the working environment and to the prevention of explosive coal dust/air mixtures developing, Dust suppression by water sprays is practised also in surface coal handling and in quarrying plants where t moisture is not detrimental to the product or where water may be used as part of the treatment process, designed chutes are themselves an important aspect in controlling dust-make at transfer points since material which is allowed to fall freely from one belt to another may allow a high concentration of dust to become airborne. so that itis appl carrying a load. Excess water at other times may promote fv lampened fines in chutes and around the transfer point. Control of the water feed is usually arranged by empl spray control v: supply valve which opens on rotation of a driving wheel. Fig. 57 shows a typical unit which is p carrying strand of the feed conveyor and arranged to, lear of the empty running belt so stationary. When a load passes on a running belt, the deflection of the belt under the lo: Wheel which then opens the valve and passes water to the dust suppression sprays, 81Fig. 57. Application of Automatic Spray Control Valve ‘The most effective sprays to control dust on conveyor belts are of the low pressure, low velocity type giving coarse droplets. ‘Two positions for the sprays are recommended. Firstly, siting the spray wit before the transfer point arranged to spray the load on the feed conveyor and deep into the material on the belt before transfer. Secondly, a spray positioned to discharge pulley ~ the spray head being located slightly higher and in front of this posi Both methods may be used together if necessary but minimal water should be applied. the material as it leaves the n giving good dust control ‘The rubber strip curtains on the entrance and exit of an enclosed chute may also be sprayed lightly with water to help contain the dust. Water sprays may be achieved by using a simple pipe wi «d holes positioned across the conveyor or head chute but better results are obtained by using propi pression nozzles. These are available from a umber of manufacturers and should have apertures not less than 1.6mm diameter to minimise blockage by foreign ‘matter in the water supply and should be of the type designed to give a full cone spray. nozzle, or cluster of nozzles for the greater volume of water -gligible amount of water ig the load on the approaching belt, @ centrally positioned single spr: i's, will give a solid cone of spray covering a circular area on the belt the load depth in the centre of the troughed belt. Correctly positioned, a at the belt edges. ‘A similar solid-cone spray directed centrally on to the discharging material in the head chute will apply the greater volume of water on to the greater depth of material and avoid overspray on to the chute. ‘Water feed pipes to the spray equipment are usually 12mm bore with feed taken from the mains water supply oF from pumped high pressure water mains when these are available. The pressure at the nozzles and hence the volume of water delivered is usually controlled by a stop valve in the supply pipe prior to the auto-control valve. Most nozzles are designed to give a 90° spray cone but adjustable nozzles are available, some with shut-off facilities, some being fitted with filters to prevent blockage and others with sediment dispersal features. ‘The volume of water required to control dust make is usually in the order of ¥2gpm to 2gpm but will vary nature and quantity of material being handled. Typically, when handling coal (bulk density 0.8 Te/m* ) only 2% moisture may be added to the load stream at any one location but over the total conveying system some 2% ~ 3% by weight may be added to suppress dust. 13.3 Dust Extraction “The object of conveying plant is funda may require dust control if the operation ‘effects on the environment. Correctly applied dust control equipment system, as well as achieving a high degree of environmental protection, ing moved from A to B and the system ‘without any detrimental benefits to the operating 2 Oe el rt ee oe et ea hak ei eke lek ek lek lea ek lee le OeIn the case of belt conveying, good dust control will avoid unnecessary wastage of the product being handled, provide protection for the a risk, as well as ensurit clean environment. An efficient, correctly sized dust contr: f a conveying system wil important that the correct type and size of equipment is selected for the particular application involved. tion can have serious detrimental effects on the system. The object is always to provide good control ithout entraining large quantities of material into the control system. The ideal system would provide good dust control without any removal of dust from the conveying system. The obj control’ not ‘extract’ the dust. Any conveyor system will have a number of dust creation points which may require dust control if a clean and efficient system is to be achieved. Each potential dust creating point in the system should be considered separately and the correct amount of control air should be determined for each of these points, bearing in mind the type and the quantity of material being handled, lll points should be enclosed as much as possible to reduce to the enclosures are not good, the amount of control air must be increased signifien this will add to the cost of operating the pla Fig. 58 shows a typical arrangement for dust control on a transfer poi transfer points, itis essential that the whole transfer point is completely enclose: is enclosure extends at least two metres along the ig belt and three metres along the outgoing and outlet apertures for the conveyor belts should be kept as small as possible and the use of rubber curtaining cut to the approximate maximum material profile will help considerably to ensure good dust control as, indicated above. between two belt conveyors. At conveyor Top Connection Volume exhausted Bottom Connection Volume exhaused 2,700 m*/hr per metre width of Belt. If product load very heavy or fall of ca material is in excess of t 3m. Fig. 58. Conveyor Transfer Point The best place to exhaust from one of these conveyor trafsfer points is at the top, as shown on Fig. $8 and an exhaust volume of 2770m°Vhr per metre of belt width is an average guide value. Where t than three metres, a secondary connection should be added at the top connection. If the material throughput is excessively values should be used and discussion Having considered each of the dust creation points on a conveyor system and determined the quant air required at each point a decision must then be made concerning the type of cont ‘The conventional method of handling the total cont points by means of a ducting system to a single plant filter (as shown in Fig. 59). This filter would then handle the total dust extracted from the conveying system and feed it back into the system at a convenient point, typically by i serew conveyor or a combined mechanical handling system.Fig. 59. Large Central Plant Filter Although many systems have th central plant type dust control, the introduction of the Insertable Filter has considerably revolutionised and fa ied the application of dust cont ‘The Insertable Filter is a caseless version of the reverse jet clea which can be supplied either with or ‘without an integral fan. Fig. 60 shows a typical fan-assisted Insertable The principle of using an Insertable Filter is 1 source so that the filter can control the dust gener some method of returning the dust back into the pl all, as it never leaves the enclosure. The use of thi and is usually more of an economic solution than. close proximity. type of filter has many advantages over the cen ye central type unless there are a large number Fig. 61 shows how an Insertable Filter can be mounted into an enclosure around a conveyor transfer point. The If the material is dropping more than three 1m of the drop along the outgoing belt. tors, horizontal conveyors, vibratory screens and storage silos. Itis ‘a complete mechanical handling plant by the sole use of Insertable Filters which means that no ducting is required and none of the produce is removed from the system, 84process will involve the consi density of the dust, the amo ir Volume divided by filter cloth area for reverse jet filters for of between 1.2 and 2 Smimi is added as an afterthought. Good quality and adequately sized equipment should always be used and the temptation to apply juipment should be resisted, as inadequate dust control can be an ongoing 8514.0 CONTROL VALVES AND FLOW DIVERSION The application of chutework frequently involves the use of control valves and other flow diversion devices to divert the flow or switch from one chute leg to another. In assessing the m operating requirements for the plant — whether the flow is to be redirected the changeover can be made during plant shutdown, 14.1 Flap Valve — Vertical Chute ‘The most usual and tr: chutework to diver nal arrangement is to employ a “lap valve’ mounted in a vertical square section of 1m one chute leg into a second. Alternatively, a number of flap valves may be used in into a number of chute legs. Fig. 62 shows typical 2:Way Che Mey Chute Fig. 62. Typical Arrangement of Vertical Chute Flap Valves the valve may have to withstand and be turned over against considerable impact fed on a cross shaft passing through the chute walls and supported in plain or i fitted with an external lever arm to actuate the change-over either manually or by rk. Many designs incorporate a square section te can be through-bolted to the shaft within the chutework leplate of the chute. 14.2. Flap Valve — Inclined Chute Change-over flap valves may also be used within sections of rectangular chutework see Fig. 63. In this reduced and the change-over actuation can usually be ioving edge of the valve. The construction must ensure close fitting of the valve edge against ty of jamming. Care must be taken to ensure adequate valley angles at the Fig. 63. Typical Arrangement for Inclined Chute Flap Valve a714.3 Flow Splitting Fiap valves may be used to split the fow between two chute legs by positioning and retaining the valve part-way between its two extremities. When applying this in a vertical chute section, the valve flap should be orientated to divide the major flow path, e.g. see Fig. 64 when the valve is used beneath a conveyor discharge pulley. aD ‘Sle acre the tow eet aot te fom sath ae oy Fig. 64. Splitting the Flow Beneath Discharge Pulley 14.4 Doors ‘Asan alternative to the inclined flap valve shown in Fig. 63 when the requirement is to achieve total flow diversion, a hinged door can sometimes be arranged in the chute bottom. This may be made to lift up or to lower down to enable the material flow to drop through the chute bottom on to a second chute beneath the aperture. This method however is likely to suffer from trapping of the flow unless the change-over is made during a period of fiow stoppage. 14.5 Flow Diversion — Heavy Duty Where heavy duty applications prove too onerous ores, the use of a ‘breeches chute” may offer a s heaviest requirements. Fig. 65 (a) shows the prin might be moved across to divert the material flow 1¢ use of simple flap valves, e.g. in handling large sized heavy native which can be robustly constructed to suit the the ‘breeches chute’ mounted on track wheels so that it the second chute leg. ‘The principle is applied also at rail loading stations where the breeches-chute is used to bridge between wagons to enable continuous loading into wagons from a conveyor system An alternative device for heavy duty appli n loading of heavy ores un ble in many heavy duty chute appl the simple flap valve. ns is provided by a ‘turn-over’ valve. The method was developed 1¢ trade name ‘Ross Rail Loading Valve’ but the principle may be ns where dimensions or robustness are required beyond the scope of ‘The arrangement of the turn-over valve is shown in Fig. 65 (b), the valve plate being mounted symmetrically about a central operating shaft enabling the unit to be built very robustly and reducing the operating torque required to change over the flow. Hh Nae (KS Vit ryt Merit Fig. 65. Heavy Duty Flow-Diversion Methods annnnanaeanaannenaananeannnanaennnrkrienannnannnhnnnTWIN FEED 24 METRES. TOTAL HEIGHT DIVERTER CHUTE BIFURCATED CHUTE SCREEN DIVERTER, BLFURCATED Fig. 66. Part of a Typical Power Station Diverter Chute System 89 14.6 Diverter Chutes ‘There are a number of specialist chute manufacturers who supply very sophisticated chute arrangements based on curved ‘U’ form chutes incorporating hinged diverter sections designed so that the whole leg of a chute section can swing into a new direction to divert the flow. Fig. 66 shows a complex arrangement of this type. # 5 3 y 5 514.7 Radial Chutes One frequently used example of chute diversion is the use ofa simple radial chute or rotating spout. The radia chute {Soften used for spreading the feed into a hopper or for distribution in ship loading operations, The radial chute in ortet alco for flow diversion in chutework systems, see Fig. 67. Note that switching between chutes 1 & 2.can be oe de uit the load stream is flowing, also switching between chutes 2 & 3 but switching between chutes 1 & 3.can only be made when the flow is stopped unless some overflow into chute 2 is tolerable adit Chute Puan view Fig. 67. Typical Arrangement of Radial Chute15.0 SAFETY CONSIDERATIONS plant for which the rion and the size and requirements yeing handled. lowing check list is given as a reminder of the safety considerations to be kept in mind: ly hazardous? Wil ive or toxie dust aj create an exp! which special 2. Is the mater likely to pose a danger to personnel by way of i Must access be restricted? /olume, velocity, density and lump sizes 3. Does the transfer chute need to be enclosed to contain the material stream, to contain dust and/or to prevent access by personnel?” 4. Is the chute inlet adequately guarded to prevent inadvertent entry by personnel? 5. Are the conveyor nip-points suitably guarded or enclosed at the discharge pulley into the chute and at the receiving conveyor? 6. Does the design incorporate fixed grid bars at insp« 7. Does the design include step-bars and hand-grips to normal height from walkways? 8. Is the chute lip at the discharge pulley suitably located and/or fitted with a sealing strip to prevent belt damage from trapped particles of material? jon apertures to prevent entry? tate access to inspection doors which are located above 9. Does the chute require monitoring equipment such as chute-blockage probe or switch? a116.0 IN CONCLUSION ‘The study covered by this manual may have raised more questions than it has answered. There is a general lack of published information on many of the aspects covered and the design of chutes remains very much an art based on ‘experience rather than a precise science. In pursuing the study, the one major question which arises is ‘at what inclination should the chute valley angle be made to ensure satisfactory flow?” Better understanding of chutes inclined at an an; against a contact surface implies that should ensure flow, but designers at slope angles of this order, even the most free flowing products. Fine materials at the side and above the main flow stream can adhere to chute walls and corners unswept by the main moving bed and the scouring effect of coarser fractions whilst impact adhesion and the build-up of boundary stream fines can also take place at changes of direction or at entry zones when particles of the bulk exhibit surface cohesive properties. Section 2.0 indicates the parameters which dictate the effective wall friction angle for materials against a contact surface. The effect of surface cohesion is often the most difficult factor to determine and may well be influenced to a considerable degree by time consolidation of the product against the chute surface during stop periods in the plant operation. It will be seen from Table 6 in Section 3.0 that the wall friction angle for Iron Ore against a steel surface is in the order of 27° excluding the effect of surface cohesion, After cons mn, and taking surface cohesion ‘account, the effective wall friction angle may increase to 45°. An accurate assessment of the effe ‘worst condition of operation is clearly one of the most important elements in predicting the ination. Fine damp coals are known to be pa where they are not swept by the flow st cchutework is specified in power stati reducing to 60° wher “U'-form chutes in built with a minimu said to be appropriate whi sometimes adopted in situations where mat ly cohesive and are known to adhere even to vertical steel surfaces Based on past experience in hand t bottom imum chute slope of ye horizontal — possibly al. Corners incorporate id steel handling similar material where the impact of material at entry is minimised may be alley angle of 50°. For other less cohesive materials, ‘U'-form chutes with valley angle 45° are for run-of-mine coal containing a mixture of smalls and lumps a minimum valley angle is unlikely to lie in the chute and become consolidated. Atentry to the chute, the material :pproach the chute surface at an impact angle. Section 10. ‘an appraisal of the reduction in flow veloci is location and .¢ apparent that the greater the impact at the greater will be the disruption to the flow pattern. Addit necessary in order to accelerate the material away from should be ‘smooth entry oF ‘measure of opinion suggests thi ide upon itself at entry to the chute and 1 chute should be made somewhat in excess of the internal friction angle of the mates indicates the internal friction angles of various materials by comparison with their ble 6 in Section 3.0 ‘ion angles. Adopting the low-friction ternal friction angle as a measure of chute slope requirements tends to ignore the benefit of ‘but may be appropriate at the chute entry zone. ‘There is litle doubt that reduction of impact at chute entry will assist both the flow and wear situation, as will ‘minimising any bends, turns, deviations or interruptions in the flow pattern of the material along the chute. Impact angles less than 20° will keep wear rates down with all Iining materials and will help to ensure that is swept by the flow stream. ‘U'-form curved chutes of smoothly changing profile may offer the best opportu direct the flow without interruption at moderate throughputs. Whilst the analysis of flow velocity at ch ‘evident that flow velocity along the chut material entry given under Section 10.3.5 may over simplify the situation, is a function of the impact angle and of the wall friction angle of the I flow down the chute ~ or For non-cohesive materials, if is the dynamic wall friction angle at which material n 10.3.5 that 90° @ is the will continue to flow down the chute ~ when the impact ang llows from Sect impact angle at which the velocity down the chute will be zero, 2 annnnaninnnninnannnnnnnnannnnnannannnn nhFig. 68 (a) illustrates the situation assuming that a v« away from the impact zone under gravity when the it chute slope, the minimum inclination of the chute, ® + a, where is the impact angle. is equal to the wi the same principle is applied between the limits and extended above the upper ion angle O = 25°, ‘based on a typical 1 Tye Range for Wa Fron Angle 25° ‘fg. 68. Proposed Chute Inclination at Entry ‘The principle shown in Fig, 68 (b) appears to have some logic in ident ing appropriate chute angles at the entry zone but will need confirmation and adaptation to cover cohesive m: Fine materials and powders are particularly difficllt to handle. Apart from variations which may occur in the basic product there may also be variations in the environment of the chute to influence surface slip. Temperature changes can give rise to condensation on a metal surface in the short term wl contamination with another product, local oil or grease spots or other foreign material may giv resist slip. corrosion or patches which yin line is beneficial in minimising side wall drag of the cakes or cohesive powders. A technique for dispersing material into a wide even stream is to form the chute surface with a convex curv 1e mate ing down a section of a shallow cone. This is useful in such cases as feeding fine solids into a avoid the globular encapsulation of agglomerated powder in lumps which may prove subsequently difficult to mix or dissolve. The use of vibrators on chutes should be considered with some care. Normally applied oscil the contact pressure and encourage the flow of granular materials but tend to cause the ad fines. ions tend to fluctuate rice and settlement of ‘Transverse vib generally tends to stimulate relative motion betwee: nthe ‘return’ stroke and thereafter mai Vibration should not be applied if the mat not be applied to ‘flooded’ chutes. 3