Is Upgrading to a Wider Conveyor Belt Worth the Investment?

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Discussion Overview

The discussion revolves around evaluating the feasibility and potential output of upgrading a conveyor belt system. Participants explore the calculations needed to determine the maximum possible throughput in tonnes per hour (T p/hr) when transitioning from a narrower to a wider conveyor belt and idler pulley, while considering factors such as incline angle, motor power, and material properties.

Discussion Character

  • Technical explanation
  • Mathematical reasoning
  • Debate/contested

Main Points Raised

  • One participant seeks to calculate the maximum output in T p/hr based on the dimensions and specifications of the conveyor system, including the current and upgraded motor power.
  • Another participant suggests that the rate of material mass flow is influenced by the height difference and conveyor velocity, referencing kinetic and potential energy equations.
  • A participant proposes a formula for T p/hr that incorporates cross-sectional area, belt speed, material density, and the incline angle, but expresses uncertainty about calculating the cross-sectional area with the given idler trough angle.
  • Concerns are raised about the importance of potential energy and kinetic energy in the calculations, questioning the omission of gravitational acceleration in the proposed equations.
  • One participant calculates the height change based on the incline angle and length of the conveyor, emphasizing the need for motor RPM to determine belt speed.

Areas of Agreement / Disagreement

Participants express differing views on the significance of various factors in the calculations, such as the role of geometry, energy considerations, and the necessity of specific parameters. No consensus is reached on the correct approach or formula for determining T p/hr.

Contextual Notes

Participants highlight the complexity of the calculations, including dependencies on assumptions about material properties, motor specifications, and conveyor geometry. Some steps in the mathematical reasoning remain unresolved, particularly regarding the calculation of cross-sectional area and the determination of belt speed.

Who May Find This Useful

Individuals involved in conveyor system design, material handling, or engineering applications related to throughput calculations may find this discussion relevant.

Volantis92
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Hey guys,

some insight to the following problem I have here would be helpful.
I need to see if a conveyor is worth upgraded (i.e. see what the output Tonne/per hour is) from a belt 745mm wide, idler pulley 800mm wide... to a 800mm belt and 850mm wide idler pulley.
Lets assume the length of the conveyor is 17m

I have a conveyor with 3 idlers on an angle of 45 deg, and assuming an angle of repose of 25 deg.
currently there is a 18KW motor on there, and let's assume the idler pulley barrel is 300mm. I want to upgrade to a 30KW motor.

How do I go about working out the max possible T p/hr?

i assume i need the speed of the motor, get velocity. Find the volume of the material over the conveyor length?

Any help is appreciated.

Cheers
 
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The rate of material mass flow will be determined by height difference? and conveyor velocity.

Material falling onto the conveyor must be accelerated to the conveyor velocity. KE = ½∙m∙v²

The change in height will require (or release) potential energy proportional to; PE = m∙g∙h
 
Thanks for that mate,

So assuming I have incline angle of 15 deg. my equation would be:
T p/hr = 3.6 * (cross sectional area of trough) * (belt speed m/s) * (material density) * Cos(15)?

Only problem I have is getting an accurate calc for the cross sectional area of the trough.
How would I do that with idler trough angle of 45 deg
Belt 745 mm
angle of repose for material = 25 deg

cheers
 
You are confusing yourself by your fixation on the geometry of the conveyor and the density of the material.
Volantis92 said:
So assuming I have incline angle of 15 deg. my equation would be:
T p/hr = 3.6 * (cross sectional area of trough) * (belt speed m/s) * (material density) * Cos(15)?
What is the coefficient 3.6 ?
Where is the acceleration g = 9.8 needed to work out the change in potential energy?

Product has a change of height, the potential energy must be provided. That height change is a fixed critical parameter.
Product must be accelerated to belt speed, that kinetic energy is not recovered. Belt speed is a critical variable.
 
Length = 17 m. Incline = 15 deg.
Height change, h = 17 * Sin( 15 ) = 4.4 m.

Material flow of 1 kg will require energy, E = KE + PE.
KE = 1/2 * 1kg * v2
PE = 1kg * 9.8 * h
E per kg = ( 1/2 * v2 ) + ( 9.8 * h )

But belt speed, v, is unknown, we still need to know motor RPM.
 

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