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Whitepaper: Advances in Conveyor Technology

Whitepaper: Advances in Conveyor Technology
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Whitepaper: Advances in Conveyor Technology - 1

Advances in Conveyor Technology Written by: Simon Shipp, President BEUMER Kansas City, LLC Introduction The modern industrial process plant is often more sophisticated than the bulk transport method connecting it to its raw materials. Advances in overland conveyor technology have improved efficiency, capital and operating costs, and made the conveying process more environmentally friendly and sustainable. This makes overland conveying considerably more attractive and economically feasible versus trucking. The belt conveyor is the most reliable and proven method to transfer bulk materials long distances at a low cost per ton. The cost per ton is really not a consideration for short in plant conveyors moving materials short distances. These short in-plant conveyors, if properly designed, can run for years with little maintenance or repair and the cost per ton is usually not a consideration. Some sophisticated operations move bulk materials long distances which demand a level of control, flexibility and environmental management that significantly exceeds the capabilities of the standard in-plant belt conveyor. Today technology exists that enables belt conveyors to transfer difficult materials in a totally enclosed manner which provides low operating costs per ton, environmental protection, routing flexibility and reliability that outclass not only the traditional belt but also, all transfer formats including trucking. Distance, route and material are no longer an obstacle to this application. Materials can be transferred spillage free in both directions adding a level of flexibility unimaginable in the past. The two most flexible types of overland conveyors are the pipe conveyor and curved trough conveyor. The advantages of both types are discussed in the following pages. In general the overland curved trough conveyor can carry a higher capacity of material than the pipe conveyor but the pipe conveyor can turn corners with shorter radii. Both have their place in the overland conveying of bulk solids and both can save civil costs of installation and reduce the operating costs when compared to trucking.

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Whitepaper: Advances in Conveyor Technology - 2

Adva nce s in Conv ey or Technolog y The Limitations of Existing Belt Conveyors A modern belt conveyor has the ability to handle a range of bulk materials that behave in a certain way. As the material becomes more fluid in behavior or contains more moisture the standard belt conveyor becomes less applicable. The ability to mitigate dusting at feed points, during transfer and at the discharge point with conventional conveyors is problematic. Unavoidably, the nature of the design means that with some materials you run the risk of blowing dust and spillage impacting the environment. Straight...

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Whitepaper: Advances in Conveyor Technology - 3

Adva nce s in Conv ey or Technolog y Belt conveyors providing interplant transfer as shown in the system at right are highly viable and often employed successfully across multiple industries. The limitations of the traditional belt conveyor really start to show over increasing distances as changing topography creates more difficult and costly elevated sections of conveyor. Creating long straight conveyor runs over distance is simply more problematic and expensive. Frequently the decision to avoid belt conveyors entirely is made and the easier solution of trucking is taken. But often this...

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Whitepaper: Advances in Conveyor Technology - 4

Adva nce s in Conv ey or Technolog y Trucking vs Conveying Model There are a number of good models to predict trucking cost per ton but most operators know their trucking costs. They either use company owned trucks or they contract out the trucking. Today there is a move toward complete contracted trucking where the trucking company makes the investment in the trucks and takes the accelerated tax depreciation benefits. To the operating company the investment becomes part of their operating cost per ton. But trucking is inherently less efficient than conveying due to the amount of labor...

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Whitepaper: Advances in Conveyor Technology - 5

Adva nce s in Conv ey or Technolog y Introduction to Advanced Overland Belt Conveying Systems Overland Conveyor systems Modern systems can be fully enclosed and overcome significant topographical obstacles including steep elevations. Now it is easy to handle materials too difficult for traditional conveyors. Conveying can replace fleets of noisy, environmentally harmful trucks and eliminate the impossible new routes with tough topographical challenges. eliminate the restrictions commonly found with the traditional straight belt conveyor design. The technology options allow miles of...

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Whitepaper: Advances in Conveyor Technology - 6

Adva nce s in Conv ey or Technolog y Application Case Studies Typically, the combination of route, material and process requirement determines which conveyor type is most applicable. The following case studies show the range and typical applications of both conveyor types. Case Study: Sichuan Province China Long Distance Horizontal Curved Trough Belt Conveyor in China The application case study looks at a long distance curved trough belt conveyor installed in a mountainous region of Sichuan Province in China. The conveyor has to navigate multiple incline and decline sections as it maneuvers...

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Whitepaper: Advances in Conveyor Technology - 7

Adva nce s in Conv ey or Technolog y System Owner Sichuan Yadong Cement Application Limestone from Quarry to Plant Location Sichuan Province China Conveying Distance 12.4km single belt with no transfer points Topography Description Mountainous region with multiple horizontal and vertical curves Conveying Rate Raised with successive upgrades to 2100tph View from the highest point on the route. Installed Power 3000kw Notes A second conveyor is in engineering and will go into construction soon to link the first one to the nearby shipping terminal over more than 14km distance View from curves 7...

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Whitepaper: Advances in Conveyor Technology - 8

Adva nce s in Conv ey or Technolog y Case Study: Ghent Kentucky Long Distance Pipe Conveyor Moving Ash to a Dry Landfill The application case study looks at a long distance pipe conveyor installed within the plant boundary of a major US power generator. This pipe conveyor transfers gypsum, fly ash and bottom ash from the plant to a new landfill location for safe disposal. The pipe conveyor adapts to the distance and overcomes topographical and environmental performance requirements impossible with conventional conveyors. Some of the curves require short radius bends which would be...

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