The Pipe Conveyor Belt, during the last decade has revolutionized the way bulk materials that are handled and transported, by adopting an Enclosed Material Transfer Principle.With an over riding stress on maintaining a clean environment and the need for higher flexibility in routing in arduous and difficult terrains, the solution lies in carrying the material by Pipe Conveyor Belts.
The Pipe Conveyor Belt assumes the shape of a normal troughed belt during its loading and discharge points but assumes an enclosed profile in the shape of a pipe during its forward and return runs. With the aid of specially designed idler system, the belt is transformed from a troughed profile to a pipe profile and vice versa.
FORECH make PIPE conveyor belts are most innovative in its design which ensure the optimal performance and reliability protecting the environment from the deleterious effects of noxious pollutants, is cost effective and has the lowest operating cost per tonne of material handled.
The pipe belts are utilized successfully in a wide variety of industries for carrying steel sintered ore, iron ore pellets, cement-limestone and hot-clinker, sized coal (from port to the coal handling plant), lignite, chemicals, fertilizers, quarry, bauxite, copper ore, grains, chemicals and petcoke.
The environment is adequately protected against the toxic hazards of pollution.
The material being carried is protected against rain, dust, abnormal temperature fluctuations and wind.
The wastage and spillage is greatly eliminated resulting in low maintenance and operating costs.
The levels of noise emission are reduced.
The total length of conveyor is significantly reduced by elimination of transfer points in a narrow terrain and the combination of multiple conveyors to one.
The belt can negotiate vertical, horizontal and 3-dimensional curves with sharp radii.
The structural cost is greatly reduced by eliminating the canopy on top of the conveyor structure.
Material can be conveyed at inclinations upto 35 degrees without carry back.
Constraint of space is overcomed to a great extent.
Forech has perfected the technology of supplying steel cord reinforced pipe conveyor belts and synthetic fabric reinforced pipe conveyor belts upto a maximum width of 2500mm which translates to an inner diameter of 700mm with adequate overlap. Various combinations are available depending on conveying path configurations.
Steel Cords are designed, open type and zinc coated. The fabric can either by Nylon (NN) or Polyester (EP) which is manufactured with a special weave according to the application.
Forech can manufacture Pipe Belts with all types of cover grades- General Purpose, Fire Resistant, Heat Resistant, Oil Resistant, Fire Resistant - Oil Resistant conforming to IS, DIN, AS, SANS, ISO and Canadian Standards. Both Bottom and Top covers are also Ozone Resistant. Forech recommends LRR (Low Rolling Resistance) covers on the bottom.
Standard hot vulcanising technique is recommended for Forech Pipe Conveyor Belts with Forech make Splicing kits under Forech's supervision by Splicing experts.
To ensure that the customer gets a perfect pipe conveyor belt, a sample with the ordered specification is manufactured first and subjected to all routine tests that are valid for a troughed belt. Apart from the above, specific tests relevant to the satisfactory operation of a pipe belt are conducted as follows:
|d/D Test||where "d" is the diameter of the pipe in Y plane and "D" is the diameter of the pipe in the X plane. Also known as the aspect ratio test. The ratio should be within a prescribed limit with the addition of longitudinal incremental load. This test checks the design of the belt with respect to its circularity.|
|Six Idler Test||Electronically reads and records the lateral and vector forces on the six idler. Checks the stiffness of the belt and provides a fair indication of whether excess power would be drawn from the drive motor while in operation.|
|Fatigue Testing Machine||A sample of the belt is subjected to a maximum number of 1,00,000 cycles of opening and closing operation. The troughability is subsequently measured to ensure that it lies within a specified value. The difference of troughability value between each roll is also measured and kept to a minimum value to maintain consistency. A typical troughability value for a ST Pipe belt is 0.35+/-0.03.|
|Nominal Pipe Diameter (mm)||Belt Width (mm)||Conveyed quantity (m3/hr) @ 1m/sec at 75% fill factor||Conveyed quantity (m3/hr) @ 1m/sec at 60% fill factor||Maximum Lump Size (mm)|
Important Aspects of a Pipe Conveyor Belt
1. In transition distance near head pulley, the belt transforms from a pipe shape to troughed shape In case the belt is badly deformed the edge of the belt dips into the material being transported and causes spillage when it opens up at head pulley. A high rigidity belt is an option that can be examined.
2. Often a pipe belt can twist while in operation. The belt edge overlap near 12o' clock position is important to be studied and idler arrangement has to be fine tuned to prevent twisting.
3. Quite often the pipe belt draws excessive power. The transverse stiffness of the belt has to be examined and rationalised. Now a days VFD (Variable Frequency Drives) are used alongwith the drive motors in a pipe belt circuit to reduce the power drawn.
4. A Pipe belt consumes more power compared to a troughed belt due to its indentation rolling resistance against 6idlers. The indentation rolling resistance is caused due to the hysteresis energy loss of the visco elastic deformation of the belt bottom cover. A Low Rolling Resistance (LRR) belt whose recipe Forech has developed and perfected gives a lower hysteresis energy loss compared to a conventional belt bottom cover A LRR cover therefore draws less power than a normal cover.
5. Theoretically buckling of a pipe belt occurs when a certain degree of negative tension is generated. The alignment of the belt and the placement of idlers have to be fine tuned to avoid occurence of negative tension.