CHAPTER THREE

3. CONVEYORS
3.1. Definition
Conveyors are gravity or powered equipment commonly used for moving bulk or unit load continuously or
intermittently, unidirectionally from one point to another over fixed path, where the primary function is
conveying of the material by the help of movement of some parts/components of the equipment. The
equipment as a whole does not move.

3.2. Classification of Conveyors

Different classes of conveyors forming the conveyor group is by far the most frequently used materials handling
equipment primarily for conveying bulk materials in process industries and also for conveying certain types of
unit loads in large quantities.

3.3. Belt Conveyor

3.3.1. Definition / Description
A belt conveyor consists of an endless flat and flexible belt of sufficient strength, made of fabric, rubber, plastic,
leather or metal, which is laid over two metallic flat pulleys at two ends, and driven in one direction by driving
one of the two end pulleys. Material is placed on this moving belt for transportation. The active half of the belt
is supported by idler rollers or slider bed. The return half of the belt may or may not be supported, as it generally
does not carry any additional load other than its own weight. The endless belt is kept taught by a belt tensioning
arrangement.

3.3.2. General Characteristics

(i) Belt conveyors operate in one vertical plane, horizontally or with an inclination (up or down) depending on
the frictional property of the load conveyed.
(ii) For changing direction of the materials being conveyed, in the horizontal plane, more than one belt conveyors
are needed.
(iii) Conveying capacity of a conveyor can be controlled by changing belt speed.
(iv) Belt conveyors are generally employed for continuous flow of materials.
(v) Metal/special belts can carry hot, abrasive or reactive materials.

3.3.3.Types of Belt Conveyors

(a) Flat Belt Conveyor: In this conveyor, the active side of belt remains flat supported by cylindrical rollers or
flat slider bed. The conveyor is generally short in length and suitable for conveying unit loads like crates,
boxes, packages, bundles etc. in manufacturing, ship-ping, warehousing and assembly operations. Flat belts
are conveniently used for conveying parts between workstations or in an assembly line in mass production
of goods. Fig. 3.3-1 shows a flat conveyor

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 Figure 3.3-1: A Flat Belt Conveyor With drive Control

(b) Troughed Belt Conveyor: In this conveyor, comparatively wide flat belt is supported on troughed carrying
rollers or shaped supporting surface so that the two edges of the active side of the belt are elevated from the
middle part to form a trough. This provides a greater carrying capacity than a flat belt of equal width for
conveying bulk materials or those materials which would slide off flat belts. These conveyors are used in
handling bulk materials of different classes. The return side of the belt is generally kept flat supported on
cylindrical rollers.
The troughed conveyors which are used within a plant for moving bulk materials from one point to another, are
generally termed as ‘‘normal’’ or ‘‘transfer’’ conveyors. These are comparatively of shorter lengths, and path of
movements are in straight line in a horizontal or an inclined plane. The stresses in the belts being within limits of
cotton fabric belts.
However, troughed belt conveyors are often used for transportation of bulk materials over long distances, by
means of a series of conveyors, over paths that are combination of in-clines, declines and horizontal sections,
following the natural contours of the ground. These are generally termed ‘‘long-center’’ conveyors. There is no
clear demarcation between a normal or long-center conveyor. Long center conveyors are those where belt tension
is high warranting use of high tension quality belts with less belt stretch, and low acceleration through gradual
starting controls for the drive. By using a number of conveyors in series, it is possible to change the direction of
materials movement at the junction of two conveyors, called ‘‘transfer terminal’’.
Long-center conveyors are used for jobs like:
i. Transportation of the output of mines to the processing plants,
ii. materials from shipping ports to the storage/transport loading sites,
iii. materials from outdoor storage yards to inside plants,
iv. movement of materials between plants etc.
(c) Closed Belt Conveyor: In a closed belt conveyor, the specially fabricated belt, after being loaded with the
material, can be wrapped completely around the load. It essentially forms a closed tube moving along with the
material. The advantages of a closed belt conveyor are:
(i) it can handle fragile materials safely and without breaking by reducing inter particle collision,
(ii) it can handle fine bulk materials without being swept by air (however, it is not really air tight at loading and
unloading points),
(iii) ability to handle corrosive and reactive materials without contamination and

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(iv) the tubed belt can travel around bends in more than one plane and hence versatile in layout
The lengths of these conveyors are generally limited. Different designs of closed belts have been manufactured
and used in different countries. In the following Fig. 3.3- 2, a type called Zipper Conveyor. The other figure
shows how the belt is closed after it is filled up at its flat configuration. Different designs for closing two ends
of the belt have been developed by different manufacturers.

Spout

Flexible

Ribber Belt Zipper Teeth Side Walls

Stages of belt being loaded and closed

Figure 3.3-2: Endless Zipper Belt

Figure 3.3-3: Spreading, filling, and locking of a closed Conveyor

(d) Metallic Belt Conveyor: This is a flat belt conveyor where the flexible belt is replaced by a cold rolled
carbon or stainless steel strip belt of thickness from 0.6 mm to 1.2 mm. The ends of the steel strip are lap joint
riveted with a single row of special wide flat head rivets. A steel belt runs flat on cylindrical idlers or runs
troughed on resilient idlers (made by suitable length of springs). Apart from all rolled strip steel belts, wire-
mesh, belts of different designs have been used. The entire length is made up of short length sections. One of the
designs is made up of flat wire spiral sections, shown in Fig.3.3- 4. The wire-mesh belts are more flexible and
the design considerations are similar to a rubberized textile belt conveyors.
Metallic strip belt conveyors are used in food, chemical industry and for conveying hot and reactive loads. Wire-
mesh belts are being widely used to handle unit and lump materials through furnaces (up to 1000°C temperature),
as mobile base for baking industry and also for wetting, cooling, dehydrating and similar operations.

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(e) Portable Conveyor: Short length flat conveyors carried on a wheeled structure is termed portable conveyor. These
are particularly useful for loading and unloading of trucks / trans-port vehicles. The inclination of the conveyor can
generally be adjusted to suit application.
Apart from above mentioned major types of belt conveyors, there are a few special types worth mentioning.
These are:
(f) Chain or Rope Driven Belt Conveyor: In which the specially designed belt is driven by a moving chain or
rope, where belt only serves as load carrier, and motion is by a chain or rope conveyor (refer section 3.2).
(g) Submerged Belt Conveyor: In which a portion of the belt moves through a metallic trough (casing) which
is filled with free flowing, powdered material at the loading end. The moving belt with holes, makes the material
flow to the unloading end of the trough. Fig. 3.3- 4 shows a line drawing of a submerged belt conveyor.
Loading

Unloading
Figure 3.3-4: Atypical submerged belt conveyor
3.3.4. Parts of a Belt Conveyor
(a) Conveyor Belts: Belt, which supports and conveys the load, is the essential and most important component
of any belt conveyor. Most common type of conveyor belting is rubber/plastics covered textile belting - the
internal carcass of woven fabric gives the longitudinal strength of pulling the loaded belt and transverse strength
for supporting the load, and the cover of rubber and/or plastics protects the carcass from damage. Specification,
requirements and testing procedures of rubber/plastics, covered textile belting for conveyor (and elevator) has
been given in IS 1891:1994, part I to V. Part I covers the ‘‘general purpose belting’’ while the subsequent parts
cover ‘‘heat resistant belting’’, ‘‘oil resistant belting’’, ‘‘hygienic belting’’ and ‘‘fire resistant belting for surface
application’’ respectively.
Belt Construction: Cotton fabric ply constructed rubber covered belting is the mostly used belt for flat and
troughed conveyor. The carcass consists of one or more plies of woven fabric or of solid woven fabric
impregnated with a rubber or plastic mix, which after vulcanization binds the plies together. The fabric used is
made of threads of cotton or polyamide or any other synthetic material or combination thereof, evenly and firmly
woven. The carcass is covered by special wear and impact resisting rubber compounds / plastics. For the

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protection of the carcass, layer or layers of open-mesh or cord fabric, termed as ‘‘breaker’’ may be placed
between the cover and the carcass, or may be embedded in the cover. Number of fabric plies varies from 3 for
shorter belt widths (300mm and above) to a maximum of 12 to 14 plies for belt width of 2000mm. Number of
plies can vary within a range for a specific belt width. Steel cord belting is used when good troughability, high
operating tensile strength and small elongation are desired. Fig 3.3- 5 shows a typical belt cross section.

Covers Carcass

Figure 3.3-5: Construction of Textile belt

Belt Covers: The primary purpose of the cover is to protect the belt carcass against dam-age. The requirements
of the cover is to work satisfactorily in contact with the materials to be carried by the belt. For this purpose,
sufficient thickness (not less than 1.0 mm) of top and bottom surface covers of different rubber compounds and
plastics are used. Covers in the following grades are available:
(i) Grade M24: Natural rubber compound with superior resistance to cutting, gauging and abrasion.
(ii) Grade N17: Compound rubber with high abrasion resistance with inferior cutting and gauging
resistance compared to M24 grade.
(iii) Grade N17 (Synthetic): Composed mainly of synthetic rubber with higher abrasion resistance. Belt made of
carcass with chemical or other superior bonding system should be used for this grade.
(iv) Grade HR: Suitable for handling load at high temperatures, up to 150°C for lumps or 125°C for
powdered materials.
(v) Grade FRAS: Used for underground mining and processes where fire resistance and antistatic charge
properties, are required.
(vi) PVC Grade: Used in fire resistance, oil resistance and hygienic belting.
Belt Designation: As per IS 1891 (Part I): 1994, belts are designated by IS No., grade of the cover, the ‘‘type’’
of belting defined by the full thickness breaking strength in KN/m and number of plies. For example, a conveyor
belt with cover grade N17 and type 250 having 4 plies shall be designated as: Conveyor Belt IS 1891 (Part I)
N17-250/4.
Steel cord belting is designated by prefix ‘‘ST’’ followed by the full thickness breaking strength in KN/m.
Example ST-1800.
Belt Width: Unless otherwise agreed between the manufacturer and buyer, the standard widths of belting as per
IS specification are:
300, 400, 500, 600, 650, 800, 1000, 1200, 1400, 1500, 1600, 1800 and 2000 mm with a tolerance of 5 mm up
to 500mm width and ±1% of belt width for widths higher than 500 mm.

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Belt Splicing: Two ends of a belt may be joined either by metallic belt fasteners or by vulcanization. Metal
fastner joining is easier and acceptable for flat belt conveyors. Vulcanized belt splicing is a superior technique
suitable for troughed belt conveyors. The later is a stepped, lapped splice in which several plies of two ends of
the belt are vulcanized together to make a joint of strength almost equal to the solid belt. Skilled operator and
vulcanizing equipment are necessary for such splicing at conveyor site.
(b) Idlers: The rollers used at certain spacing for supporting the active as well as return side of the belt are called
idlers. Accurately made, rigidly installed and well maintained idlers are vital for smooth and efficient running
of a belt conveyor.
There are two types of idlers used in belt conveyors:
(i) straight carrying and return idlers, which are used for supporting active side of the belt for a flat belt conveyor
and also for supporting the return belt in flat orientation in both flat or troughed belt conveyor

Figure 3.3-6: Three roll idler carrying idler with straight return idler in the same frame, and
photograph shows a set of assembled idlers

(ii) Troughing idler set consisting of 2, 3 or 5 rollers arranged in the form of trough to support the belt in a
troughed belt conveyor. Fig. 3.3- 6 shows sketch and photograph of a 3-roll idler.
Idler construction: Idlers are generally made from steel tubes conforming to IS 9295:1983, uniformly machined
all over at the outer diameter and at the two ends of the inner diameter. The tubes are mounted on antifriction
bearings over a fixed steel spindle. The ends of the spindles are flat machined to standard dimensions for quick
fixing in slots of idler structure. The idlers may be made of heavy steel tubes for severe service condition (like
in material loading section) or cast iron in corrosive application (handling coke etc.).

Idler dimensions: Diameter, length and troughing angle have been standardized by BIS in IS 8598: 1987. The
carrying and return idler diameters in mm are: 63.5, 76.1, 88.9, 101.6, 108, 114.3, 127, 133, 139.7, 152.4, 159, 168.3
and 193.7. The maximum diameter of 219.1mm is used for carrying idler only. These sizes correspond to the available
tube sizes. Selection of roller diameter depends on factors like bulk weight of load in kg per cubic meter, particle size
and belt speed. Higher are these factors, higher is the roller size to be selected. Length of the idlers vary from 100 mm
up to 2200 mm. The smaller lengths are generally made in smaller diameters while longer lengths are made in larger
diameters. Troughed idler sets are made with troughing angle (the angle made by the inclined roller with horizontal)
of 15°, 20°, 25°, 30°, 35°, 40° and 50°. Troughing angle of 15° is applicable only to two roll troughed idlers. The
value of troughing angle of troughed return idlers are selected from 0°, (i.e., straight idler), 10° and 15° for all widths

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of belt. The length of the straight or troughed idler set is based on the selected width of belt, and desirable edge
clearance between belt and roller edges. Table 3.3- 1 shows the recommended edge clearances.
Table 3.3-1: Edge Clearance

Belt Width Edge Clearance

B Flat idler 2-roll idler 3-roll idler

400 50 40 35
500 50 40 40
650 50 50 50
800 75 75 70
1000 75 75 70
1200 to 2000 100 100 100

Idler spacing: Spacing of idlers in the loaded run is a function of bulk weight of materials and width of belt. Selection
of idler spacing has been further discussed in section 3.3.5(e).
(c) Conveyor Pulleys: At each of the two ends of a belt conveyor, one large diameter pulley is installed against
which the belt turns and changes direction. These pulleys are called terminal or bend pulley. Drive is imparted
to the belt through friction by one of the terminal pulleys called drive pulley. As the conveyor belt passes around
these bend pulleys, the plies of the belt are elongated in proportion to the distance of the ply form center of the
pulley. The differential elongation of one ply over the other is taken up by the rubberized bonding between two
plies. Larger the pulley, less is differential elongation between the plies hence less tendency to ply separation.
This is the reason the bend pulleys are made large.
The conveyor pulleys are either fabricated from rolled steel plates or of cast iron construction. The central steel
shaft is keyed into the pulley drum and then the finished dimensions are machined. The pulleys are generally
given a crowning at the face for keeping the belt at the center of the pulley. The face length is generally 100 mm
to 200 mm more than the belt width.
The surface of the pulley may be left bare smooth, or may be covered up to a thickness of 6 to 12 mm by rubber,
polyurethane or ceramic layer with herringbone patterned grooves to increase the friction between the pulley
and belt. The pulleys are mounted on heavy duty antifriction bearings in suitable bearing housings.
(d) Drives for Belt Conveyors: The belt conveyors are generally driven at the head end pulley, where material
is discharged. The drive pulley is connected to the drive motor through suitable speed reduction gear box and
flexible shaft couplings. Drive of an inclined conveyor necessarily includes a braking device which prevents
downward movement of the loaded belt in case of power failure of the motor.
(e) Take-ups or Belt Tensioning Devices: Endless conveyor belt after being threaded through the entire length of the
conveyor need to be tightened so that sufficient frictional force is developed between the drive pulley and the belt, to
make the belt move. Belts working under tension invariably gets elongated with time, which needs to be taken-up to

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maintain the desired tension in the belt. A belt conveyor generally have a screw-type (mechanical) or a gravity-
type counterweighted take-up unit, also termed as belt tensioning device.
In the screw-type take-up, the bearing blocks for the tail end pulley are located in guide ways, so that these may
be moved by rotating two screws as and when belt tension needs to be increased.
In gravity take up, the tail end pulley is mounted on a movable carriage which is pulled backwards along the
length of the conveyor by a vertically hanging counterweight connected through a steel rope and deflecting
pulleys. In an alternate design, the return side of the belt passes by the bottom of a counter-loaded deflector roll
which is free to move down to keep the belt taught.
(f) Loading and unloading devices: Free flowing material may be directly delivered from a hopper, bin or storage
pile through a chute, the delivery rate being controlled by regulating the gate at the hopper / bin output. For no free
flowing materials a suitable feeder unit with a chute is used for loading the material centrally onto the belt as evenly
and gently as possible. Side boards or skirt plates, extending a considerable length (2 to 3 m), is generally attached to
the conveyor structure to be placed centrally to the belt, covering 2/3rd to 3/4th width of the belt, and maintaining a
small clearance with the moving belt.
For unloading of materials at the end of the head pulley, no device is required excepting proper chutes to guide
the discharged materials. For discharging at any point along the length of the conveyor, a plough or a belt tripper
is used. A plough consists of a rubber tipped blade extending across the belt width at an angle of 60°. The plough
may be one-side discharge or a V-shaped blade for two-side discharge. The belt carrying material must be made
flat passing over a slider plate at the plough to allow close contact between the belt and rubber tipped blade.
Plough is pivoted so that its position can be adjusted above the belt to allow control of material being discharged.
A belt tripper is an unloading device which consists of two pulleys, of comparable size of the head pulley,
supported in a fixed or movable frame. One pulley serves to elevate the belt a sufficient height from carrying
rollers to permit a discharge chute to be set under the pulley. The chute receives the entire amount of material
flowing over the pulley and dis-charge it on one or both sides of the conveyor. The belt passes around the second
pulley and beneath the chute, to resume its position on carrying rollers.
(g) Belt Cleaners: For cleaning the outer surface of the belt a wiper or scraper blade is used for dry particles
adhering to the belt. A rotary brush type cleaner is used for wet and sticky materials. To clean the inner surface
of belt, if warranted, a scraper is placed near the end of return run before the tail end pulley.
(h) Training idlers: For various reasons like eccentric loading, sticking of material to belt or idlers etc.,
particularly for a long center conveyor, the belt may tend to move out of center line. To prevent this tendency,
belt training idlers are used which automatically maintain belt alignment.
The belt training idler consists of an ordinary troughed idler which is mounted on its base by pivot shaft about which
it can swivel within a limited angle. Two short vertical rollers, mounted on bearings are fixed at the two ends of the
idler, such that they are perpendicular to the belt edges. The vertical rollers are placed slightly ahead of the idler center
line. When the belt shifts off center, it makes contact with one of the vertical rollers which makes the entire idlers
frame to swivel through an angle. This skewed position of the idler creates a force which tends to bring the belt
back to its central position.

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In a long conveyor, such trainer idlers may be spaced at about 30 meters. Fig. 3.3- 7 shows such a troughed belt
training idler.

Figure 3.3-7: Troughed belt training idlers

To align belt travel, at times, troughed idlers having its side idlers tilted to a small angle not more than 3°, are
used. However, this tilted rollers cause the belt to wear rapidly, hence should be used with caution.
(i) Conveyor structure: The structure supporting the pulleys and idlers consists of suitable sized channel
stringers, with supporting legs to the main structure or floor. For long conveyors, lightweight truss sections are
used that permit longer spans between supporting legs, and economical structural cost. A decking is provided to
allow return run of the belt which also lends lateral rigidity to the structure. For long centre conveyors, sidewalk
ways are provided for inspection and adjustment to idlers. The structures are often covered by tin plate at the top
and sides to protect the materials being conveyed under the sky outside the plant. Fig. 6.1.11 shows photographs
of two long centre conveyors with their covered structures, sidewalks etc.

Figure 3.3-8: Long center conveyors with their

(j) Transfer terminals: In a long-centre conveyor, direction of the conveyor is changed in a transfer terminal
where materials from one conveyor is transferred into another conveyor. The second conveyor is laid out at
certain angle (generally 90°) to the first one. The dis-charge from first conveyor takes place at a higher point,
and materials is directed to the second conveyor situated at a lower height, through properly shaped and sized
transfer chute. This transfer is a critical operation. The transfer terminal is enclosed within a structural
framework, covered in all sides, called a junction tower.

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3.3.5. Aspects of Belt Conveyor Design
The major points in selection and design of a belt conveyor are:
(a) Checking/determining capacity of a conveyor.
(b) Calculating maximum belt tension required to convey the load and selection of belt.
(c) Selection of driving pulley.
(d) Determining motor power.
(e) Selection of idlers and its spacing.
Above points have been discussed below in respect of flat as well as troughed belt conveyor. Necessary references
have been made to IS 11592:2000 which provides guidance for selection and design practices to be followed for belt
conveyors of sizes ranging from 300 mm to 2000 mm width of belt.
(a) Checking/Determining Conveyor Capacity
This basically means to check at what rate (tons/hrs. or units/min) a belt conveyor of a given belt width and
speed can convey a particular bulk material or unit loads. Conversely, it is to find out the size and speed of the
conveyor to achieve a given conveying rate.
Belt Width:
i) On a flat belt, free flowing materials will assume the shape of an isosceles triangle (Fig. 3.3- 9 [a]). The angle
of dynamic repose ‘‘𝜙1 ’’ may be considered to be equal to 0.35𝜙, where ‘‘𝜙’’ is the static angle of repose for
the material. To avoid spillage, the belt width ‘‘B’’ is taken at least 25% more than the base of triangle ‘‘b’’.
Thus 𝑏 = 0.8𝐵. As per table 7 and 8 of IS 11592, 𝑏 = 0.9𝐵 − 0.05𝑚 for 𝐵 ≤ 2 𝑚. Therefore, the
assumption 𝑏 = 0.8𝐵 is more conservative for 𝐵 > 500 𝑚𝑚
Referring to Fig. 3.3- 9(a), the cross sectional area of the load on a flat belt is:
𝑏ℎ 1
𝐴1 = 2
= 2 (0.8𝐵 × 0.4𝐵𝑡𝑎𝑛𝜙) = 0.16𝐵2 tan(0.35𝜙) (1)

Therefore, the conveying capacity “𝑄𝑓 ” of a flat belt conveyor is given by;

𝑄𝑓 = 3600𝐴1 × 𝑉 × 𝑌 = 576𝐵2 𝑉𝑌𝑡𝑎𝑛(0.35𝜙), 𝑡𝑜𝑛⁄ℎ𝑟 (2)

𝑤ℎ𝑒𝑟𝑒,
Y = bulk density of material in tons /m3,

V = velocity of belt in m/sec.

B = Belt width in metres.
(ii) For a three roller troughed belt conveyor (Fig. 3.3-9 [b]), where the length of the carrier rollers are equal,
the length of each roller 𝑙𝑟 can be taken as 𝑙𝑟 = 0.4𝐵. Let the trough angle is ‘‘𝜆’’. Then, cross sectional
area of the load, A = A1 + A2
The trapezoidal area
1
𝐴2 = (0.4𝐵 + 0.8𝐵) × 0.2𝐵𝑡𝑎𝑛𝜆 = 0.12𝐵2 𝑡𝑎𝑛𝜆 (3)
2
This is based on the assumption that the base “b” of top triangular area is given by b = 0.8B, as considered
in (i) earlier.

∴ 𝐴 = 0.16𝐵2 𝑡𝑎𝑛(0.35𝜙) + 0.12𝐵2 𝑡𝑎𝑛𝜆 (4)

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 The conveying capacity ‘‘𝑄𝑡𝑟 ’’ of the troughed conveyor is
𝑄𝑡𝑟 = 3600𝐴𝑉𝑌 = 𝐵2 𝑉𝑌[576𝑡𝑎𝑛(0.35𝜙) + 432𝑡𝑎𝑛𝜆], 𝑡𝑜𝑛/ℎ𝑟 (5)

Figure 3.3-9: Bulk load on flat and troughed belt conveyor

(iii) In case of flat belt carrying unit (box shaped) load the belt width B is taken to be
𝐵 ≅ width of the load + 200 mm (6)
The capacity of the conveyor in terms of number of unit loads conveyed per unit time depends on
orientation of unit loads on belt and speed of belt. Orientation of load depends on strength of the belt to
carry unit load as well as on stability of the load on conveyor. This can be explained by an example given
below.
Example:
Boxes of size 220 mm × 180 mm × 100 mm have to be conveyed by a belt conveyor of sufficient belt strength,
at the rate of 2000 boxes per hour. What will be the size and speed of the conveyor?
Solution:
For stability, the boxes should be conveyed with their 100mm side as height. For safe conveying of boxes without
moving off the belt, the belt width should be suitable for conveying the boxes with 220 mm side as width on the
belt. So belt width should be 220 + 2×100 = 420mm or its’ nearest higher standard size. With 420 mm belt width,
even the maximum corner dimension of the box √2202 + 1802 = 284𝑚𝑚 will leave the side clearance of;
1
(420 − 284)𝑚𝑚 = 68𝑚𝑚. As per IS 1891:1994 (part I), the next higher standard size of 500 mm wide belt
2

is chosen.
If the boxes are placed with a gap of say 200 mm between two boxes, then the maximum speed of conveyor is
2000×(180+200)
𝑉= = 12.67𝑚/𝑚𝑖𝑛, which is quite a low speed for a 500 mm belt conveyor, hence acceptable.
60×1000

In this problem, it is to be noted that, delivery of 2000 boxes per hour means same number of boxes to be
3600
loaded also i.e., at a rate of 2000 = 1.8𝑠𝑒𝑐⁄𝑏𝑜𝑥.

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This may not be possible by manual loading and some type of automatic loading device needs to be incorporated.
IS: 11592:2000 has detailed out the maximum sectional area of materials on flat, two roller troughed and triple
roller troughed belts for different belt widths, surcharge angles (dynamic angle of repose) and trough angles.
These data may be interpolated for intermediate values of trough angles and dynamic angle of repose for different
bulk materials as specified in IS: 8730.

Belt Speed: Recommended belt speed depends on the width of the belt as well as lump size factor of the bulk
material, its air borne factor and also its abrasiveness factor. IS: 11592:2000 gives the maximum recommended
belt speeds for different sizes of belts based on ‘‘speed factor’’ (speed factor = lump size factor + air borne factor
+ abrasiveness factor). Tables 3.3- 2 and 3.3- 3 give the above factors and Table 3.3- 4 shows the recommended
maximum belt speeds. Higher belt speeds may be considered under special design conditions only.

Table 3.3-2: Lump Size Factor

Lump Size Air Borne

Material Lump Size
Factor Factor

Fine Grain to Dust < 10 mm 0 4

Granular < 25 mm 1 0
Quantity of largest lump is < 20 per cent of maximum
Sized and Unsized 2 0
permissible lump size (for the selected belt width)
Quantity of largest lump is < 60 per cent of maximum
Sized 3 0
permissible lump size (for the selected belt width)
Largest lump does not exceed maximum permissible
Unsized 4 0
lump size (for the selected belt width)

Table 3.3-3: Abrasiveness Factor

Abrasiveness
Abrasiveness Type of Material
Factor
Free flowing materials, such as cereal grains, wood, chips, wood
Non Abrasive pulp, fullers earth, flue dust, soda lime, char, loam sand, ground 1
gravel.
Materials, such as aggregate, run-of-bank sand and gravel, slate, coal,
Mildly Abrasive 2
salt, sand stone.
Abrasive Materials, such as slag, spar, limestone concentrates, pellets. 3
Iron ores, taconite, jaspar, heavy minerals, flint rock, glass cullet,
Very Abrasive 4
granite, traprock, pyrites, sinter, coke etc.

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Table 3.3-4: Maximum Recommended Belt Speed (m/s)

Belt Width,
mm Up to 500 600 to 650 750 to 800 950 to 1050 1200 to 2000
Speed Factor

1 2.50 3.00 3.50 4.00 4.50

2 2.30 2.75 3.20 3.65 4.12
3-4 2.00 2.38 2.75 3.15 3.55
5-6 1.65 2.00 2.35 2.65 3.00
7-8 1.45 1.75 2.05 2.35 2.62

For a conveyor sloping up (ascending), a slope factor ‘k’ is multiplied with the calculated conveyor capacity to
get the actual capacity. The ‘k’ factors with angle of inclination is given in following table:
Table 3.3-5: Slop Factor, k

Degrees 0-2 4 6 8 10 12 14 16 18 20

‘k’ factor 1 0.99 0.98 0.97 0.95 0.93 0.91 0.89 0.85 0.81
(b) Belt Tension
In belt conveyor, the motive force to draw the belt with load is transmitted to the belt by friction between the
belt and the driving pulley rotated by an electric motor. From Euler's law of friction drive, considering no slip
between the belt and pulley;
𝑇1
𝑇2
= 𝑒 𝜇𝛼 (7)

𝑊ℎ𝑒𝑟𝑒: 𝑇1 = 𝐵𝑒𝑙𝑡 𝑡𝑒𝑛𝑡𝑖𝑜𝑛 𝑎𝑡 𝑡𝑖𝑔ℎ𝑡𝑒𝑟 𝑠𝑖𝑑𝑒

𝑇2 = 𝐵𝑒𝑙𝑡 𝑡𝑒𝑛𝑡𝑖𝑜𝑛 𝑎𝑡 𝑠𝑙𝑎𝑐𝑘 𝑠𝑖𝑑𝑒
𝛼 = 𝑤𝑟𝑎𝑝 𝑎𝑛𝑔𝑙𝑒 𝑖𝑛 𝑟𝑎𝑑𝑖𝑎𝑛
𝜇 = 𝐶𝑜𝑒𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 𝑎𝑛𝑑 𝑏𝑒𝑙𝑡
𝑇1 – 𝑇2 = ‘‘𝑇𝑒 ’’, is the effective pull in the belt which is pulling the loaded belt against all resistances against
the belt movement.
From eq (7),
𝑇𝑒 = 𝑇1 − 𝑇2 = 𝑇2 (𝑒 𝜇𝛼 − 1) (8)
Estimation of Effective Pull, 𝐓𝐞 : ‘‘Te’’ is the sum total of all the resistive forces against the motion of belt
carrying the load. The various components of resistances are discussed here under:
Main resistance ‘‘R’’ comprising of:
(i) The resistance force caused by rolling friction in the bearings and seals of the carrying and return idlers.
(ii) The belt advancement resistance caused due to sagging of belt between idlers. i.e. due to recurrent flexing
of belt and material over idlers.

Secondary resistance ‘‘Rs’’ comprising of:

(i) The inertial and frictional resistances Ra due to the acceleration and friction of the material at loading area.

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 (ii) The force Rw required for bending (or wrapping) of the belt over pulleys.

(iii) Resistance Rska due to sliding friction between belt and side walls of the skirt at loading area.

(iv) Bearing resistance Rb of pulleys (with the exception of driving pulley, which is overcome directly by driving

motor).

Special main resistance ‘‘Rsp1’’ comprising of:

i) Drag due to forward tilt of idlers.
Special secondary resistance ‘‘Rsp2’’ comprising of:
(i) Resistance from belt cleaners.
(ii) Resistance from discharge ploughs and belt trippers.
Slope resistance ‘‘Rsl’’, which is the vertical component of the loaded belt when the conveyor is inclined
to horizontal by an angle ‘‘δ’’.

Thus effective pull ‘‘Te’’ can be written as:

T𝑒 = 𝑓Lg {m𝑐 + m𝑟 + (2m𝑏 + m𝐺 )cos δ} + R𝑆 + R𝑆𝑃1 + R 𝑠𝑝2 + m𝐺 gLsinδ

𝑤ℎ𝑒𝑟𝑒 𝑓 = artificial coefficient of friction taking care of rolling resistance of idlers and belt advancement
resistance.

The value of ‘𝑓’ = 0.02 for horizontal belt conveyor.

= 0.012 for a downhill conveyor requiring a brake motor.
L = length of the conveyor, m.
𝑚𝑐 = moving mass of carrying idlers per meter, kg/m.
𝑚𝑟 = moving mass of return idlers per meter, kg/m.
𝑚𝑏 = mass of belt per meter, kg/m.
𝑚𝐺 = mass of load per metre of belt length, kg/m.
δ = angle of inclination.
L (Sin δ) = lift of conveyor between loading and discharge point.
Calculation of secondary resistance is based on,

𝑅𝑠 = 𝑅𝑎 + 𝑅𝑤 + 𝑅𝑠𝑘𝑎 + 𝑅𝑏 (8)

𝑤ℎ𝑒𝑟𝑒
i. 𝑅𝑎 , is inertial and frictional resistance of material at loading area
𝑅𝑎 = QX1000 × 𝜌(V − V0 ) (9)
𝑤ℎ𝑒𝑟𝑒 Q = Volumetric conveyor capacity, m3/s.
ρ = bulk density, tonnes/m3.
V = velocity of belt, m/sec.
V0 = velocity of material at the point of loading, m/sec.

ii. 𝑅𝑤 , is wrapping resistance between belt and pulley, generally calculated from the formula

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 For fabric carcass belt
𝑇𝑎𝑣 𝑡
𝑅𝑤 = 9𝐵 (140 + 0.01 ( × )) (10𝑎)
𝐵 𝐷

For steel cord belt

𝑇 𝑡
𝑅𝑤 = 12𝐵 (200 + 0.1 ( 𝐵𝑎𝑣 × 𝐷)) (10𝑏)
𝑇1 +𝑇2
𝑤ℎ𝑒𝑟𝑒 𝑇𝑎𝑣 = , 𝑁𝑒𝑤𝑡𝑜𝑛
2

𝐷 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑚𝑚
𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑒𝑙𝑡, 𝑚𝑚
𝐵 = 𝑏𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ
However, the wrapping force is approximated as a percentage of maximum belt tensions on tight and slack side.

Following values of Rw may be assumed as a thumb rule.

Location of Degree of wrap Wrap resistance,

pulley Newton
Tight side 150° to 240° 230
Slack side 150° to 240° 175
All other pulleys — 140
The other resistances Rska and Rb under secondary resistance and other special resistances Rsp1 and Rsp2, can

be calculated based on different formulae given in IS: 11592, which are either small in values or not always
applicable.

Once ‘Te’ is estimated, tensions at the tight side (T1) and slack side (T2) are worked out using eqns. (7) and (8).

The coefficient of friction between belt and driving pulley under different operating conditions can be in
considered as given in Table 6.1.5.
Table 3.3-6: Friction Coefficient between Driving pulley and Rubber Belting

Smooth Rubber Pulyurethane Caramic PVC Belt

Pulley Bare Rim Lagging with Lagging with Lagging with Type
Surface Steel Herringbone Harringbone Harringbone
Operating Pulley Patterned Patterned Patterned
conditions Grooves Grooves Grooves
Dry condition
operation 0.35 to 0.4 0.4 to 0.45 0.35 to 0.4 0.4 to 0.45 0.25 to 0.35

Clean wet
condition (water) 0.1 0.35 0.35 0.35 to 0.4 0.15 to 0.30
operation
Operation under
wet and dirty
(clay or loam) 0.05 to 0.1 0.25 to 0.3 0.2 0.35 Less than 0.25
conditions
Operation under
very wet and 0.05 0.25 0.2 0.3 0.15
dirty condition

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Checking for belt sag: The minimum tensile force ‘𝑇𝑚𝑖𝑛 ’ which should be exerted on the belt to limit belt sag
between two sets of idlers is calculated by the formula:
For carrying side:
𝑙𝑐2 (𝑚𝑏 +𝑚𝐺 )𝑔
𝑇𝑚𝑖𝑛 ≥ (11𝑎)
8𝑆

For return side:

𝑙𝑟2 𝑚𝑏 𝑔
𝑇𝑚𝑖𝑛 ≥ 8𝑆
(11𝑏)

𝑤ℎ𝑒𝑟𝑒 𝑙𝑟 , 𝑙𝑐 𝑎𝑟𝑒 𝑖𝑑𝑙𝑒𝑟 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 𝑖𝑛 𝑚𝑒𝑡𝑒𝑟

and 𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑏𝑒𝑙𝑡 𝑠𝑎𝑔 = 0.005 𝑡𝑜 0.02 𝑚.
If the Tc min and Tr min are higher than the tensions T1 and T2 calculated from total resistance consideration,
these higher values of belt tensions should be achieved through proper belt tensioning and should be considered
in calculation of different design parameters.
In order to increase the effective pull without slippage, the wrap angle of belt over driving pulley or pulleys is
generally increased. Fig. 6.1.14 below shows the different drive arrangements for achieving higher value of wrap
angle ‘𝛼’

Figure 3.3-10: Different Belt rive arrangement

(c) Selection of Driving and Other Pulleys

The large diameter driving and tail end pulleys are generally fabricated from steel plates. The pulley shafts are
made integral with the barrel. The barrel and journal portions are machined in one setting to make them
concentric. The pulley faces are given a ‘‘crown’’ of around 0.5% of the pulley diameter, but not less than 4mm.

Diameter of pulley is selected based on the construction (number of plies which is proportional to carcass
thickness) of the belt used. The recommended values of minimum pulley diameters based on carcass thickness
and fibre materials is given in Indian standard IS: 1891 (part I).
However, as a thumb rule, diameter ‘D’ can be approximated from the relation, D ≥ ki, where i = number of plies
of belt. For i between 2 to 6, k = 125 to 150, and for i between 8 to 12, k = 150. Calculated ‘D’ is rounded off to
the larger standard sizes of 250, 315, 400, 500, 630, 800,1000,1250,1400,1600, 1800 and 2000 mm.
The length of the barrel is kept 100mm to 200 mm more than the belt width. The drive pulley may be covered
(lagged) with a layer of suitable material like rubber, polyurethane, ceramics etc, whenever necessary, to increase

16 | P a g e
the coefficient of friction between the pulley and belt. The thickness of such lagging may vary between 6 to 12
mm, and having a hardness between 55 to 65 shore A scale. However, the lagging on other pulleys like snub and
bend pulleys, the hardness chosen is much less (35 to 45 shore A) to protect damage to the surface covering of
the belt.
(d) Motor Power
The power required at the driving pulley just for driving the belt is given by the formula;
𝑇𝑒 ×𝑉
𝑃𝑑 = ( ) 𝑘𝑊 (12)
1000

𝑊ℎ𝑒𝑟𝑒, 𝑇𝑒 = 𝑇1 − 𝑇2 , 𝑖𝑛 𝑁𝑒𝑤𝑡𝑜𝑛
𝑉 = 𝑏𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑, 𝑖𝑛 𝑚/𝑠𝑒𝑐
𝑃𝑑 = 𝑑𝑟𝑖𝑣𝑒 𝑝𝑜𝑤𝑒𝑟, 𝑖𝑛 𝑘𝑊
However, the actual power requirements, considering the wrap resistance between belt and driving pulley, and
driving pulley bearings resistance, the actual motor power, PA is given by
𝑒𝑇𝑉 (𝑅𝑤𝑑 +𝑅𝑏𝑑 )×𝑉
𝑃𝐴 = 1000 + 1000
(13)
Rwd = wrap resistance between belt and driving pulley.
Rbd = driving pulley bearing resistance.

Additional power requirements should be taken into considerations for each belt tripper, and belt cleaner used
with the conveyor.

The final motor power ‘‘PM’’ is calculated based on efficiency ‘‘η’’ of the transmission system used consisting

of gear box, chain / belt drive, coupling etc.

𝑃𝐴
𝑃𝑊 = 𝜂
(14)
Actual motor is chosen with a power rating of 15% to 20% greater than the calculated power ‘PM’
(e) Selection of Idlers
Depending on the type of belt conveyor, the carrying idlers can be troughed or straight, while the return idlers
are generally always straight. The major selection criteria are the roller diameters and spacing of these idlers.
The range of idler diameters to be selected depends on belt width, maximum belt speed and type of materials to
be conveyed. Based on these, the idlers are classified into following six series as specified in IS: 11592: 2000
Table 3.3-7: Idler Classification
Maximum
Idler Roller Belt
Belt Speed, Suitable for
Series Diameter Width, mm
m/s

I 63.5 to 101.6 300-800 2.5 Fine material with small lumps Nonabrasive, intermittent duty.

II 88.9 to 139.7 400-1000 4 Fine material, small sized lumps, slightly abrasive, continuous duty.
101.6 to 139.7 500-1200 Unsized medium lumps, mixed with fine sized small lumps,
III 4 moderately abrasive, Continuous duty.
127 to 139.7 500-1400 Unsized, large lumps, mixed with small sized medium lumps
IV 4 moderately abrasive continuous duty.
V 139.7 to 219.1. 800-2000 5 Large size lumps, highly abrasive, critical duty.

VI 168.3 to 219.1 1600-2000 4 Large capacity conveyor with lumps.

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Spacing for carrying and return idlers also depends on belt width, and bulk density of the material to be conveyed.
The recommended spacing as per IS: 11592: 2000 is given in table 3.3-8 below.
Table 3.3-8: Recommended Idler Spacing

Belt Width Troughed Belt Flat Belt Return Idler Sets

Carrying Idler Sets for Materials Troughed and Flat Belt
3
of Bulk Density (t/m )
0.40 to 1.20 1.20 to 2.80 -

Recommended Spacing, mm

300
400 1500 1200
500
650 1000

800
1000 1200 1000 3000

1200
1400
1600 1000 1000 750
1800
2000

3.4. Chain Conveyor

3.4.1. Definition / Description
The term chain conveyor means a group of different types of conveyors used in diverse applications, characterized by
one or multiple strands of endless chains that travel entire conveyor path, driven by one or a set of sprockets at one
end and supported by one or a set of sprockets on the other end. Materials to be conveyed are carried directly on the
links of the chain or on specially designed elements attached to the chain. The load carrying chain is generally
supported on idle sprockets or guide ways. The endless chains are kept taught by suitable chain tensioning device at
the non-driven end.

3.4.2. General Characteristics

Different types of chain conveyors are used in wide varieties of applications. It is, therefore, not possible to have a set
of common characteristics for all these chain conveyors. Special characteristics of individual type of chain conveyors
have been described while discussing them.

Chain, compared to belts of a belt conveyor, have certain advantages as well as disadvantages. The major advantages
are that the chain easily wraparound sprockets of small diameter, and the drive is positive i.e. no slippage takes place
between chain and sprocket. The chain stretch is also little. The disadvantages of chain are its high weight, high initial
cost, higher maintenance cost and most importantly, limited running speed because of dynamic loading that come into

18 | P a g e
play in chain-sprocket drive causing intensive wear at high speeds. Maximum length and maximum lift of chain
conveyors are limited by the maximum allowable working tension of the chain used.
3.4.3. Types of Chain Conveyors
There are many types of chain conveyors. Some of widely applicable chain conveyors are discussed here under.

a) Apron or Pan Conveyor:

This is the most common type of chain conveyor. It consists of one or more strands of endless chain, usually link
plate roller type, running in steel guides. Rollers ensure minimum pulling effort in the chain, while roller guides
supported on the superstructure of the conveyor, carry the entire load of the materials and chains. The carrying
surface of the conveyor is composed of a series of plates or shapes called apron, which are attached to the links
of the chains through cleats. The bed created by the aprons is used for carrying bulk materials as well as unit
loads. When the conveyor aprons have vertical flanges on all sides to form a pan like shape, if is specifically
called a pan conveyor. Materials carried by the apron is discharged over the sprockets at the driven end, and the
conveyor chain with aprons comes back empty on its return Journey. These are generally slow speed conveyors
with a speed range of 20 to 35 rpm. Arrangement of a typical apron conveyor is shown in Fig. 6.2.1.

Figure 3.4-1: Photographic View of Typical Apron Conveyor

Applications: Generally apron and pan conveyors are used to perform severe duties of conveying large quantities
of bulk load such as coal, ore, slag, rock, foundry sand etc. These are frequently used for feeding materials to
large crushers, breakers, grinders and similar machines. Specially designed aprons are used for conveying unit
loads, coils, and hot forgings. Part of an apron conveyor may be run through a liquid or water bath for washing
of the materials and then allow drainage of liquid from wet materials. Apron conveyors can have flexible layout
to follow combined horizontal and inclined movement in the same vertical plane.
b) Cross-Bar or Arm Conveyor:
This type of conveyor consists of a single or two strands of endless chain, to which are attached spaced, removable
or fixed arms (or cross members) from which materials are hung or festooned. The arms may be replaced by
shelves/trays to support packages or objects to carry them in a vertical or an inclined path.
Special arms are designed to suit specific load configuration. Depending on the design of arms, they are called
by different names, some of which are:
(i) pendent conveyor,
(ii) pocket conveyor,
(iii) wire mesh deck conveyor,
(iv) removable crossbar conveyor,
(v) fixed cross-bar (or arm) conveyor,

19 | P a g e
 (vi) swing tray conveyor.
Applications: Crossbar conveyors are used for conveying and elevating or lowering unit loads like barrels,
drums, rolls, bags, bales, boxes etc. The conveyors may be loaded/unloaded manually or at automatic loading/
discharging stations. Cross-bar conveyors are also used in a wide range of process applications such as dipping,
washing, spraying, drying and assembly etc.
c) Car-Type Conveyor:
This type of conveyor consists of a series of small platform cars, propelled by an endless chain, running on a
closed track. Car-type conveyors may have vertical runarounds over sprockets having horizontal axis. However,
more often they are designed with horizontal runarounds (carousels) over sprockets (or sheaves for rope drive)
with vertical axis. This type of conveyor is also called a carousel conveyor or a pallet-type conveyor.
The track is placed more or less in a horizontal plane. The cars may either be permanently attached to the driving
chain (or cable) or may be propelled by pusher dogs on chain or rope against lugs on cars. The driving chain is
generally positioned at the bottom side of the cars, between the two track rails. Loads may be manually loaded
/ unloaded, or may be designed for automatic loading, and unloading through tilting of car top at unloading point.
Applications: Car-type chain conveyors are particularly used for carrying heavy or irregular shaped large
objects like moulds in foundries, coils for rolling plants etc.
These conveyors are conveniently used to combine different processing operations during transportation of the
loads. Rolled coils may be cooled, molten metals may be solidified in moulds, assembly of components may be
achieved, testing inspection may be performed etc.
The conveyors with horizontal runarounds can be arranged to move in any straight or irregular shaped path in
the same horizontal plane, hence called contour type, which makes them very suitable for use in different process
plant for picking up and delivery of materials from and to desired locations of the plant. On horizontal
runarounds, a load not removed will continue to move with the conveyor. This gives an obvious advantage of
using a short conveyor for accomplishing long duration processes (drying, cooling etc.) and irregular processes
(foundry, testing etc). Horizontal carousel conveyor usually occupies larger floor space.
d) Carrier chain
Carrier chain conveyor consists of one or more number of endless chains to which may be attached one of the
many different attachments for the purpose of carrying unit materials or objects. In many cases, the materials are
conveyed while being directly in contact with the chain/chains.
These conveyors have a broad application in practically all fabricating and processing industries. Different
designs of attachments are used for different types of materials.
Carrier chain conveyors are generally classified into two basic types:
(i) Rolling-type carrier chain conveyors: In this class of conveyor, the chains are provided with rollers moving
on tracks for minimum of friction. The materials are supported on the attachments. In a variation of this type
of conveyor, the rollers may be used for supporting the objects while the chain acts as the connecting and
propelling link for the rollers. The rollers may be shaped to accommodate curved faced objects or may be
flat-faced to carry objects with flat surfaces. Rotation of the carrying rollers often causes the objects to move
at a higher velocity than that of the chain.
(ii) Sliding-type carrier chain conveyor: In this class of conveyor, the loads are carried directly on one or more
chains, while the individual chain slides on a track or surface or a trough. Attachments or specially designed
links may be used to suit the loads

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 Figure 3.4-2: Rolling type carrier chain conveyor

(d) Trolley Conveyor:

These conveyors consist of a series of trolleys supported from an overhead endless track and propelled by
an endless chain or cable, with the loads usually suspended from the trolleys. This is one of the most versatile
type of chain conveyors which can work in horizontal and inclined paths, vertical curves and horizontal
turns to follow complicated routes.
Different structural members are used as track for
overhead trolley-conveyor which include I-beam,
double angles, T-rails, steel bars, pipes and fabricated
sections. However, I-beam is the most common track.
These tracks are laid at a higher level, suspended from
roof, building structures or hung from floor-mounted
columns, and routed around obstacles. Overhead
operation allows free floor space and no interference
with equipment or traffic at the floor level. For this
reason, trolley conveyors are also called overhead
conveyors. Generally two wheeled trolleys or more
wheeled trolleys with load bar between them for
handling large loads, are used. Loads are suspended
from carriers bolted to the trolley bracket. Hooks and
trays are the most common carriers.
As the trolleys can move in three dimensions, this type
of conveyor is extensively used for carrying materials
continuously through different processes, like cleaning,
washing, painting, drying, baking, degreasing, sand
Figure 3.4-3: Load carrying Trolley Conveyor
blasting etc. These conveyors may be, and usually are,
used as a storage conveyor, at the same time as a processing and delivery conveyor. The carriers can be
loaded and unloaded in route, at one or more points of the conveyor run, either manually or automatically.

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 According to the method by which load is conveyed, trolley conveyors are further classified into following
three types:
(i) Load-carrying trolley conveyor: Which is the main type, in which the trolley and the load carriers are
permanently fixed to the pulling chain [Fig. 3.4-3].
(ii) Load-propelling trolley conveyor: In which the trolleys with load carriers travel on track being pushed by
pusher dogs attached to the pulling chain or chain trolley. The special advantage of this load-propelling
conveyor (also called pusher trolley conveyor) is the capacity to divert the load carriers from the main track
to a branch track for achieving different operational requirements.
(iii) Load towing trolley conveyor: in which the trolleys are permanently secured to the pulling member, and
specially designed hooks or rods from the trolley engage and tow floor mounted trucks carrying the load. In
this case the conveyor may be made very light as the load in basically carried on the floor, but the advantage
of free floor / working space is lost. This particular type of trolley conveyor is also classified as overhead
tow conveyor. Fig. 3.4-4 shows schematic view of a load towing trolley conveyor.

Figure 3.4-4: Load towing trolley conveyor

The advantages of an overhead trolley conveyor may be summarized as follows:

 movement is three dimensional and easily adopted to changes in direction;

 large length with one or multiple drives;
 free floor space;
 small power consumption;
 Little maintenance and high salvage value.

3.4.4.Components of Chain Conveyor

The major components of a chain conveyor are: (i) Pulling chain, (ii) Sprocket to drive and support the chain,
(iii) Take-up arrangement, (iv) Drive arrangement and (v) Various other components specific to various type of
chain conveyors.

22 | P a g e
(a) Pulling Chains: Different types of chains are used in chain conveyors, which have their merits and demerits,
briefly discussed below:
(i) Round-link chains are low in cost and high flexibility in all directions. This have flexibility which is
particularly desirable in trolley conveyors (Fig. 3.4-5). However, limitations of this chain are less
contact area, high stretch under load and rapid wear

Figure 3.4-5: Round-link chain being driven by sprocket

(ii) Combination chains are widely used in many different conveyors (Fig. 3.4-6). The links are generally
of cast malleable iron construction with machined steel pins and may be with or without roller.

Figure 3.4-6: Combination Chain

(iii) Link-plate chains (Sometimes called leaf chain) are the most common type used in chain conveyors.
The link plates allow different types of attachments to be fitted in the chains. The pitch of the chain may
be made large enough (pitch usually vary from 65 mm to 1250 mm) by making the links from steel
plates.
Construction of link-plate chains may be bush-less chain with or without rollers, and bushed chain with
or without rollers, as shown in Fig. 3.4-7. The bushes decrease the wear at the link joints. The rollers
fitted with bushes or with antifriction bearing for large size chain generally run on guided tracks or
toughs which carry the entire weight of the chain and load being carried, thereby reducing the pull in
the chain. Because of these advantages, chain with bush and roller are the preferred ones.

23 | P a g e
 Figure 3.4-7: Link plate chain (a) Roller chain and Roller chain drive

Chain selection is based on

i. largest practical pitch (being cheaper than the shorter pitch chain of equal strength),
ii. allowable tension load,
iii. capital cost and
iv. Degree of maintenance needed.

(b) Sprockets: The sprockets are made of good grade cast iron with chilled hardened teeth or from cast steel or
plate steel. The teeth are machined to suit type of chain used. The advantage of using a large sized sprocket
with greater number of teeth is to obtain smoother operation. How-ever, larger the size of sprocket t, costlier
it is and taking larger space. Thus a compromise is made in selecting the size of a conveyor sprocket.
(c) Take-up arrangements: The most common type of take-ups is adjusting screw type for positioning the
bearing blocks supporting the take up sprocket shaft. The range of adjustment should be sufficient to permit
initial slack-off of the conveyor chains for joining of two links to make them endless and ample adjustment
for initial stretch and subsequent wear / elongation.
The alternative design is counterweighted-type, providing automatic constant tension in chain. This type
provides constant chain tension under variable temperature conditions also.
(d) Drive arrangement: Drive for a conveyor generally consists of an electric motor coupled to a speed
reduction gear unit which in turn is coupled to the driving sprocket. For a conveyor having a simple
configuration (as in an apron conveyor), the drive is located at the sprocket at the end of loaded strands of
chain. For conveyors like trolley, car, tray etc. having a complicated path of motion, the drive location is
determined by analysis of tension variation in the path of conveyor motion.

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 Drives may have fixed or variable speed. Variable speed may be achieved by using a variable speed gear
box or change speed gear box or multiple speed motor or by having an electrical speed control system. For
a long chain conveyor, synchronously working multiple motor drives at different sections are employed
which decrease the total tension in the chain.
A crawler drive is employed for giving drive to a straight portion of the pulling chain. The crawler drive
arrangement is shown in Fig. 3.4-8.
Straight portion of the conveyor chain, supported by the set of supporting rollers, is driven by the dogs of
the drive chain.

Figure 3.4-8: Crawler drive

(e) Frame structures: Frame structures supporting the entire conveyor, chain guide rails or troughs, skirt plates
are the other components which are common to most type of chain conveyors.
Frame structures are generally custom designed to suit the location and application. The frames may be floor
supported, set below the floor, be hung from the roof or bracket from wall/columns, as required by the
different types of conveyor.
Different types of chain conveyors may need other specific components and structural arrangements, which
have been mentioned in the discourse on the individual type of conveyor.

3.4.5. Aspects of Chain Conveyor Design

(a) Dynamic Phenomena in Chain Conveyors:
In a chain-sprocket drive, engagement of sprocket to chain being discontinuous in nature, the linear velocity
of the chain between two successive engagements with sprocket teeth becomes non-uniform. The reason for
this is that the chain does not wrap around the driving sprocket on the pitch circle, but traces a pitch polygon,
a phenomenon known as chordal action. The period of irregularity is equal to the time taken by the sprocket
between two successive engagements (i.e. time taken by the sprocket to rotate by one pitch)

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 2𝜋
𝑡0 = (15)
𝜔𝑧
2𝜋𝑛
𝑊ℎ𝑒𝑟𝑒: 𝜔 = 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
60

𝑧 = 𝑁𝑜 𝑜𝑓 𝑠𝑝𝑟𝑜𝑘𝑒𝑡 𝑡𝑒𝑒𝑡ℎ
𝑛 = 𝑟𝑝𝑚 𝑜𝑓 𝑆𝑝𝑟𝑜𝑘𝑒𝑡
Fig. 3.4-9 shows a chain running on a sprocket. In the position pictured in the diagram, the pull is transmitted
by the tooth 1, is in mesh with chain link 1′. As the sprocket rotates clockwise, tooth 2 engages with link 2′,
then tooth 3 with link 3′ etc.
At constant angular velocity of the sprocket, the peripheral speed of the tooth remains constant 𝑖. 𝑒. Vo = 𝜔𝑅
while the chain translatory speed in the direction of the chain movement will be V = V0 cos φ = ωRcos φ,
where φ is the variable angle formed by the contacting tooth radius 𝑂1 with vertical axis OY

Figure 3.4-9: Analysis of Chain Movement over Sprocket

𝛼𝑜
The chain speed reaches its peak value, vmax = v0 = 𝜔𝑅 𝑤ℎ𝑒𝑛 𝜙 = 0 and it is minimum when 𝜙 = 2
.

The acceleration ‘𝑎 ’ of the chain can be determined as the first derivative of the speed with time, or as the
projection of centripetal acceleration 𝑎0 = 𝑅𝜔2 to the direction of chain travel (tangential acceleration
being zero). 𝑎 = 𝑎0 𝑠𝑖𝑛 𝜙 = 𝑅𝜔2.
Acceleration diagram is also shown in. It becomes zero when 𝜙 = 0 and reaches its peak value at;
𝛼0 𝛼0
𝜙=± 2
, ∴ 𝑎𝑚𝑎𝑥 = ±𝑅𝜔2 𝑠𝑖𝑛 2
(16)

(b) Chain Pull and Conveyor Horsepower: The entire weight of materials and the moving parts of a chain
conveyor is pulled by the chain or chains employed. It is, therefore, important to calculate the tension of
each chain and select the chain with adequate strength to work safely under the working pull, the chain will
be subjected to. The tension or pull necessary to move conveyor chains is sum total of live load i.e. the force
required for conveying the material plus the dead load and the resistance to the movement of conveyor parts.

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 Thus, the total chain pull = Force required to raise material up an inclination + Force required to raise
conveyor parts up the inclination + Frictional resistance to the movement of loaded conveyor parts in the
carrying run + Frictional resistance of empty conveyor parts during return run.
If the various factors are represented with following notations:
𝑇 = 𝑇𝑜𝑡𝑎𝑙 𝑐ℎ𝑎𝑖𝑛 𝑝𝑢𝑙𝑙, 𝑁𝑒𝑤𝑡𝑜𝑛
𝑓 = 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑚𝑜𝑣𝑖𝑛𝑔 𝑐ℎ𝑎𝑖𝑛 𝑜𝑛 𝑟𝑢𝑛𝑤𝑎𝑦𝑠.
𝐿 = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑐𝑒𝑛𝑡𝑒𝑟𝑠, 𝑚.
𝐻 = 𝐻𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑝𝑟𝑜𝑗𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟, 𝑚.
𝑉 = 𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑝𝑟𝑜𝑗𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟, 𝑚.
𝑚𝐺 = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑙𝑜𝑎𝑑 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟, 𝑘𝑔/𝑚.
𝑚𝐶 = 𝑀𝑜𝑣𝑖𝑛𝑔 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟, 𝑘𝑔/𝑚.
𝑆 = 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟, 𝑚/𝑚𝑖𝑛.
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛
Then, 𝑇 = 𝑚𝐺 . 𝑔. 𝑉 + 𝑚𝐶 . 𝑔. 𝑉 + 𝑚𝐺 . 𝑔. 𝑓𝐻 + 2𝑚𝐶 . 𝑔. 𝑓𝐻 − 𝑚𝐶 . 𝑔. 𝑉
𝑇 = 𝑚𝐺 . 𝑔(𝑉 + 𝑓𝐻) + 𝑚𝐶 . 𝑔(𝑉 + 𝑓𝐻) + 𝑚𝐶 . 𝑔(𝑓𝐻 − 𝑉) (17)
If V in the quantity 𝑚𝐶 . 𝑔(𝑓𝐻 − 𝑉) exceeds 𝑓𝐻, the conveyor return run will move down the inclination
owing to the gravitational pull overcoming the frictional resistance of the return run. In this condition the
term 𝑚𝐶 . 𝑔(𝑓𝐻 − 𝑉) is taken to be zero. If 𝑓𝐻 > 𝑉, then this additional pull is necessary to pull the return
part of the conveyor.
Q
If ‘Q’ is capacity of the conveyor in tonnes/hr, we can write 𝑚𝐺 = 16.66 , equation (17) can be rewritten;
𝑆
𝑄
𝑇 = 16.66 𝑆 . 𝑔(𝑉 + 𝑓𝐻) + 𝑚𝐶 . 𝑔(𝑉 + 𝑓𝐻) + 𝑚𝐶 . 𝑔(𝑓𝐻 − 𝑉) (18)
The frictional coefficient ‘f’ depends whether the chain is sliding or rolling. For non-roller flat linked chain,
sliding on steel track or trough, the value of ‘f’ may be taken as 0.2 and 0.33 for well lubricated and dry run
respectively. The rolling friction depends on roller size, condition of track etc. For 50mm diameter it is 0.15 while
for 150mm it can be taken as 0.06.
When the load on conveyor passes through stationary skirt plates as in a deep apron or pan conveyor, additional
frictional pull due to rubbing, must be added to the chain pull ‘T’ obtained from above formula. If this pull is
‘‘Y’’ in Newton per meter length of skirt plate, then

𝑌 ≅ 2.3ℎ2 /𝑘,
𝑤ℎ𝑒𝑟𝑒 ℎ = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 𝑟𝑢𝑏𝑏𝑖𝑛𝑔 𝑖𝑛 𝑠𝑘𝑖𝑟𝑡 𝑖𝑛 𝑐𝑚,
𝑎𝑛𝑑 𝑘 𝑖𝑠 𝑎 𝑓𝑎𝑐𝑡𝑜𝑟 𝑑𝑒𝑝𝑒𝑛𝑑𝑖𝑛𝑔 𝑜𝑛 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑎𝑠 𝑔𝑖𝑣𝑒𝑛 𝑖𝑛 𝑡ℎ𝑒 𝑇𝑎𝑏𝑙𝑒 𝑔𝑖𝑣𝑒𝑛 𝑏𝑒𝑙𝑜𝑤.

Materials K

Iron ore, crushed 4

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 Cement clinker 8
Gravel or stone 8
Coal, fines and lumps mixed 30
Chips, pulpwood 48
Sugar cane 80

The basic power for driving the conveyor is calculated by the formula:
1.15×S×[𝑇𝑜𝑡𝑎𝑙 𝑐ℎ𝑎𝑖𝑛 𝑝𝑢𝑙𝑙−𝑚𝐶 .𝑔(𝑉−𝑓𝐻)]
P= 1000×60
, 𝑘𝑊 (19)
This formula takes care of 10% headshaft and 5% tailshaft friction. However, for actual motor power calculation, the
efficiency of the drive system consisting of gearbox, pulley and belt, coupling etc. have to be considered.
The drive is generally applied to the delivery end. The required power is practically same if drive is applied to the tail
end. The advantage of a head-end drive is that, only the active side of the chain is under maximum load. A tail end
drive will put the entire length of the chain under this maximum tension and this causes greater friction at the head
shaft and greater wear of the chain.

3.5. Screw Conveyor

3.5.1. Definition, Characteristics and Use
A screw conveyor consists of a continuous or interrupted helical screw fastened to a shaft which is rotated in a
U-shaped trough to push fine grained bulk material through the trough. The bulk material slides along the trough
by the same principle a nut prevented from rotating would move in a rotating screw. The load is prevented from
rotating with screw by the weight of the material and by the friction of the material against the wall of the trough.
A screw conveyor is suitable for any pulverized or granular non viscous material, and even at high temperature.
The conveyor is particularly suitable for mixing or blending more than one materials during transportation, and
also for controlling feed rate of materials in a processing plant. Abrasion and consequently certain amount of
degradation of the material is unavoidable, hence it is not suitable for brittle and high abrasive materials. It is
also not suitable for large-lumped, packing or sticking materials.

3.5.2. Descriptive Specifications

A typical screw conveyor is shown in Fig. 3.5-1. The screw shaft, if short (up to 5 meters), is supported at two
ends. But for longer shafts (up to 40 to 50 m), they are supported by bearing hangers, at intermediate points. The
shaft may be solid or hollow. Hollow shafts are lighter and can be easily joined to make a long shaft. The screw
shaft is driven at one end, and the design may permit discharge of material from the bottom or one end. Opposite
handed screw at two sides will cause the center dis-charge. The U-shaped fabricated trough are generally covered
at the top to avoid particulate pollution. The bottom portion of the trough is of circular cross section matching
the diameter of the screw. Generally a radial gap of 10 mm to 20 mm is kept between the screw and the trough,
depending on size of the screw.
Screws of different constructional design and style are used, which are shown in Fig. 3.5-1. Continuous screws

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 Figure 3.5-1: Photographic View of Screw Conveyor

are generally made from 4 to 8 mm sheet steel of circular section hole corresponding to the size of the shaft.
One radial slit is made in this section, and then formed into one pitch of the screw. The section is welded to the
shaft and welded or riveted to each other to form the entire length of the screw. The screw may also be cast
integral with the shaft. The paddle type flights consist of cast straight or curved segments fixed to the shaft. A
ribbon screw is fixed to the shaft by means of radial rods.

(a) (b)
Figure 3.5-2: Different Types of screw (a): solid continuous; ribbon; paddle-flight; cut-flight (b): Photograph

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The drive unit comprises of an electrical motor, gear box and couplings. Material is fed through the feed hopper
fixed on the trough cover. A number of discharge sprouts with rack gears for closing and opening as required,
are provided.
Screw conveyors are generally operated horizontally or at a small inclination (10° to 20°). However, there are
special designs where the load is moved vertically up or at a small angle to vertical. These are called vertical
screw conveyors.
3.5.3. Aspects of Screw Conveyor Design
(a) Recommended Dimension of a Screw Conveyor: The dimensions of principal components of a screw
conveyor are nominal diameter of the helical screw, pitch of the screw, diameter of screw shaft, width
of trough determining the gap between trough and screw, trough height from center of screw shaft,
thickness of trough material and nominal thickness of screw flights.

Indian standard specification IS: 5563:1985 has specified the standard dimensions for all above components.
The recommended dimensions as per IS are given in Table 3.5-1. Table 3.5-1, however, does not include the
standard values of screw pitches. There are given below in mm.

Value of screw pitch ‘𝑆’ generally varies between 0.8 and 1.0 time diameter ′𝐷′ of the screw. Screw pitch
equal to the screw diameter is commonly used.
Table 3.5-1: Screw Dimension

Nominal Thickness of Helical Screws

Upper Edge of the Trough

Outside Diameter of Solid

Coupling Shaft Diameter

Center of Screw Shaft to

Thickness of
Tubular Shaft (d ) ×2
Trough Height from

Trough Segmental root Continuous root

Trough Width, C
Nominal size, D

Medium Duty

Thickness*
Heavy Duty

Light Duty

Medium

Medium
Heavy

Heavy
shaft

Light

Light
(a)

100 63 120 --- 2.0 1.6 33.7 × 2.5 30 25 --- 3.15 2.0 ---- 5.0 3.15
125 75 145 --- 2.0 1.6 33.7 × 2.5 30 25 --- 3.15 2.0 ---- 5.0 3.15
160 90 180 5.0 3.15 1.6 42.4 × 2.5 35 40 5.0 3.15 2.0 7.0 5.0 3.15
200 112 220 5.0 3.15 2.0 48.3 × 3.5 40 40 5.0 3.15 2.0 7.5 5.0 3.15
250 140 270 5.0 3.15 2.0 60.3 × 4.0 50 50 6.0 5.0 3.15 10.0 7.0 5.0
315 180 335 5.0 3.15 --- 76.1 × 5.0 60 50 7.0 5.0 3.15 10.0 7.0 5.0
400 224 420 5.0 3.15 --- 76.1 × 5.0 60 75 8.0 6.0 5.0 12.0 10.0 7.0
400 224 420 5.0 3.15 --- 88.9 × 5.0 70 75 8.0 6.0 5.0 12.0 10.0 7.0
500 280 530 5.0 3.15 --- 88.9 × 5.0 70 75 8.0 7.0 5.0 ---- ---- ----
500 280 530 5.0 3.15 --- 114.3 × 5.5 80 75 8.0 7.0 5.0 ---- ---- ----
630 355 660 6.0 5.0 --- 114.3 × 5.5 80 100 10.0 8.0 ---- ---- ---- ----
630 355 660 6.0 5.0 --- 139.7 × 6.0 90 100 10.0 8.0 ---- ---- ---- ----
800 450 830 6.0 5.0 --- 139.7 × 6.0 90 100 10.0 8.0 ---- ---- ---- ----
800 450 830 6.0 5.0 --- 152.4 × 7.0 100 100 10.0 8.0 ---- ---- ---- ----
1000 560 1040 7.0 5.0 --- 152.4 × 7.0 100 125 12.0 10.0 ---- ---- ---- ----
1000 560 1040 7.0 5.0 --- 193.7 × 8.0 110 125 12.0 10.0 ---- ---- ---- ----
1250 710 1290 7.0 5.0 --- 193.7 × 8.0 110 150 12.0 10.0 ---- ---- ---- ----
*Tubular shaft diameter d has been taken preferably from IS:3501:1966 all dimensions in mm

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(b) Effect of Lump Size: The selection of size of a screw conveyor basically depends on two factors. (i) the
conveying capacity required and (ii) the lump size of the materials to be conveyed.
The lump size of materials determines the minimum size of the screw diameter ′𝐷′ to be chosen. 𝐷 is
recommended to be at least 12 times the lump size of a sized material or at least 4 times the largest lumps
of unsized material.
(c) Capacity of Screw Conveyor: The volumetric capacity ‘𝑉’ in 𝑚3 /ℎ𝑟 depends on screw diameter ‘𝐷’ in
meters, screw pitch ‘𝑆’ in meters, its rotational speed ‘𝑛’ rpm and the loading efficiency of the vertical cross
sectional area ‘𝜑’. The tonnage capacity ‘Q’ in tons/hr is given by:
𝜋𝐷 2 𝑡𝑜𝑛
𝑄 = 𝑉𝛾 = (
4
) × (𝑆 × 60𝑛𝜑𝛾𝐶), ℎ𝑟
(20)

𝑤ℎ𝑒𝑟𝑒 γ = bulk density of material in tons per m3

C = factor depending on inclination of conveyor.
In a typical design, 𝑆 = 𝐷 𝑡𝑜 0.8 𝐷.
ϕ varies with flowability of the material as shown in the table here under:

Material Characteristics Value of ϕ

1. Slow flowing, abrasive (clinker, ash) 0.125
2. Slow flowing, mild abrasive 0.25
3. Free flowing, mild abrasive (sand) 0.32
4. Free flowing, non-abrasive (grain) 0.4

Value of ‘C’ varying with inclination angle β is related as shown in following chart.
β 0° 5° 10° 15° 20°

C 1.0 0.9 0.8 0.7 0.65

The screw diameter and speeds vary widely depending on the designed capacity of the conveyor and the
nature of the material handled. However, the speed is generally reduced as the diameter goes up, as shown
in following table:

Screw dia, mm 160 200 250 300 400 500 630

Maximum rpm 150 150 120 120 95 90 75

Minimum, rpm 25 25 20 20 20 15 10

(d) Power Requirements of Screw Conveyor: IS: 12960: 1990 “Determination of Power Requirement of Screw
Feeder—General Requirements”, has recommended the method for calculation of power requirement of a
screw conveyor. The driving power of a loaded screw conveyor may be estimated by the formula:
𝑃 = 𝑃𝐻 + 𝑃𝑁 + 𝑃𝑠𝑡 (21)
𝑤ℎ𝑒𝑟𝑒,

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PH = power necessary for conveying the material.

PN = driving power of the conveyor at no load.

Pst = power requirement for inclination of the conveyor.

Power necessary for conveying the material 𝑷𝑯 : in kW is the product of the mass flow rate ‘Q’ of the
material, the length ‘L’ of material movement in the conveyor and an artificial frictional coefficient ‘λ’,
also called progress resistance coefficient.
𝑄𝐿 𝑄𝐿
𝑃𝐻 = 3600 𝜆𝑔 = 367 𝜆, 𝑘𝑊 (22)

𝜆 depends on the material and its size. It is generally of the order of 2 to 4. It should be noted that during
progress of material, over and above of sliding between the material, trough and screw, the material particles
slide against each other which results in internal friction. There-fore, λ is naturally expected to be more than
normal coefficient of friction for the material.
Drive power of the screw at no load, 𝑷𝑵: is comparatively low. It is proportional to the screw diameter 𝐷
and total length of the screw 𝐿. The recommended formula is;
𝐷𝐿
𝑃𝑁 = , 𝑘𝑊 (23)
20

Power due to inclination 𝑷𝒔𝒕: This power requirement is the product of the mass flow rate and height to
which the material is being conveyed. Thus
𝑄𝐻𝑔 𝑄𝐻
𝑃𝑠𝑡 = = , 𝑘𝑊 (24)
3600 367

Where, Q = mass flow rate in t/hr.

H = height in m.
If material is moving down the inclination, H is to be taken as negative.
So, total power requirement is;
𝑄(𝜆𝐿+𝐻) 𝐷𝐿
𝑃= 367
+ 20 , 𝑘𝑊 (25)

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