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Welcome
S.A.K.JEELANIMay 15th2015
Advanced Bulk Material ConveyingTechnologies in Cement Industry
Very Promising professionals with well
planned Vision to achieve 500Crores by
2016.
Three different manufacturing set-ups
with latest Technology two in Hyderabad
& oneat Raipur areISO Certified.
Only company in India to have all kinds
of material handling productsmanufacturedunder onecommonroof.
Marketing, Constructions & After Sales
ServiceOfficesat all regions.
Export business with SAARC, E. Africa,
S.Africa,SouthEast Asia & UAE.
BEVCON AT A GLANCE
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Bevcon Wayors is the industry leader in providing high-
quality and technologically advanced Bulk Material
Handling & Processing Solutions Crushing, Screening,
Conveying, Dust Extraction, Pneumatic conveying and
Special Conveying Systems.
OUR PRESENCE
Bevcon Wayors Leadership Areas:
Comprehensive Range of Bulk Material Handling &Processing Solutions
Innovation Excellence & in-house Fabrication
Track Record & Credentials
World-Class Technology Partnerships
Vast Domain Expertise
BEVCON
FOCUSSED AREAS
Advanced Conveying Systemsto
Simplify the Cement Plant Operations
Steep Angle CleatedBelt Conveyor
Overland Troughed BeltConveyor
Overland Pipe Conveyor
Sandwich BeltConveyor
A Total Solutions Provider toYour business needs
Bevcon Wayors is engaged inproviding End to End solutions toPower, Steel, Cement , Ports andMines with an experience of overthan 20 years on Turnkey basiswhich include Design, Engineering,
Manufacturing, Installation andServicing.
Bevcon Wayors is the industryleader in providing high-quality andtechnologically advanced BulkMaterial Handling & ProcessingSolutions
ADVANCED CONVEYING SYSTEMS
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STEEP ANGLE CONVEYOR CONVENTIONAL / STEEP ANGLE CONVEYOR COMPARISON
INCLINE ANGLES UP TO 90 DEGREES.
NO TRANSFER POINTS.
NO SPILLAGE.
MAXIMUM UTILISATION OF SPACE.
MINIMUM MAINTENANCE, LONG BELT LIFE.
WIDE RANGE OF MATERIALS CAN BE HANDLED.
LOW POWER REQUIREMENT, QUIET AND SMOOTH RUNNING.
HIGH/MEDIUM CAPACITY, HIGH LIFTS CAN BE ACCOMPLISHED.
FEATURES
STEEP ANGLE CONVEYOR
LUMP SIZE IS SOMEWHAT LIMITED PARTICULARLY IN HI GH ANGLES OF INCLINE
THE BELT IS MORE DIFFICULT TO CLEAN THAN STANDARD CONVEYOR BELTS.
LIMITATIONS
STEEP ANGLE CONVEYOR
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STEEP ANGLE CLEATED BELT CONVEYOR
Steep Angle (90o) Sidewall Cleated Belt Conveyor
JK Cement - Jhajjar
Case Study JK Cement - Jhajjar CASE STUDYJK CEMENT - JHAJJAR
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Case Study JK Cement - Jhajjar
Belt Width
Capacity
Material
Lift
Bulk Density
Feed Size
: 2000mm
: 1650TPH
: Clinker
: 19 Meters
: 1700 kg/m3
: (-)50mm
Power Sector
Handling FerroAlloys atVatvedt
Technologies
HandlingDolomite,
Limestone & DRIat Kamachi
Steel & Power
HandlingFerro Alloys
at Kalyan Garuda
Handling Coal& Husk at
Mylanlaboratories
Handling Dolomite& Lime mixture at
Viraj Profiles Ltd.
SAC Installations
Handling
Coal atMalabon Oil & Soap
Handling
Coalat Phoenix
Commodities
Handling
Municipal SolidWaste atSelco Intl.
Handling
Raw Sugarat Silkroad Sugar
SAC Installations
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Handling Granitepower at Restile
Ceramics
SAC Handling
Coal
SAC Installations
OVERLAND PIPE CONVEYOR
;
.
Working Operation Process
In thematerialloadingarea, the conveyingb el t i s o pe n. The c onve ye d mater ia l i ssupplied in the same way as in aconventional belt conveyor. Then speciald ev ic es e nc lo se the b el t c ar ry ing the
conveyed materia l. The diameter of theclosed pipes can be selected dependingonthe materialconveyingcapacity.
Atthispoint, thebeltforms asealed pipefortheentire conveyingline.Thus, thecontentis protected against external influenceswhile the environment is protected againstanypotential materiallosses.
At this point, the beltopens on its ownbefore the materia ldischarge point andthe material isdischarged.
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Pipe Conveyor is as similar as conventional belt conveyorsys tem, and compr ises a head and tail pul ley, one of
which is driven, over which an endless conveyor belt isspanned.
The belt is tensionedin a similar manner to conventional
belt conveyors. Beyondthe loading point, thebelt passesthrough a series of pipe forming idlers which effect thetransition from conventional to rolled form. This transition
takes place over a distance calculated to minimize beltstresses.
Once formedthepipeshape ismaintainedby sixidlerssetin a hexagonal pattern at each idler frame. Idler framespacing depends on pipe diameter andranges from 1 to
3.5m
Working Principle - Overland Pipe Conveyor
Dustfree withminimalnoise emissions.
No spillageor scatteringof materialfrom loaded belt.
Anydesiredhorizontaland verticalcurves with
minimal radius upto45 meters.
Materialcanbe conveyedon thefeedandas
wellas on return belteven withdifferentmaterials. Nobuildup onIdlers.
Canelevatevertically50% morethan conventional
conveyors.
Conveyingangleup to 30 degree.
Hasexcellentbeltedge damage control.
Unaffectedby windand rainthus requires no covers.
Reduced structuralcostsby eliminating walkways.
SUPERIOR FEATURES OF PIPE CONVEYOR
PROJECT HIGHLIGHTS
TYPE Overland Pipe Conveyor
LOCATION Khapradih, Raipur, CG
SYSTEM 3150TPH Limestone Handling System (Ongoing Project)
SCOPE OF WORK Engineering, Manufacturing, Supply
EQUIPMENT Details
M at er ia l t o b e c on veyed : L imestoneP ip e Co nv ey or L en gt h : 1 .4 K ms
Lift : 10.5 Mtr
Lump Size : 60 mm
Pipe Dia : 600 mm
Belt Width : 2100 mm
Capacity : 3190 TPH
Belt Speed : 3.5Mtr/sec
STATUS Under Commissioning Stage
SHREE CEMENT -PIPE CONVEYOR SHREE CEMENT -PIPE CONVEYOR
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SHREE CEMENT -PIPE CONVEYOR
Simply, SandwichSnakeBelt Conveyor consists of twoendless belt conveyors that share a
common load carrying path. The top and bottom belts are independently driven andtensioned. Along the carrying path the top and bottom belts are alternately supportedagainst closely spaced toughing idlers. Radial pressure,due to belttension and the curving
profile, continuouslyhugs the material that is Sandwiched between the two belts. Internalfrictionis developedand bulkmaterial canbe conveyedat anyhigh angleup to Vertical.
Sandwich Snake Belt Conveyor uses all and only conventional conveyor components and
smooth surfaced belts that can be continuously
scraped clean.
What isa SandwichBelt Conveyor?
Sandwich ConveyorProfiles
Snakes are available in widely ranging profi les of C and S-Shape. In any case, a longbottombeltapproach is possible to thesandwich entrance, anddischarge maybe on the
high incline or may be after theextension of the carrying belt beyond the mouth of thesandwich
Basic Profile Extended Profile
Sandwich Belt Conveyor
Increased angle of lift including vertical lift.
Uses standard belting.
Some environmental protection.
Good for sticky material.
FEATURES
SANDWICH CONVETOR
LIMITATIONS
Difficulty to handle large lumps, dry fines or spherical material.
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Typical Layout
Dos Santos Sandwich Belt High Angle Conveyor, Majdanpek Copper Mine, Serbia.Part of an IPCC (In-pit Crushing and conveying) system
Installation
Limestone Quarry, Midwest, USAMaterial - Limestone
Density - 1.60 t/cu -m (100 PCF)
Size - 76 mm (3) minus
Conveyin g Rate - 762 t/h (800
STPH)
Conveyin g Angle - 60 degrees
Belt Width - 1067 mm
(42)
Belt Speed - 2.54 m/s
(500 FPM)
Lift - 48,000 mm (158)
Length - 79,000 mm (258)
Drives
- Top Belt - 168 kW (125 HP)
- B ottom Belt - 168 kW (125
HP)
Applications & Installations
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LoadingCurve 1
Inflection 1
Curve 2
Inflection 2
Material - CoalDensity - 0.8 t/cu-m (50 PCF)
Size - 50 mm (2) minusConveying Rate - 250 t/h (276 STPH)Conveying Angle - 75 degreesBelt Width - 1200 mm (47)
Belt Speed - 2.29 m/s (450 FPM)Lift - 35,100 mm (115)Length - 45,065 mm (148)
Snake DrivesTop Belt - 30 kW (40.2 HP)
Bottom Bel t - 30 kW (40.2 HP)
Aceralia Steel Mill, Spain
Applications & Installations
DSI Snake Sandwich Conveyor Shiploaderfor
Cortex Resources at Port Adelaide, Australia
Material - Titanium Ore-Density - 2.4 t/cu-m (150 PCF)
Con veying Rate -1 0 00 t /h (11 02 STPH)C on ve yi ng An gl e - 5 0 d eg re esBelt Width - 1200 mm (47)Belt Speed - 2 m/s (394 FPM)Lift - 21,805 mm (71.5)Length - 56,656 mm (185.9)Snake Drives
- Top Belt - 5 5 kW (74 HP )-Bottom Belt -55 kW (74 HP)
Applications & Installations
Continental CN at INCO Voiseys Bay Proj
Material - Pebble OreDensity - 2.25 t/cu-m (140PCF)Size - 60 mm (2.4) minus
Conveying Rate - 102 t/h (112 STPH)Conveying Angle - 90 degreesBelt Width - 762 mm (30)
Belt Speed - 1 .02 m/s (200 FPM)Lift - 13,010 mm (42.7)
Length - 23,500 mm (77.1)Snake DrivesTop Belt - 7.46 kW (10 HP)Bott om Bel t - 7 .46 kW (10 HP)
Applications & Installations
Hamilton Ontario, Canada
SNAKE CONV. ELEVATION
Steel Mill Project
Material - Various
Density - 4.16 t/cu-m (260 PCF)Size - 75 mm (3) minusConveying Rate - 188 t/h (200STPH)
Conveying Angle - 70 degreesBel t Width - 914 mm (36)
B el t S peed - 1. 02 m /s (20 7 F PM)Lift - 35,235 mm (115.6)Length - 48,768 mm (160.0)
Snake DrivesTop Belt - 18.64 kW (25 HP)B ot to m B el t - 18. 64 kW (25 HP )
Applications & Installations
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Overland troughed belt conveyors (also known as long distance or cross country
conveyors) are belt conveyors that have been designed to carry high tonnage
loads over long distances. Overland conveyors can be applied in many different
industr ies and can range from just a few thousand feet to several miles in length.
Industr ies such as mining, power, paper, waste and cement require rel iable
conveyingof largequantities ofmaterialto long distances day in& day out.
Over land troughed belt conveyorshavebeen provento bean efficientmethodof
transporting bulk material over long distancesand costs areoftenlower than with
truck& railtransportation.
These overland troughed belt conveyors can followmost terrains andhave littleor
no impact on the environment. Operating andmaintenancecosts arelow andthey
areextremely safeto operateand doesnt produceloud sounds.
AN INTRODUCTION - OVERLAND TROUGHED BELT CONVEYOR LATEST DEVELOPMENTS
Belt Conveyor and Pipe
Conveyor Systems
System Design
Energy Efficiency
Distributed Power
Analysis and
Simulation
Advanced Controls
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Model Project
Complex Overland Conveyor
19.1km center-to-center length. 3 meter lift from head to tail
11 horizontal curves with radius ranging from 2100m to 3500m
Many Vertical Curves
Conveying ~1100 mtph of Lignite Coal
Real Installed Application
Reference List(Overland Troughed Belt Conveyor)
Client : Aker Solutions
Mine : Peru Copper- Toromocho
Location : P eru, S outh Amer ica
Commissioned : Under Const ruct ion (2012)
Role : Designer
Application : S ur face Copper M ine
Material : Copper
Capacity (TPH) : 10,292
Length (km) : 4.93
Lift (m) : +196, -276
Belt Width (mm) : 1800
Belt Spec : ST5200
Belt Speed (mps) : 6.00
P ower Att ached (kW) : 10, 000
Drive Type : CST
No of Drive : 4x2,500
Intermediate : 0
Take-up : Winch
Horizontal Curves : 2
Radii (M) : 5000
Installation & Application
Client : Lycopodium
Mine : Rio Tinto- Western Turner Syncline
Location : Western Australia
Commissioned : Pre-Feasibility Design in Progress
Role : Design Auditor
Application : Surface Iron Ore Mine
Material : Iron Ore
Cap acity (tph) : 5,000
Length(km) : 15.16
Lift (m) : +106
Belt Width (mm) : 1500
Belt Spec : ST3800
Belt Speed (mps) : 4.00
P ower At tached ( kW) : 8 ,000
Drive Type : VFD
No of Drive : 5x1,600
Intermediate : 1
Take-up : Gravity
Horizontal Curves : 2
Radii (M) : 5000
Installation & Application
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Installation & Application
Consulting Engineer
Typical Project
Installed 2005, USA
19 km Centers
10 Horizontal Curves
Intermediate Drive
R6900R10000
R9750
R8500
R8000 R10000
R12000
14
R12000
5
8 23
31
31
33
R10000
R10000
65
10
Capacity: 1200 tph
Length: 62,791 ft
Lift: 11 ft
Belt Width: 36 in
Belt Speed: 1400 fpm
Tail Head
Installation & Application
Material : Molybdenum
Capacity (tph) : 2500
Length (km) : 6.4
Lift (m) : 76
Belt Width (mm) : 1200
Belt Spec : ST2500
Belt Speed (mps) : 4.5
Power Attached (kW) : 3,000
No of Drive : 2x1500
Drive Type : VFD
Intermediate : 0
Take-up : Gravity
Horizontal Curves : 7
Radii (M) : 1524
Client : FREEPORT MCMORAN
Mine : Henderson PC-3Location : Cl im ax, CO U SACommissioned : 1999Role : Design T eam
Application : Underground MolybdenumMine
Client : Peabody EnergyMine : NARMLocation : Gil lette WY, USACommissioned : 2006Role : Designe r Application : Surface Coal Mine
Material : Coal
Capacity (tph) : 6000
Length(km) : 3.70
Lift (m) : -14
Belt Width (mm) : 1830
Belt Spec : ST2500
Belt Speed (mps) : 4.87
P ower At tached (kW) : 4400
Drive Type : VFD
No of Drive : 4x1100
Intermediate : 0
Take-up : Gravity
Horizontal Curves : 0
Radii (M) : NA
Installation & Application
Material : Copper Ore
Capacity(tph) : 3000
Length(km) : 3.50
Lift (m) : +65
Belt Width (mm) : 1200
Belt Spec : ST2500
Belt Speed (mps) : 4.80
P ow er Att ach ed (k W) : 1 05 0
Drive Type : VFD
No of Drive : 3x350
Intermediate : 0
Take-up
Gravity
Horizontal Curves : 0
Radii (M) : NA
Client : Metso Brazil
Mine : Vale-Sossego
Location : Brazil
Commissioned : 2002
Role : Designer
Application : Sur face Copper Mine
Installation & Application
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Installation & Application
Client : ThyssenKrupp RobinsMine : Barrick- Cortez Hills MineLocation : Elko, NV, USACommissioned : 2010Role : Designer Application : S ur face Gold Mine
Material : Gold
Capacity(tph) : 1100
Length(km) : 11.6
Lift (m) : -216
Belt Width(mm) : 900
Belt Spec : ST1400
Belt Speed(mps) : 4.50
P ower At tached(kW) : 1200
Drive Type : VFD
No of Drive : 2x600
Intermediate : 0
Take-up : Winch
Horizontal Curves : 1
Radii (M) : 5000
Sichuan, China
7.8 miles (12.5 km) Long
1500 TPH Limestone
48 Belt Width
800 FPM
8 Horizontal Curves
Built by Beumer
Installation & Application
Material : Molybdenum
Capacity (tph) : 2500
Length(km) : 16.8
Lift (m) : 474
Belt Width (mm) : 1200
Belt Spec : ST6800 Belt Speed (mps) : 6.0
P ower At tached ( kW) : 10, 000
Drive Type : VFD
No of Drive : 4x2500
Intermediate : 0
Take-up : Gravity/Winch
Horizontal Curves : 0
Radii (M) : NA
PC 2
PC 3
Client : F re ep or t M cMo ra nMine : H end er so n PC -2Location : Climax, CO USACommissioned : 1999Role : Design TeamApplication : Underground
Molybdenum Mine
Installation & Application
Material : Muck
Capacity (tph) : 1150
Length(km) : 13.4 and 15.0
Lift (m) : -78
Belt Width(mm) : 900
Belt Spec : ST1000
Belt Speed(mps) : 3.55 P ower Att ached( kW) : 1085 and 1280
Drive Type : VFD
No of Drive : 7x160 and 8x160
Intermediate : 3 and 3
Take-up
Winch/Storage Unit
Horizontal Curves : 4
Radii (M) : 800
Client : Continental Conveyor EnglandMine : UTE GuadarramaLocation : SpainCommissioned : 2004Role : Designer Application : Tunnel Boring Much Removal
Installation & Application
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Installation & Application
R3000
R4000
24
36Capacity: 6000 mtph
Length: 8980 m
Lift: 8m
BeltWidth: 1800 mm
Belt Speed: 5.6 mps
Head
Tail
Material : Coal
Capacity (tph) : 6000
Length(km) : 8.98 Lift (m) : 8
Belt Width (mm) : 1800
Belt Spec : ST3500
Belt Speed (mps) : 5.6
P ower At tached ( kW) : 6 ,000
Drive Type : VFD
No of Drive : 3x2000
Intermediate : 0
Take-up
Gravity
Horizontal Curves : 2
Radii (M) : 3000-4000
Client : Continental Conveyor AustraliaMine : Tiangin Port AuthorityLocation : Tiangin, ChinaCommissioned : 2003Role : Design AuditorApplication : Coal Ship Loader
Material : Coal
Capacity (tph) : 1950
Length(km) : 1.0 Lift (m) : 12
Belt Width (mm) : 1200
Belt Spec : ST800
Belt Speed (mps) : 4.57
Power Atta ched (kW) : 750
Drive Type : VFD
No of Drive : 1x750
Intermediate : 0
Take-up
Gravity
Horizontal Curves : 1
Radii (M) : 1500
Client : Black Hills EnergyMine : WyodakLocation : Gil lette, WY, USACommissioned : 2004Role : Designer Application : S ur face Coal Mine
Installation & Application
Client : Hatch
Mine : Xstrata-Koniambo Nickel
Location : New Calidonia
Commissioned : In Construction 2010
Role : Design Auditor
Application : Surface Nickel Mine
Material : Nickel Ore
Capacity (tph) : 700
Length(km) : 11.41
Lift (m) : -757
Belt Width (mm) : 1050
Belt Spec : ST1600
Belt Speed (mps) : 4.50 P ower At tached (kW) : 1575
Drive Type : VFD
No of Drive : 5x315
Intermediate : 0
Take-up : Gravity
Horizontal Curves : 4
Radii (M) : 1500-2000
Installation & Application