外文翻譯--帶式輸送機(jī)技術(shù)的最新發(fā)展 英文版

1、<p>　　Latest Developments in Belt Conveyor Technology </p><p>　　M. A. Alspaugh</p><p>　　Overland Conveyor Co., Inc.</p><p>　　Presented at MINExpo 2004Las Vegas, NV, USA Septemb

2、er 27, 2004</p><p><b>　　Abstract </b></p><p>　　Bulk material transportation requirements have continued to press the belt conveyor industry to carry higher tonnages over longer dista

3、nces and more diverse routes. In order keep up, significant technology advances have been required in the field of system design, analysis and numerical simulation. The application of traditional components in non-tradit

4、ional applications requiring horizontal curves and intermediate drives have changed and expanded belt conveyor possibilities. Examples of complex</p><p>　　Introduction </p><p>　　Although the tit

5、le of this presentation indicates “new” developments in belt conveyor technology will be presented, most of the ideas and methods offered here have been around for some time. We doubt any single piece of equipment or ide

6、a presented will be “new” to many of you. What is “new” are the significant and complex systems being built with mostly mature components. What is also “new” are the system design tools and methods used to put these comp

7、onents together into unique conveyance syste</p><p>　　As such, the main focus of this presentation will be the latest developments in complex system design essential to properly engineer and optimize today’s

8、 long distance conveyance requirements.</p><p>　　The four specific topics covered will be: </p><p>　　Idler Resistance </p><p>　　Energy Efficiency </p><p>　　Distributed

9、 Power </p><p>　　Analysis and Simulation </p><p>　　Energy Efficiency</p><p>　　Minimizing overall power consumption is a critical aspect of any project and belt conveyors are no diff

10、erent. Although belt conveyors have always been an efficient means of transporting large tonnages as compared to other transport methods, there are still various methods to reduce power requirements on overland conveyors

11、. The main resistances of a belt conveyor are made up of:</p><p>　　Idler Resistance</p><p>　　Rubber indentation due to idler support</p><p>　　Material/Belt flexure due to sag being

12、idlers</p><p><b>　　Alignment</b></p><p>　　These resistances plus miscellaneous secondary resistances and forces to over come gravity (lift) make up the required power to move the mat

13、erial.1 </p><p>　　In a typical in-plant conveyor of 400m length, power might be broken into its components as per Figure 1 with lift making up the largest single component but all friction forces making up t

14、he majority.</p><p><b>　　Figure 1</b></p><p>　　In a high incline conveyor such as an underground mine slope belt, power might be broken down as per Figure 2, with lift contributing a

15、 huge majority. Since there is no way to reduce gravity forces, there are no means to significantly reduce power on high incline belts. </p><p><b>　　Figure 2</b></p><p>　　But in a lo

16、ng overland conveyor, power components will look much more like Figure 3, with frictional components making up almost all the power. In this case, attention to the main resistances is essential. </p><p><

17、b>　　Figure 3</b></p><p>　　The specifics of power calculation is beyond the scope of this paper but it is important to note that significant research has been done on all four areas of idlers, rubber

18、 indentation, alignment and material/belt flexure over the last few years. And although not everyone is in agreement as to how to handle each specific area, it is generally well accepted that attention to these main resi

19、stances is necessary and important to overall project economics.</p><p>　　At the 2004 SME annual meeting, Walter Kung of MAN Takraf presented a paper titled “The Henderson Coarse Ore Conveying System- A Revi

20、ew of Commissioning, </p><p>　　Start-up and Operation”2. This project was commissioned in December 1999 and consisted of a 24 km (3 flight) overland conveying system to replace the underground </p>&l

21、t;p>　　mine to mill rail haulage system. </p><p>　　Figure 4 Henderson PC2 to PC3 Transfer House </p><p>　　The longest conveyor in this system (PC2) was 16.28 km in length with 475m of lift. Th

22、e most important system fact was that 50% of the operating power (~4000 kW at 1783 mtph and 4.6 m/s) was required to turn an empty belt therefore power efficiency was critical. Very close attention was focused on the idl

23、ers, belt cover rubber and alignment. One way to document relative differences in efficiency is to use the DIN 22101 standard definition of “equivalent friction factor- f” as a way to compare th</p><p>　　Rou

24、te Optimization </p><p>　　Figure 5- Tiangin China</p><p>　　Horizontal Adaptability </p><p>　　Of course the most efficient way to transport material from one point to the next is as

25、directly as possible. But as we continue to transport longer distances by conveyor, the possibility of conveying in a straight line is less and less likely as many natural and man-made obstacles exist. The first horizont

26、ally curved conveyors were installed many years ago, but today it seems just about every overland conveyor being installed has at least one horizontal change in direction. And today’s technolo</p><p>　　Figur

27、es 5 and 6 shows an overland conveyor transporting coal from the stockpile to the shiploader at the Tianjin China Port Authority installed this year. Designed by E.J. O’Donovan & Associates and built by Continental C

28、onveyor Ltd of Australia, this 9 km overland carries 6000 mtph with 4x1500 kW drives installed. </p><p>　　Figure 6 Tiangin China Plan View</p><p>　　The Wyodak Mine, located in the Powder River B

29、asin of Wyoming, USA, is the oldest continuously operating coal mine in the US having recorded annual production since 1923. It currently utilizes an overland (Figure 7) from the new pit to the plant 756m long (2,482 ft)

30、 with a 700m (2,300 ft) horizontal radius. This proves a conveyor does not need to be extremely long to benefit from a horizontal turn. 3 </p><p>　　Figure 7 Wyodak Coal</p><p>　　Tunneling </p

31、><p>　　Another industry that would not be able to use belt conveyors without the ability to negotiate horizontal curves is construction tunneling. Tunnels are being bore around the world for infrastructure such

32、 as waste water and transportation. The most efficient method of removing tunnel muck is by connecting an advancing conveyor to the tail of the tunnel boring machine. But these tunnels are seldom if ever straight. </p

33、><p>　　One example in Spain is the development of a 10.9m diameter tunnel under Barcelona as part of the Metro (Train) Extension Project. Continental Conveyor Ltd. installed the first 4.7km conveyor as shown in

34、 Figures 8 and 9 and has recently received the contract to install the second 8.39 km conveyor. </p><p>　　Figure 8 Barcelona Tunnel Plan View</p><p>　　Figure 9 Inside Tunnel</p><p>

35、　　In another example, Frontier Kemper Construction is currently starting to bore 6.18 km (20,275 ft) of 3.6m (12 foot) diameter tunnel for the Metropolitan St. Louis (Missouri) Sewer District. The Baumgartner tunnel (Fig

36、ure 10) will be equipped with a 6.1 km conveyor of 600mm wide belting with 4 intermediate drives. </p><p>　　Figure 10 Baumgartner Tunnel Plan View</p><p>　　Pipe Conveyors </p><p>　　

37、And if conventional conveyors cannot negotiate the required radii, other variations of belt conveyor such as the Pipe Conveyor might be used. </p><p>　　Figure 11 Pipe Conveyor</p><p>　　In its si

38、mplest description, a pipe conveyor consists of a rubber conveyor belt rolled into a pipe shape with idler rolls. This fundamental design causes the transported material to be totaled enclosed by the belt which directly

39、creates all the advantages. </p><p>　　The idlers constrain the belt on all sides allowing much tighter curves to be negotiated in any direction. The curves can be horizontal, vertical or combinations of both

40、. A conventional conveyor has only gravity and friction between the belt and idlers to keep it within the conveyance path. </p><p><b>　　Figure 12</b></p><p>　　Another benefit of pipe

41、 conveyor is dust and/or spillage can be reduced because the material is completely enclosed. A classic example where both environment and adaptability to path were particularly applicable was at the Skyline Mine in UT,

42、USA (Figure 12). This 3.38 km (11,088 ft) Pipe Conveyor was installed by ThyssenKrupp Robins through a national forest and traversed 22 horizontal and 45 vertical curves.4</p><p>　　Metso Rope Conveyor </p

43、><p>　　Another variation from conventional is the Metso Rope Conveyor (MRC) more commonly known as Cable Belt. This product is known for long distance conveying and it claims the longest single flight conveyor

44、in the world at Worsley Alumina in Australia at 30.4 km. With Cable Belt, the driving tensions (ropes) and the carrying medium (belt) are separated (Figure 13). </p><p>　　Figure 13 MRC- Straight Section</

45、p><p>　　This separation of the tension carrying member allows positive tracking of the ropes (Figure 14) which allow very small radius horizontal curves to be adopted that defeat the traditional design paramete

46、rs based on tension and topography. </p><p><b>　　Figure 14</b></p><p>　　MRC vs. Conventional Conveyor in Horizontal Curve</p><p>　　Figure 15 MRC at Line Cre

47、ek, Canada</p><p>　　Figure 15 shows a 10.4 km Cable Belt with a 430m horizontal radius at Line Creek in Canada. </p><p>　　Vertical Adaptability </p><p>　　Sometimes material needs to

48、 be raised or lowered and the conventional conveyor is limited to incline angles around 16-18 degrees. But again non-traditional variations of belt conveyors have been quite successful at increased angles as well as stra

49、ight up. </p><p>　　High Angle Conveyor (HAC.) </p><p>　　The first example manufactured by Continental Conveyor & Equipment Co. uses conventional conveyor components in a non-conventional way

50、 (Figure 16). The concept is known as a sandwich conveyor as the material is carried between two belts. </p><p><b>　　Figure 16</b></p><p>　　Continental’s 100th installation of the HA

51、C was a unique shiftable installation at Mexican de Canenea’s heap leach pad (Figure 17). </p><p><b>　　Figure 17</b></p><p>　　Pocketlift. </p><p>　　The second example sh

52、ows a non-traditional belt construction which can be used to convey vertically (Figure 18). </p><p>　　This Metso Pocketlift. belt was installed by Frontier Kemper Constructors at the Pattiki 2 Mine of White

53、County Coal in 2001 (Figure 19). It currently lifts 1,818 mtph of run-of-mine coal up 273 m (895 ft). 5 </p><p><b>　　Figure 18</b></p><p>　　Figure 19 Pattiki 2 Mine</p><p&

54、gt;　　Distributed Power </p><p>　　One of the most interesting developments in technology in the recent past has been the distribution of power along the conveyor path. Is has not been uncommon to see drives p

55、ositioned at the head and tail ends of long conveyors and let the tail drive do the work of pulling the belt back along the return run of the conveyor. But now that idea has expanded to allow designers to position drive

56、power wherever it is most needed. </p><p>　　The idea of distributing power in multiple locations on a belt conveyor has been around for a long time. The first application in the USA was installed at Kaiser C

57、oal in 1974. It was shortly thereafter that underground coal mining began consolidating and longwall mines began to realize tremendous growth in output. Mining equipment efficiencies and capabilities were improving drama

58、tically. Miners were looking for ways to increase the size of mining blocks in order to decrease the percentage of id</p><p>　　When panel lengths were increased, conveyance concerns began to appear. The powe

59、r and belt strengths needed for these lengths approaching 4 -5 km were much larger than had ever been used underground before. Problems included the large size of high power drives not to mention being able to handle and

60、 move them around. And, although belting technology could handle the increased strength requirements, it meant moving to steel reinforced belting that was much heavier and harder to handle and more im</p><p>

61、;　　Today, intermediate drive technology is very well accepted and widely used in underground coal mining. Many mines around the world have incorporated it into their current and future mine plans to increase the efficien

62、cy of their overall mining operations. 6 </p><p>　　The tension diagram in Figure 20 shows the simple principal and most significant benefit of intermediate belt conveyor drives. This flat, head driven convey

63、or has a simple belt tension distribution as shown in black. Although the average belt tension during each cycle is only about 40% of the peak value, all the belting must be sized for the maximum. The large drop in the b

64、lack line at the head pulley represents the total torque or power required to run the conveyor. </p><p>　　By splitting the power into two locations (red line), the maximum belt tension is reduced by almost 4

65、0% while the total power requirement remains virtually the same. A much smaller belt can be used and smaller individual power units can be used. To extend the example further, a second intermediate drive is added (green

66、line) and the peak belt tension drops further. </p><p>　　The tunneling industry was also quick to adopt this technology and even take it to higher levels of complexity and sophistication. But the main need i

67、n tunneling was the necessity of using very tight horizontal curves. </p><p>　　By applying intermediate drives (Figure 21) to an application such as the Baumgartner Tunnel as described in Figure 10 above, be

68、lt tensions can be controlled in the horizontal curves by strategically placing drives in critical locations thereby allowing the belt to turn small curves. </p><p><b>　　Figure 20</b></p>

69、<p><b>　　Figure 21</b></p><p>　　In Figure 22, the hatched areas in green represent the location of curved structure. The blue line represents carry side belt tensions and the pink line repre

70、sents return side belt tensions. Notice belt tensions in both the carry and return sides are minimized in the curves, particularly the tightest 750m radius. </p><p><b>　　Figure 22</b></p>

71、<p>　　Although aboveground overland conveyors have not used this technology extensively to date, applications are now starting to be developed due to horizontal curve requirements. Figure 23 shows a South American,

72、8.5km hard rock application which requires an intermediate drive to accommodate the four relatively tight 2000m radii from the midpoint to discharge. </p><p>　　Figure 23 Plan View</p><p>　　Figur

73、e 23 shows a comparison of belt tensions in the curved areas with and without distributed power. </p><p>　　The benefit of distributed power is also being used on the MRC Cable Belt. However, since the tensio

74、n carrying ropes are separate from the load carrying belt, installing intermediate drives is even easier as the material never has to leave the carry belt surface. The tension carrying ropes are separated from the belt l

75、ong enough to wrap around drive sheaves and the carry belt is set back on the ropes to continue on (Figure 24). </p><p>　　Figure 24 Tension Diagram</p><p>　　Analysis and Simulation </p>&

76、lt;p>　　Many will argue the major reason for our ability to build complex conveyors as described above is advancements in the analysis and simulation tools available to the designer. A component manufacturer can usuall

77、y test his product to insure it meets the specification; however the system engineer can seldom test the finished system until it is completed on site. Therefore computational methods and tools are absolutely critical to

78、 simulate the interactions of various diverse disciplines and componen</p><p>　　Dynamic Starting and Stopping </p><p>　　When performing starting and stopping calculations per CEMA or DIN 22101 (

79、static analysis), it is assumed all masses are accelerated at the same time and rate; in other words the belt is a rigid body (non-elastic). In reality, drive torque transmitted to the belt via the drive pulley creates a

80、 stress wave which starts the belt moving gradually as the wave propagates along the belt. Stress variations along the belt (and therefore elastic stretch of the belt) are caused by these longitudinal waves</p>&l

81、t;p>　　Many publications since 1959 have documented that neglecting belt elasticity in high capacity and/or long length conveyors during stopping and starting can lead to incorrect selection of the belting, drives, tak

82、e-up, etc. Failure to include transient response to elasticity can result in inaccurate prediction of: </p><p>　　Maximum belt stresses </p><p>　　Maximum forces on pulleys </p><p>　　

83、Minimum belt stresses and material spillage </p><p>　　Take-up force requirements </p><p>　　Take-up travel and speed requirements </p><p>　　Drive slip </p><p>　　Breakaw

84、ay torque </p><p>　　Holdback torque </p><p>　　Load sharing between multiple drives </p><p>　　Material stability on an incline </p><p>　　It is, therefore, important a ma

85、thematical model of the belt conveyor that takes belt elasticity into account during stopping and starting be considered in these critical, long applications. </p><p>　　A model of the complete conveyor syste

86、m can be achieved by dividing the conveyor into a series of finite elements. Each element has a mass and rheological spring as illustrated in Figure 26. </p><p><b>　　Figure 25</b></p><

87、p>　　Many methods of analyzing a belt’s physical behavior as a rheological spring have been studied and various techniques have been used. An appropriate model needs to address: </p><p>　　1. Elastic modulu

88、s of the belt longitudinal tensile member </p><p>　　2. Resistances to motion which are velocity dependent (i.e. idlers) </p><p>　　3. Viscoelastic losses due to rubber-idler indentation </p>

89、;<p>　　4. Apparent belt modulus changes due to belt sag between idlers </p><p>　　Since the mathematics necessary to solve these dynamic problems are very complex, it is not the goal of this presentati

90、on to detail the theoretical basis of dynamic analysis. Rather, the purpose is to stress that as belt lengths increase and as horizontal curves and distributed power becomes more common, the importance of dynamic analysi

91、s taking belt elasticity into account is vital to properly develop control algorithms during both stopping and starting. </p><p>　　Using the 8.5 km conveyor in Figure 23 as an example, two simulations of sta

92、rting were performed to compare control algorithms. With a 2x1000 kW drive installed at the head end, a 2x1000 kW drive at a midpoint carry side location and a 1x1000kW drive at the tail, extreme care must be taken to in

93、sure proper coordination of all drives is maintained. </p><p>　　Mass Flow at Transfer Points </p><p>　　One of the reasons for using intermediate drives and running single flight conveyors longer

94、 and longer is to eliminate transfer points. Many of the most difficult problems associated with belt conveyors center around loading and unloading. The transfer chute is often sited as the highest maintenance area of th

95、e conveyor and many significant production risks are centered here. </p><p><b>　　Plugging </b></p><p>　　Belt and Chute Damage and Abrasion </p><p>　　Material Degradation

96、 </p><p><b>　　Dust </b></p><p>　　Off Center Loading/Spillage </p><p>　　In the past, no analytical tools have been available to the design engineer so trial-and-error and

97、 experience were the only design methods available. Today, numerical simulation methods exist which allow designers to “test” their design prior to fabrication. </p><p>　　Numerical simulation is the discipli

98、ne of designing a model of an actual physical system, executing the model on a computer, and analyzing the results. Simulation embodies the principle of “l(fā)earning by doing''. To understand reality and all of its

99、complexity, we build artificial objects in the computer and dynamically watch the interactions. </p><p>　　The Discrete Element Method (DEM) is a family of numerical modeling techniques and equations specific

100、ally designed to solve problems in engineering and applied science that exhibit gross discontinuous mechanical behavior such as bulk material flow. It should be noted that problems dominated by discontinuum behavior cann

101、ot be simulated with conventional continuum based computer modeling methods such as finite element analysis, finite difference procedures and/or even computational fluid dynamics </p><p>　　The DEM explicitly

102、 models the dynamic motion and mechanical interactions of each body or particle in the physical problem throughout a simulation and provides a detailed description of the positions, velocities, and forces acting on each