Conveyors: highly effective means of transporting material over long distances

Recently there has been a trend towards long conveyor systems with high-capacity single flights, writes Ulf Richter, Diplom-Ingenieur (TU) Elektrotechnik, Global Portfolio Manager of Conveyor Systems at ABB Automation GmbH in Germany. These conveyor systems are an efficient alternative to costly truck fleets. Also, with deeper mines, the use of diesel-driven trucks becomes more difficult. Another trend is in underground mining, where conveyers are an efficient alternative to drift hoists or dedicated rail systems.
The selection of the right electrical, instrumentation and automation equipment directly impacts the performance, flexibility of operation, efficiency, reliability and total life cycle cost of the conveyor system. Conveying systems are required to be solid and dependable and use process repeatable technology, to ensure the highest availability, under the most diverse conditions.
Based upon ABB’s experience, a comprehensive applications portfolio of conveyors solutions has been developed. The application portfolio includes integrated systems for different types and geometric conveyor configurations of conveyors in the mining industry.
The ABB Conveyor System portfolio includes:
  • conveyor drive systems;
  • conveyor interlocking, automation and optimization;
  • conveyor material tracking;
  • conveyor instrumentation; and
  • containerized drive and control system solutions.
 
DRIVES SYSTEM
ABB’s conveyor drive solutions correspond to state-of-the-art
technology and are designed for reliable, long-life and low maintenance operation. In addition to classic motor starting methods such as binary or the new ABB ECOSS electronic resistor starters, there are Variable Speed Drives (VSD) solutions in medium- and low-voltage designs satisfying a variety of applications including even the largest and longest conveyor systems.
Variable-speed control provides the opportunity for smooth starting, belt load profile optimization, belt slack and anti-slip controls, which result in higher reliability and lower operating costs.
Different configurations can be designed for geared or gearless conveyor drive system solutions, depending upon an economic life cycle evaluation and the site requirements. ABB’s high-speed solution (geared) significantly reduces the mechanical stress on the complete drive train. The low-speed solution even eliminates the need for maintenance intensive gearboxes and makes high drive powers even possible.
ABB has also developed a Mining Conveyor Control Program (MCCP) which provides the conveyor main drives’ control. A sophisticated control loop is superior to traditional control methods (such as a basic master — follower) in control accuracy and flexibility.
The ABB MCCP provides adjustable speed for conveyors and offers the opportunity to tune a soft start profile (e.g. dwell function) and soft operation at the speed set point for optimal conveying with the maximum transport volume. Special attention is given to the load shared starting and operation between the motors on the head and tail end drive stations in order to mitigate high torque peaks and longitudinal oscillation in the belt.
 
CONVEYOR INTERLOCKING, AUTOMATION AND OPTIMIZATION
In normal operation, the conveyor will operate in an interlocked mode. This ensures that, as the conveyor is started, the single flights in a conveyor system will each start when the conveyor ahead of it has reached a critical target speed. Belt slip, belt splice and belt rip detection as well as running at the torque limit have an influence on the interlocking of the upstream conveyor. When in interlocked mode, the whole conveyor system is controlled from a central control point.
Conveyor control system overview.
When controlling a conveyor system a main issue to consider is potential blockage and spillage at chutes. A major aspect to avoiding downtime and reducing belt wear is a correct baffle plate position control to direct the material flow properly.
With Variable Speed Drives operation at any speed is possible. This means, for example, that the filling level of the conveyed material on the belt can be kept constant and so matched to the upstream volume and process requirements. This saves energy and increases mechanical life.
 
MATERIAL TRACKING
Material tracking, or Mass Flow Monitoring System (MFMS), is essential where material quality and conveyor load tracking is required. It provides input data for stockpile management or optimum conveyor load control.
The MFMS stores the current amount of material on each conveyor segment, including the material properties and provides a virtual overview of current load and position of the load on all conveyors.
The input data for the MFMS are load measurements provided at those places where the first conveyor in a conveying
route is loaded.The measurement can be done by laser scanners or belt scales.
The screen display example above shows a visualization of current status in the MFMS.The height of segment blocks is the ratio of material amount on the conveyor segment, and colour of the segment block specifies material property.
 
INSTRUMENTATION
Conveyor instrumentation incorporates all sensors and switches as well as actuators to protect the conveyor’s mechanics and costly belt. Important features are, for example; tramp metal detection, belt misalignment avoidance and detection, slip detection and control, belt wear monitoring, belt rip and splice damage detection, and chute overfilling avoidance.
The conveyor’s controller to be effective, measurements such as weight, volume, temperature, vibration, belt position and thickness, etc. must be taken in the right way.
CONTAINERIZED SOLUTION FOR ALL CLIMATE CONDITIONS
All electrical equipment, such as power distribution, drives and switchgear as well as the control system and auxiliary components need to be properly protected from the harsh conditions present in mining environment. Dust, shock and vibration, extreme temperatures and/ or high altitudes require a containerized E-house which is fully air conditioned and vibration proof. It is difficult to create a ‘standard’ E-house solution: therefore each situation must be viewed as unique. Design considerations include factors such as the heat losses, size of the room, available space and reduced cooling capability and electrical strength of the air at higher altitudes such as those found in most mines in South America.
Container in the copper open-pit mine, Collahuasi, Chile.
 
CONVEYOR SCAN
Remote Access is essential to reduce maintenance costs, decreasing time of process breakdown and for using a ‘proactive’ service. Finally it increases the efficiency of maintenance and trouble shooting as well as equipment live time.
Today machines are connected in a network.Via firewalls and while using Virtual Private Network (VPN) connections the remote access can be established over the internet independent of the distance in between. If no network connection is available also a low speed GSM connection allows access per remote.
 
 
Getting the best from your conveyor belts
Conveyors continue to be the most effective method of transshipment and on-site transportation but their durability and reliability can be critical factors in both productivity and cost management. Readers of DCI certainly need no reminder of the huge cost implications of a ship sitting quayside that cannot be unloaded because a conveyor belt needs to be repaired or replaced.
Especially during recent years, the technology used to manufacture conveyor belts has advanced enormously and today’s users of belts should rightfully expect a much higher level of performance and longer operational life from their belts. Sadly, this is often not the case. Getting the best advice and guidance is not always as easy because for many suppliers and service companies, conveyor belts that last longer and require less maintenance are not good for business. All too often, their philosophy seems to be “sell cheap and replace often”.
As if to confuse us even further, conveyor belt suppliers (and the companies that fit and maintain them) also seem to have developed a language all of their own. So, for the benefit of our readers who may not necessarily be conveyor belt experts, we asked for help from Netherlands-based Dunlop Conveyor Belting, which has a long-established tradition of developing high- performance rubber multi-ply belts.
Below, their general sales manager, Les Williams, explains conveyor belt construction and gives some valuable advice on how to choose the best type of belt to deal with the different kinds of demands that are placed on them.
 
CONVEYOR BELTS — THE BASIC STRUCTURE
Rubber belts with ‘multi-ply’ textile reinforcement are the most commonly used type within the dry cargo industry and usually consist of two elements. The basis of every conveyor belt is the carcass, which typically contain layers of extremely strong but flexible fabric embedded in the rubber. It is the carcass that provides the inherent characteristics of a conveyor belt such as its tensile strength and elongation (elasticity or ‘stretch’ under tension).
The use of wide conveyors naturally helps to increase the capacity. It is important, that the belt has good flexibility to allow troughing when empty while at the same time provide sufficient transversal stiffness or cross-stability for good support when loaded. This means that the belt strength and construction should not only be based on calculated belt forces and required safety factors but also on transversal stiffness to fulfill the criteria for both the loaded and unloaded situation. Consideration needs to be given to the type of material being carried because weight influences the required stiffness of the belt. In other words, the heavier the material then the stiffer the belt has to be.
This kind of calculation requires specialist knowledge but a good manufacturer or supplier should be able to help. Dunlop’s application engineering and local sales representatives provide this technical support service to its customers as part of what it calls its “total service package”.
 
PROTECTING THE CARCASS
An outer cover of rubber protects the belt carcass. Different types of rubber compound are used for rubber multi-ply belting covers; each designed to withstand damaging effects such as wear caused by abrasion, tearing and cutting, heat, fire and oil penetration. These different covers are generally referred to as “cover grade qualities”. The most commonly used types of cover grade used for dry cargo are abrasion resistant and oil resistant.
Selecting the best type of outer cover will largely determine the effectiveness and operational lifetime of conveyor belts. The wear resistance qualities of a conveyor belt are one of the major factors that determine its life expectancy and ultimately the truest test of its value for money. As a general rule, 80% of conveyor belt surface wear occurs on the top cover of the belt with approximately 20% of wear on the bottom cover.
Wear on the top cover is primarily caused by the abrasive action of the materials being carried, especially at the loading point or ‘station’ where the belt is exposed to impact by the bulk material and at the discharge point where the material is effectively ‘accelerated’ by the belt surface. Contrary to popular belief, short belts (below 50 metres) usually wear at a faster rate because they pass the loading and discharge points more frequently compared to longer belts. For these reasons, the selection of the correct type of cover quality and the thickness of shorter length belts becomes even more important than usual.
Wear on the bottom cover of the belt is mainly caused by the friction contact with the drum surface and idlers. The rate and uniformity of this type of wear can be adversely affected by many other factors such as misaligned or worn drums and idlers set at incorrect angles. Factors such as ozone penetration or an unclean environment where there is a build up of waste material can accelerate wear. Belt cleaning systems, especially steel edged scrapers, can also cause wear to the top cover surface.
 
THICKER IS NOT ALWAYS BETTER
The actual thickness of the cover is an important consideration. In principle, the difference in thickness between the top cover and the bottom cover should not exceed a ratio of more than 3 to 1.
In theory, the more abrasive the material and the shorter the conveyor, the thicker the cover should be. In reality, the actual abrasion resistance quality of the belt cover is more important than the thickness. In an effort to compensate for poor abrasion resistant qualities, many conveyor belt suppliers offer belts with covers that are thicker than are actually necessary but this can lead to other operational problems.
 
DIFFERENT TYPES OF ABRASION
It is a common misconception that a belt specified by a supplier as being ‘abrasion resistant’ should naturally be expected not to wear quickly. In actual fact, because of the variety of materials that are carried on conveyor belts, there are a number of different causes of wear and abrasion. For example, heavy and/or sharp objects can cause cutting and gouging of the belt surface whereas materials such as coal, sand and gravel literally act like sandpaper constantly scouring the rubber cover. For this reason, there are different types of abrasion resistant cover.
There are two internationally recognized sets of standards for abrasion, EN ISO 14890 (H, D and L) and DIN 22102 (Y,W and X). In Europe, it is the longer-established DIN standards that are most commonly recognized and accepted. Generally speaking, DIN Y relates to ‘normal’ service conditions and DIN W for resistance to abrasion, cutting, impact (from high drop heights), and gouging resulting from large lump sizes of heavy and sharp materials.
Each manufacturer uses its own mix or ‘recipe’ of polymers to create cover compounds that have different abrasion (wear) resistance qualities. The main polymers used are SBR (Styrene- Butadiene-Rubber) and BR (Butadiene-Rubber). Both SBR and BR have particularly good resistance not only to abrasion but also tearing, cutting, ripping and gouging. Many manufacturers try to avoid the use of natural rubber wherever possible in order to keep costs (prices) low.
BUYER BEWARE!
It is important that buyers of conveyor belts remember that DIN and ISO standards are only the minimum benchmark of acceptability. Belts that conform to international standards still often have to be replaced after unacceptably short periods. Despite the claims of the manufacturers, tests reveal that more
than 50% are found to be significantly below those minimum standards.
In terms of resistance to wear, Dunlop’s approach has been to provide a longer lasting and therefore more cost-effective solution by developing covers that significantly exceed international quality standards. An excellent example of this is its RA ‘standard’ abrasion resistant cover, which exceeds the DIN Y standard by more than 30%.
For extremely abrasive materials, or simply to achieve an even more extended working life, Dunlop has developed its RS cover, which exceeds the highest abrasion standard (DIN W) by nearly 30% and the equivalent ISO ‘D’ standard by more than 40%.
 
OIL AND FAT PENETRATION
Many cargo materials such as grain contain oil and fat. This can have a very detrimental effect on the performance and life expectancy of a conveyor belt because it penetrates into the rubber causing it to swell and distort, often resulting in serious operational problems. Despite the untold damage caused to
rubber there are, as yet, no recognized EN/ISO test standards for oil and fat penetration. This in itself can pose a big question mark against the oil resistance claims made by some manufacturers. In the Dunlop laboratories, the company applies the stringent ASTM D 1460 test standard, which originated in the USA.
Oil and fat (grease) resistance can be divided into two sources — mineral oils and greases and vegetable, animal oils and fats. Mineral oil and grease is most commonly present when transshipping goods that have either contained or been exposed to oil or grease at some stage. Mineral oils are the most aggressive kind and therefore require a particularly high level of protection. This is when a full nitrile belt is usually the best type to use. Dunlop recommends its ROS specification.
Cargo such as grain can have a surprisingly high level of vegetable oil. To provide added protection compared to standard abrasion-resistant covers, Dunlop has developed a very special compound formula in the ROM cover grade quality, which is specifically designed to resist wear as well as the penetration of this type of oil and fat. When particularly high concentrations of animal and vegetable oils are present then nitrile compound belts (ROS) should be used.

 
 
4B Braime’s B400 Elite conveyor belt misalignment system
The B400 Elite from 4B Braime Elevator Components detects dangerous misalignment of belt to prevent costly downtime and help eliminate the risk of explosions.
The B400 Elite uses an electronic microprocessor control unit and up to four contact alignment sensors to monitor the alignment of the belts of one or two belt conveyors.
The belt misalignment is detected by contact — using the 4B Touchswitch — or by the CBS2 system. If the conveyor belt becomes misaligned, the control will then cause the alarm relay to energize and, after a delay, the
stop relay will de-energize. Two separate alarm relays and two separate stop relays are provided. A self-test feature allows the control unit to check itself for correct function. An option for RS485 comms allows remote monitoring by PLC or PC.
The B400 Elite has been ATEX, CSA and IECEx certified.
4B Braime Elevator Components offers a range of hazard monitoring systems for
belt conveyors, including misalignment switches, bearing temperature sensors, speed switches and multi-functional hazard monitoring systems.


Flexco boasts a century of service to the belt conveyor industry
For more than 100 years, Flexco has been providing belt conveyor operators around the world with efficient, safe products, services, and solutions for their systems. Flexco manufactures mechanical belt fasteners, belt cleaning products, and tools, growing from a small Chicago workshop in 1907 to emerge as a major company active in the field of maximizing belt conveyor productivity.
The company serves customers in a variety of industries on six continents through a global network of subsidiary offices, sales representatives, and distributors. Flexco operates subsidiaries in Australia, China, England, Germany, India, Mexico, Singapore, and South Africa, marketing its broad line of products through a worldwide network of subsidiary offices, sales representatives, and distributors under well-known brand names, including Flexco®, Alligator®, Clipper®, Rockline®, Mineline®    and Eliminator®.
As a major player in the industry, Flexco understands that conveyors play a critical role in an operation’s productivity. When conveyors run efficiently, they make a real impact on an operation’s bottom line. Flexco takes a holistic approach to belt conveyor systems, recognizing each system as a whole and working to address challenges and develop solutions. That’s why Flexco goes beyond manufacturing fasteners, cleaners, and maintenance products to develop real solutions to belt challenges.
Flexco makes products that enhance belt conveyor productivity including:
  • mechanical belt fastening systems;
  • belt cleaners and ploughs;
  • pulley lagging;
  • belt cleats;
  • transfer-point systems; and
  • belt maintenance and installation tools.
 
Flexco understands that in coal handling operations, you need to be able to perform belt maintenance quickly. That’s why the company offers easy-to-install mechanical fastening systems and portable maintenance tools for timely, effective belt repairs, including conveyor belt clamps, skivers, cutters, and lifters. It also has a variety of products to enhance overall productivity, including pulley lagging, belt cleaners, impact beds, and more.
The company views its role as more than a manufacturer of products, but rather the provider of belt conveyor solutions for splicing, cleaning, tracking, and belt slippage. As a result, company representatives and distributors meet with customers, analyse conveyor operations and offer solutions designed to reduce downtime, accelerate belt repairs, and help achieve maximum productivity.
With an experienced team, Flexco is able to address almost any conveyor challenge — from slippage and spillage, to mistracking and wear and tear, to safety and environmental concerns. Even after a belt is up and running, Flexco stays involved to ensure that its products are delivering the top-notch performance needed for maximum productivity.
To support the needs of its customers, Flexco has developed a worldwide network of distribution partners who know Flexco products inside and out. The company ensures that its partners understand not just what its products do, but how they are constructed, and how they are best suited for customers’ applications.
The Flexco team of field representatives and global distributors can help customers evaluate their system’s performance, identify opportunities for improvement, and implement complete solutions.
Flexco provides the world's belt conveyors with efficient, safe products, services, and solutions for splicing, belt cleaning, belt tracking, spillage, and slippage. The company is based in Downers Grove, Illinois, USA, and operates subsidiaries in Australia, China, England, Germany, India, Mexico, Singapore, and South Africa. Flexco markets its broad line of products through a worldwide network of distributors, under the Flexco®, Alligator®, Clipper®, Mineline®, Rockline®, and Eliminator® brand names.
 
 
Superior’s TeleStacker® Conveyor offers cost-efficient shiploading/unloading
 
 
 
 
Superior Industries, a major US-based manufacturer of conveyor systems and components, offers a range of cost- efficient barge and ship loading/unloading solutionswithitsTeleStacker® Conveyor
systems, which are custom-configured to meet the requirements of specific marine handling applications. While delivering the advantages of a lower capital investment, shorter lead
times and quick on-site assembly, Superior TeleStacker Conveyor systems are an ideal and environmentally friendly alternative to the use of labour-intensive cranes and clamshell buckets, cable stackers, and other more costly stationary shiploading systems. Systems are sized for the application with conveyor lengths from 110ft to
190ft; belt widths from 30in to 72in; and capacities ranging from 500tph (tonnes per hour) to 5,000tph.
Each customized TeleStacker Conveyor system is designed and engineered to perform both load and unload functions, while providing highly mobile flexibility with the three key travel modes required for effective marine material handling: 1) an inline travel mode; 2) a dock travel or transverse travel mode with 360° rotation; and 3) a radial travel or tow mode. Systems are equipped with a mobile pivot base that allowsfree-ranging transfer point mobility; and a fixed-width head axle with a swivelling wheel carriage that allows rotation into each mode. Axle jacks relieve the weight, a hydraulic pin is released, and the unit swivels into the
next position. With push-button operation on the control panel, changing from one mode to another is quick, easy and safe. All loading and unload functions can be operated via the control panel or with a wireless remote belly pack.
A complete range of options are available for environmentally-sound operation and precision loading. Mainframe and stinger belt covers eliminate any dust emission or material spillage, while full-length drip pans prevent carryback material from spilling onto the dock or polluting water resources. A telescoping discharge chute is available to control dust emission and material drop height during loading;
and a 360°, rotating trimming spoon can be combined with the telescoping discharge chute for clean, even and fine-tuned trimming around the hatches when loading.
For any customized barge or ship load/unload system, Superior Industries engineers and service technicians are available from consultation through design, engineering, and manufacturing, and into installation and startup. Headquartered in Morris, Minnesota, USA, Superior Industries designs and fabricates a full line of portable and stationary conveying equipment including telescoping conveyors, truck unloading systems, feed systems, and design-build conveyor systems; and a complete line of idlers, pulleys and other conveyor components.
 
LIFTUBE® modular conveyor system sets the ‘Standard’ for belt sealing
Standard Industrie International, founded in 1978 by Herve´ Simoe¨ns, is a global specialist is the supply of equipment related to the storage, flow and conveying of dry bulk materials.
Standard Industrie is present in over 90 countries through its subsidiaries, and works in more than 60 business sectors including cement plants, mines and quarries, steel works, power stations, incinerators, foundries, chemical industries, glass manufacturing plants, and so forth.
The company owes its success to its proprietary AIRCHOC® air cannon (ten patents have been registered for it since it was developed in 1978), a product that is well-known and respected in the field of ‘declogging’.
Over the last ten years, the company has developed a range of new products, including: industrial vacuuming, mechanized cleaning of silos, scrapers, rubber conveyor buckets, flexible flappers and LIFTUBE® (belt conveyor optimization).
LIFTUBE® is a modular system that optimizes the sealing of any existing conveyor belt (any width, any length, PVC, rubber, etc.), between the loading point and the unloading point.
Instead of being in contact with idlers, the belt slides on a single central idler roller set up between lateral glideboards. Both idler roller and glideboards are tiltable to allow easy access when needed.
A removable hood can be set up on top to ensure the reduction of airborne dust
from the conveyor. Components are standard, the dimensions of
the central idler and hood will only vary with the width of the conveyor belt.
In addition, a patented system of tilting glideboards and idlers allows much simpler and safer maintenance and far less cleaning.
This patented system, made of standard, adaptable, evolutionary components, can be set up on existing or new installations.
Traditional system drawbacks include:
  • spillages — loss of product;
  • wear of flaps;
  • wear of belt;
  • safety risks — pinch point; and
  • maintenance takes time.
 
The advantages of the LIFTUBE® system include:
  • investment is quickly repaid;
  • glideboards and tilting roller system ensure a drastic reduction in maintenance, which is made even simpler. There is a two-year warranty on these;
  • protection of pinch point: complete safety (conforms to European standards);
  • hood and lateral curtains: drastic reduction of airborne dust, between loading and unloading, conforms to the ISO 14001 standard and also ensures a reduction in the loss of materials. The product is totally protected. No material contamination is possible;
  • longer life expectancy of the belt;
  • adaptable to every existing type of conveyor thanks to its standard, adaptable and evolutionary components.
  • by reducing the loss of product, the cost of cleaning is also reduced; moreover, the LIFTUBE® system reduces the cost of maintenance. Thus, payback is generally under 18 months.
  • installations have taken place in all the bulk handling business sectors; and
  • the LIFTUBE® system allows for the transport of fine bulk products (cement, lime, sugar...) as well as products of bigger sizes (limestone, chromium, iron, manganese...) and very abrasive ones (aluminium oxide, coal...). 

Since 2006, more than 7,500 metres of LIFTUBE® have been installed all around the world.A few examples of installations include:
  • in 2008, the HOLCIM Romania cement plant installed two conveyor belts (800mm wide and a total of 235m length — see picture above) to feed the kiln with alternative fuels. This is the fourth installation of LIFTUBE® forAFR;and
  • in another example, in 2010 the ELECTRABEL power station in the Netherlands opted for the LIFTUBE® system to carry biomass on the port (two conveyors, 218m in total), in order to comply with ATEx regulation (ATEx 21).
Since January 2011, Standard Industrie International has developed a new glideboard that is temperature resistant up to 250°C.
 
BELT SCRAPERS & PINCH POINT PROTECTIONS
As well as the LIFTUBE® system, Standard Industrie International also supplies a range of accessories for conveyor belts: belt scrapers and protection equipment to avoid pinch point.
It offers two types of belt scraper: a modular front cleaner
and subjacent belt cleaner. There are three types of blades in the product range,
according to the requirements of the product being transported:
  • carbide or ceramic blade for the scraping of abrasive products;
  • polyurethane blade for the scraping of other products or damaged belts.
Standard Industrie International’s belt scrapers guarantee perfect cleaning of the
belt. They improve the life expectancy of the belt and ensure that the running costs are reduced.
Tensioning is done by an integrated torsion bar or an external spring in order to exercise a flexible and equal pressure on to the belt.
The subjacent scraper has a patented tension spring system which, after regulation, maintains constant
pressure of the belt blades. The fastening system of the blades enables the scraper to
adapt itself whatever the head pulley profile. The Standard Industrie International belt scrapers are
compact and can be installed even in confined places. Pinch point protection: in order to upgrade the conveyor system in accordance with the n° 93-40 European safety bill,
Standard Industries offers three different pinch point protection systems:
  • head pulley protection;
  • tail pulley protection; and
  • return roller protection.

Martin Engineering poised to open business unit in India
Martin Engineering has announced plans to open a business unit in Pune, India in 2011. The company has been active in the India market since 2004, establishing a solid presence through its licensee,Thejo, to distribute and support select bulk material handling technologies across the continent. Already incorporated in India, Martin Engineering completed a detailed market study and entry strategy in 2010, finding huge potential in further developing its business there.
“Before making the decision to expand our business in India, we focused on providing high-quality conveyor products to a number of different industries,” commented Martin Engineering CFO Ron Vick. “Now that a business unit with full manufacturing capabilities will be opened, we’ll be positioned to offer our complete line of bulk material handling solutions, beyond the limited products currently available. This full line will include air cannons, railcar unloading products, engineered vibration and dust management.”
Vick said that Martin Engineering is looking forward to its role as a full-service supplier to the cement, steel, power and mining industries in India. “With growth rates expected to rival those in China, the India market represents an unprecedented opportunity for us,” he added.
A strategic business plan is currently under development, and Martin Engineering is in the process of hiring a managing director to run the new operation. During the beginning months of 2011, the company expects to finalize its lease on a new, 20,000 square foot facility. The company expects to have full operating capabilities by the second quarter of 2011. In addition to the new Pune facility, Martin Engineering will have sales and service offices and staff in three other areas of India: Calcutta, Delhi and Chennai. The firm is also aggressively investigating acquisition opportunities, as well.
Early in 2010, Martin Engineering exhibited at the Bulk Solids India trade show and was very well received, adding to the excitement of developing a full-service business unit in India. The company plans to utilize its expanded FOUNDATIONSTM Training Program, focused on the design and development of more productive belt conveyors, to help introduce Martin Engineering technologies and educate the industry.
The programme features three levels of training: Introduction to Conveyors and Conveyor Safety; Operation and Maintenance of Belt Conveyors; and Advanced Topics and Conveyor Engineering. The FOUNDATIONSTM series has been teaching bulk materials handling personnel how to operate and maintain clean, safe belt conveyors for nearly 20 years.
Founded in 1944, Martin Engineering is the world leader in making bulk materials handling cleaner, safer and more productive. The firm is headquartered in Neponset, IL, with global reach from operations in Brazil, China, France, Germany, Indonesia, Mexico, South Africa, Turkey, and the UK.
 
Transporting coal using Beumer’s curved belt conveying systems
Modern mining technologies need belt conveying systems that are capable of moving increasingly large volumes over ever-greater distances, especially in the field of coal mining. The BEUMER Group, a major player in conveying technology, develops and installs such systems.
Companies need effective options for transporting bulk goods such as coal from the mine to the power plant. Transportation by truck is expensive and has a negative impact on the environment. An economical alternative is a continuous conveyor, such as troughed or tubular belt conveyors. With the right design, these conveyors can be optimally adapted to the environmental conditions. Pollutants such as dust, noise and exhaust gases are minimized or even eliminated. By comparison to transportation by truck, large mass flows can be transported. Even in difficult environments, the construction work for these systems is minimal.
 
INDIVIDUAL ADAPTATION TO THE MATERIAL
BEUMER belt conveyors are used as closed tubular belt conveyors or as open troughed belt conveyors. The open troughed belt conveyors are especially used for robust and coarse material. Due to their routing, belt conveying systems negotiate rugged terrain and other obstacles, such as rivers, streets, buildings or train tracks. This reduces the costs of moving earth and expensive transfer points are significantly reduced. Horizontal and vertical curves can even overlap.
BEUMER can respond to all needs with an appropriate solution. Tubular belt conveyors are particularly suited to negotiate steep slopes or inclines. They are ideal for high-quality or powdery materials. Inside the closed system, the material does not fall backwards and the excellent sealing allows the material to be transported dust-free. BEUMER tubular belt conveyors are used for particularly tight curves, as they are able to better negotiate curves than troughed belt conveyors. Troughed belt conveyors transport larger volumes and mass flows and consume less energy. BEUMER has already implemented belt conveying systems with centre distances of more than 10km.
The curved belt conveying systems often negotiate impassable and mountainous terrain.
 
FOCUS ON ENERGY EFFICIENCY
The motors in these systems can be controlled, making optimal load distribution in the belt possible in all operating conditions. Depending on the terrain and loading condition, the systems can also operate as generators. The generated electric energy is fed to the mains by a regenerative feedback unit. This reduces the energy costs of operating the whole system.
 
MADE FOR A LONG SERVICE LIFE
Belts on BEUMER systems reach long service lives of up to 20 years. The reason for this is the optimal design of the routes, drive technology, the take-up station and the arrangement of belt-guiding idlers.
Exact calculations of the idler positions enable the belt conveyor to negotiate curves. If the system is designed optimally, an even stress on all components is ensured and the overall strain on the belt is minimized.
 
CONSULTING AND DESIGN COMPETENCE INCLUDED
BEUMER engineers, together with the customer, optimize the route of the belt conveyor on-site. They also develop the entire construction and design the static requirements for the bridges and belt conveying systems. Using their design competence, they make sure the investment and operating costs, as well as the required energy, are minimized.