带式输送机技术的最新发展外文文献翻译中英文翻译.docx
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带式输送机技术的最新发展外文文献翻译中英文翻译.docx
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带式输送机技术的最新发展外文文献翻译中英文翻译
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LatestDevelopmentsinBeltConveyorTechnology
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LatestDevelopmentsinBeltConveyorTechnology
M.A.Alspaugh
OverlandConveyorCo.Inc.
PresentedatMINExpo2004LasVegas,NV,USASeptember27,2004
Abstract
Bulkmaterialtransportationrequirementshavecontinuedtopressthebeltconveyorindustrytocarryhighertonnagesoverlongerdistancesandmorediverseroutes.Inorderkeepup,significanttechnologyadvanceshavebeenrequiredinthefieldofsystemdesign,analysisandnumericalsimulation.Theapplicationoftraditionalcomponentsinnon-traditionalapplicationsrequiringhorizontalcurvesandintermediatedriveshavechangedandexpandedbeltconveyorpossibilities.Examplesofcomplexconveyingapplicationsalongwiththenumericaltoolsrequiredtoinsurereliabilityandavailabilitywillbereviewed.
Introduction
Althoughthetitleofthispresentationindicates“new”developmentsinbeltconveyortechnologywillbepresented,mostoftheideasandmethodsofferedherehavebeenaroundforsometime.Wedoubtanysinglepieceofequipmentorideapresentedwillbe“new”tomanyofyou.Whatis“new”arethesignificantandcomplexsystemsbeingbuiltwithmostlymaturecomponents.Whatisalso“new”arethesystemdesigntoolsandmethodsusedtoputthesecomponentstogetherintouniqueconveyancesystemsdesignedtosolveeverexpandingbulkmaterialhandlingneeds.Andwhatisalso“new”istheincreasingabilitytoproduceaccurateEnergyEfficiencycomputersimulationsofsystemperformancepriortothefirstsystemtest(commissioning).
Assuch,themainfocusofthispresentationwillbethelatestdevelopmentsincomplexsystemdesignessentialtoproperlyengineerandoptimizetoday’slongdistanceconveyancerequirements.
Thefourspecifictopicscoveredwillbe:
●IdlerResistance
●EnergyEfficiency
●DistributedPower
●AnalysisandSimulation
EnergyEfficiency
Minimizingoverallpowerconsumptionisacriticalaspectofanyprojectandbeltconveyorsarenodifferent.Althoughbeltconveyorshavealwaysbeenanefficientmeansoftransportinglargetonnagesascomparedtoothertransportmethods,therearestillvariousmethodstoreducepowerrequirementsonoverlandconveyors.Themainresistancesofabeltconveyoraremadeupof:
●IdlerResistance
●Rubberindentationduetoidlersupport
●Material/Beltflexureduetosagbeingidlers
●Alignment
Theseresistancesplusmiscellaneoussecondaryresistancesandforcestoovercomegravity(lift)makeuptherequiredpowertomovethematerial.
Inatypicalin-plantconveyorof400mlength,powermightbebrokenintoitscomponentsasperFigure1withliftmakingupthelargestsinglecomponentbutallfrictionforcesmakingupthemajority.
Figure1
Inahighinclineconveyorsuchasanundergroundmineslopebelt,powermightbebrokendownasperFigure2,withliftcontributingahugemajority.Sincethereisnowaytoreducegravityforces,therearenomeanstosignificantlyreducepoweronhighinclinebelts.
Figure2
Butinalongoverlandconveyor,powercomponentswilllookmuchmorelikeFigure3,withfrictionalcomponentsmakingupalmostallthepower.Inthiscase,attentiontothemainresistancesisessential.
Figure3
Thespecificsofpowercalculationisbeyondthescopeofthispaperbutitisimportanttonotethatsignificantresearchhasbeendoneonallfourareasofidlers,rubberindentation,alignmentandmaterial/beltflexureoverthelastfewyears.Andalthoughnoteveryoneisinagreementastohowtohandleeachspecificarea,itisgenerallywellacceptedthatattentiontothesemainresistancesisnecessaryandimportanttooverallprojecteconomics.
Atthe2004SMEannualmeeting,WalterKungofMANTakrafpresentedapapertitled“TheHendersonCoarseOreConveyingSystem-AReviewofCommissioning,Start-upandOperation”2.ThisprojectwascommissionedinDecember1999andconsistedofa24km(3flight)overlandconveyingsystemtoreplacetheundergroundminetomillrailhaulagesystem.
Figure4-HendersonPC2toPC3TransferHouse
Thelongestconveyorinthissystem(PC2)was16.28kminlengthwith475moflift.Themostimportantsystemfactwasthat50%oftheoperatingpower(~4000kWat1783mtphand4.6m/s)wasrequiredtoturnanemptybeltthereforepowerefficiencywascritical.Verycloseattentionwasfocusedontheidlers,beltcoverrubberandalignment.OnewaytodocumentrelativedifferencesinefficiencyistousetheDIN22101standarddefinitionof“equivalentfrictionfactor-f”asawaytocomparethetotalofthemainresistances.Inthepast,atypicalDINfusedfordesignofaconveyorlikethismightbearound0.016.MANTakrafwasestimatingtheirattentiontopowerwouldallowthemtorealizeanfof0.011,areductionofover30%.Thisreductioncontributedasignificantsavingincapitalcostoftheequipment.Theactualmeasuredresultsover6operatingshiftsaftercommissioningshowedthevaluetobe0.0075,oreven30%lowerthanexpected.Mr.KungstatedthisreductionfromexpectedtoresultinanadditionalUS$100,000savingsperyearinelectricitycostsalone.
RouteOptimization
Figure5-TianginChina
HorizontalAdaptability
Ofcoursethemostefficientwaytotransportmaterialfromonepointtothenextisasdirectlyaspossible.Butaswecontinuetotransportlongerdistancesbyconveyor,thepossibilityofconveyinginastraightlineislessandlesslikelyasmanynaturalandman-madeobstaclesexist.Thefirsthorizontallycurvedconveyorswereinstalledmanyyearsago,buttodayitseemsjustabouteveryoverlandconveyorbeinginstalledhasatleastonehorizontalchangeindirection.Andtoday’stechnologyallowsdesignerstoaccommodatethesecurvesrelativelyeasily.
Figures5and6showsanoverlandconveyortransportingcoalfromthestockpiletotheshiploaderattheTianjinChinaPortAuthorityinstalledthisyear.DesignedbyE.J.O’Donovan&AssociatesandbuiltbyContinentalConveyorLtdofAustralia,this9kmoverlandcarries6000mtphwith4x1500kWdrivesinstalled.
Figure6-TianginChinaPlanView
TheWyodakMine,locatedinthePowderRiverBasinofWyoming,USA,istheoldestcontinuouslyoperatingcoalmineintheUShavingrecordedannualproductionsince1923.Itcurrentlyutilizesanoverland(Figure7)fromthenewpittotheplant756mlong(2,482ft)witha700m(2,300ft)horizontalradius.Thisprovesaconveyordoesnotneedtobeextremelylongtobenefitfromahorizontalturn.
Figure7-WyodakCoal
Tunneling
Anotherindustrythatwouldnotbeabletousebeltconveyorswithouttheabilitytonegotiatehorizontalcurvesisconstructiontunneling.Tunnelsarebeingborearoundtheworldforinfrastructuresuchaswastewaterandtransportation.Themostefficientmethodofremovingtunnelmuckisbyconnectinganadvancingconveyortothetailofthetunnelboringmachine.Butthesetunnelsareseldomifeverstraight.
OneexampleinSpainisthedevelopmentofa10.9mdiametertunnelunderBarcelonaaspartoftheMetro(Train)ExtensionProject.ContinentalConveyorLtd.installedthefirst4.7kmconveyorasshowninFigures8and9andhasrecentlyreceivedthecontracttoinstallthesecond8.39kmconveyor.
Figure8-BarcelonaTunnelPlanView
Figure9-InsideTunnel
Inanotherexample,FrontierKemperConstructioniscurrentlystartingtobore6.18km(20,275ft)of3.6m(12foot)diametertunnelfortheMetropolitanSt.Louis(Missouri)SewerDistrict.TheBaumgartnertunnel(Figure10)willbeequippedwitha6.1kmconveyorof600mmwidebeltingwith4intermediatedrives.
Figure10-BaumgartnerTunnelPlanView
PipeConveyors
Andifconventionalconveyorscannotnegotiatetherequiredradii,othervariationsofbeltconveyorsuchasthePipeConveyormightbeused.
Figure11-PipeConveyor
Initssimplestdescription,apipeconveyorconsistsofarubberconveyorbeltrolledintoapipeshapewithidlerrolls.Thisfundamentaldesigncausesthetransportedmaterialtobetotaledenclosedbythebeltwhichdirectlycreatesalltheadvantages.
Theidlersconstrainthebeltonallsidesallowingmuchtightercurvestobenegotiatedinanydirection.Thecurvescanbehorizontal,verticalorcombinationsofboth.Aconventionalconveyorhasonlygravityandfrictionbetweenthebeltandidlerstokeepitwithintheconveyancepath.
Figure12
Anotherbenefitofpipeconveyorisdustand/orspillagecanbereducedbecausethematerialiscompletelyenclosed.AclassicexamplewherebothenvironmentandadaptabilitytopathwereparticularlyapplicablewasattheSkylineMineinUT,USA(Figure12).This3.38km(11,088ft)PipeConveyorwasinstalledbyThyssenKruppRobinsthroughanationalforestandtraversed22horizontaland45verticalcurves.
MetsoRopeConveyor
AnothervariationfromconventionalistheMetsoRopeConveyor(MRC)morecommonlyknownasCableBelt.ThisproductisknownforlongdistanceconveyinganditclaimsthelongestsingleflightconveyorintheworldatWorsleyAluminainAustraliaat30.4km.WithCableBelt,thedrivingtensions(ropes)andthecarryingmedium(belt)areseparated(Figure13).
Figure13-MRC-StraightSection
Thisseparationofthetensioncarryingmemberallowspositivetrackingoftheropes(Figure14)whichallowverysmallradiushorizontalcurvestobeadoptedthatdefeatthetraditionaldesignparametersbasedontensionandtopography.
Figure14
MRCvs.ConventionalConveyorinHorizontalC
Figure15-MRCatLineCreek,Canada
Figure15showsa10.4kmCa
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