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Reducing Belt Conveyor Transfer Impact Energy using a Dynamic Idler

Written by Portelli, C.T. edited by mhd on 18. Oct. 2019

2. Conventional Options for Reducing Transfer Impact

An ideally designed transfer is one where the following exists:

Fig. 6: Typical Hood and Spoon (105° acute system to system angle change, 5 m drop height).
Fig. 6: Typical Hood and Spoon (105° acute system to system angle change, 5 m drop height).
  • Equivalent free fall of material is less than 1.2 meters.
  • Material feed is in the same direction as belt travel.
  • Loading area of the belt is horizontal.
  • It was shown by Conveyor Equipment Manufacturers Association [2] that chutes and skirt boards were designed to contain and settle the product on the belt.

The above is not always possible due to topographical or other design constraints. Given the need to protect the belt from impact in a system transfer that is not ideal, many solutions exist, with varying advantages and disadvantages. ​​

2.1 Hood and Spoon

Hood and spoon chute designs redirect the product stream from the preceding system gradually to be as close as possible to the following conveyor system in height and speed.

Advantages Disadvantages
  • Effectively reduces the free fall height close to zero, reducing impact.
  • Modifies the flow of the product stream to reduce the need for the belt to accelerate the product in the following system direction, reducing power consumption and abrasion wear on the belt.
  • Product is uniformly transitioned to settle it on the belt, reducing dust.
  • Space constraints and current infrastructure may not allow install.
  • High design costs.
  • High manufacture cost. Need to factor in a low friction wear surface such as polymer or ceramic. This also requires maintenance/replacement.
  • Potential lump sizes may exceed possible spoon widths without the risk of chute blockages.
2.2 Rock Boxes

A rock box allows the material to be retained in a box section of the chute before rebounding to the new path. Multiple ‘box’ sections of the chute can exist to gradually change the direction of the material path from one box to the next.

Advantages Disadvantages
  • Opportunity to direct flow in the same way as a hood and spoon chute to reduce impact and abrasion on the belt.
  • Uses the conveyed product as a wear surface, reducing the need for chute repair of wear surfaces. Very useful for highly abrasive and lumpy material.
  • Space constraints and current infrastructure may not allow install.
  • High design costs. Need to factor DEM modelling, particularly when angles between conveyor systems are large and multiple rebound ‘boxes’ exist.
Fig. 7: Rock Box.
Fig. 7: Rock Box.
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