Plant Conveyor and Systems
What is a Plant Transporter?
In-plant conveyor systems find use in many industries and environments where it is necessary to move materials efficiently from one point to another.
Conveyor systems in plant manufacturing are crucial for the efficient transportation of bulk materials. They allow plants to be productive and more profitable.
Conveyors can handle a wide range of materials. They can move from flat distances to long distances. They may also include integrated applications such as transfer chutes, bins, hoppers, silos, bunkers, and feeders.
Each conveyor system will have its own requirements and there are several types of conveyors to meet individual needs. These include chain conveyors (roller conveyors), pneumatic conveyors (pneumatic conveyors), and belt conveyors.
Each has its own application. We at Carmaky Engineering are experts in belt conveyors that are most suitable for power stations, bulk handling terminals, and mining industries.
The conveyor system plays a critical role in these environments. It is therefore essential to optimize the system.
Belt Conveyor Systems
Although belt conveyors come in many forms and can function differently, the majority of them are pulley-driven belts (or conveyor belts), which use friction to transport materials continuously.
When moving bulk materials, belt conveyors offer several advantages over other types of conveying systems. Some of the advantages are:
- It's a cost-efficient method to transport bulk materials long distances.
- Very little material is lost in transit
- The conveyor can move materials through elevation changes, along a curve, or over an arc.
- You can load materials on the conveyor at any point along its path.
In addition to these advantages, belt conveyors can include a variety of integrated systems to handle different needs, conditions, or materials. These systems include:
- The surface may be covered or closed.
- You can also include unloading tippers for loading at different points along your travel route
- Separators can also be used for sorting operations
- For weighing, you can integrate weigh belt sections
- To provide extra support when climbing an incline, you can attach cleats to the belt.
You have many options, so it is important to take into account these things when designing and choosing a belt conveyor.
Important Considerations
A conveyor system's primary considerations should be the material that will be transported, the route to take, and any constraints or space restrictions. These considerations will inform the design of the system, and one will immediately see whether the design will be complex or not.
These are important factors. You should consider the following properties:
- What form does the material take (Hard / soft / discreet units or continuous 'flow'(sand etc)
- How big and heavy are the individual units? Is that consistent?
- How abrasive does the material?
- Preservation requirements ie. Protection against decomposing/breaking
- There are certain coverage requirements
Transport Route
Factors to consider regarding the route through which the material must be moved include:
- Length of travel
- Curves or elevation changes
- Points for loading and unloading
- Integrated systems (weight measuring or sorting).
Constraints
Pre-existing infrastructure, or the environment will most likely limit the ability to construct a conveyor system. Some considerations include:
- Space limitations. Is the conveyor housed in an enclosed facility, or will it need to pass through existing portions of a plant or over another conveyor?
- Pre-existing operations. Must the conveyor route navigate around other infrastructure, or must it be integrated into existing operations?
Other considerations
These primary considerations will determine the basic form of the conveyor system. The system must meet certain criteria to be functional.
- Safety. Safety is key to any system's construction or operation.
- Build cost effective homes
- Energy efficiency and power consumption.
- Robustness is a key feature of good design. Materials handling is abrasive, and equipment must be designed accordingly.
- Reliability. To reap the benefits, the system must be reliable. This includes the careful design and integration for transfer chutes as well overall system control design and PLC programming.
- Maintenance. Maintaining reliable systems is not an easy task.
- Brownfield projects require tie-in and shutdown planning. It is important to plan this in the design phase so that there are no disruptions to other operations during construction.
- Standardised components are used.
Conveyor Design
When designing a conveyor system, efficiency and cost effectiveness should be the top priorities. These are important but not the only ones that will be realized as the system develops. This includes the creation of detailed drawings and the selection of specific equipment.
The following interrelated factors, based on current knowledge, affect the cost effectiveness and efficiency a conveyor system or system:
- Power demand
- Idler spacing
- Belt velocity
- Belt width, class, and type
- Dynamic performance of a conveyor
Because of the influence each factor has on the desired outcomes, it is difficult to determine how they will affect them. This depends on factors such as conveyor parameters like horizontal length, vertical profile and capacity. While the methods used are consistent, the tools used for design and optimization may be different.
What Are We Offering
We design and provide plant conveyors, systems, and other equipment that are cost-efficient, fit-for purpose, reliable, and durable.
The Carmaky design team works closely with clients to fully understand their system requirements. Our team includes construction experts. We work closely alongside client operations and construction teams in order to plan critical tieins and commissioning activities. This ensures minimal disruption to operation. We also provide exceptional leadership in risk management and HAZOP processes.
Our team is able to provide comprehensive solutions for our clients and ensure their peace of mind.
Our plant system expertise includes:
- Belt conveyors - elevated, enclosed, curved
- Transfer chutes and structures
- Bins, hoppers, silos, bunkers
- Feeders
- Dust control
- Modular electrical rooms
- Systems and equipment for ancillary use