YPT Conveyor Belts

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YPT Conveyor Belts

A conveyor belt is a continuous loop of material (typically rubber, fabric, steel-cord reinforced) driven by pulleys that transports bulk material from one point to another.

In mineral processing, belt conveyors form the backbone of material movement — from ore feed to crushers, mills to classifiers, tailings transport and stockpile reclaim.

The basic principle is simple: a carrying pulley, a return pulley, the belt loop, and idlers/rollers to support load and return.

Areas of Application

  • Long-distance haulage of ore, overburden or concentrates (surface or underground).
  • Inplant movement: between crushers, mills, classifiers, stockpiles.
  • Inclined or declined transport (troughed, pipe, sandwich conveyors) where terrain or site layout demands elevation change.
  • Material handling of raw ores, concentrates, tailings, sand, slag, aggregates — the belt must match the material’s characteristics (size, abrasiveness, moisture).
  • Integration with weighers, tripper mechanisms, stacker reclaim systems, and automated monitoring.

Principle of Operation

  • The belt loop is driven by a drive pulley, which is powered (motor & gearbox). The tail pulley returns the belt. Idlers support the belt and load on the carry side, and rollers on return side.
  • Material is loaded onto the belt in the loading zone; it is carried along (in a trough or flat) and discharged at the head end. Load shape, speed and belt width determine capacity.
  • Tension take-up ensures proper belt tension to avoid slippage or elongation.
  • For mining conveyors over long distances or with elevation changes, additional features such as belt trackers, scrapers, cleaning systems, belt monitoring (rip switch, sway switch) are used.
  • Maintenance of belt alignment, load centre, and effective cleaning are vital to prevent carryback and spillage which reduce capacity and increase costs

Reliable Conveying for Demanding Mining Operations

YPT Conveyor Belts Highlights

Engineered Flow. Continuous Performance

Design Criteria

Material characteristics:

Lump or particle size, bulk density, moisture/slurry content, abrasiveness, angle of repose and surcharge. These influence belt width, trough angle, idler spacing, skirtboard width.

Capacity
(tons per hour):

Determines belt speed × cross-sectional loading determines width.

Belt width,
speed and
troughing geometry:

From design guides: wider belt means lower speed for same capacity, reducing wear and spillage; troughing sets (typically 35°, 45° rollers) help maintain load.

Belt construction:

Top cover (abrasion resistance), carcass (tensile strength, elongation), bottom cover (wear from rollers). For mining: fabric carcasses or steel-cord belts for long distances or high tension.

Speed limitation:

High belt speeds increase wear, dust, spillage. As per “Ten common mistakes” article: substituting speed for width is a frequent error.

Skirtboard width
and sealing:

To prevent spillage in loading zone, as per CEMA guidance ~⅔ belt width for skirtboard in many bulk handling conveyors.

Tensioning and
drive system:

Proper take-up arrangement (screw, counterweight, hydraulic) required to maintain belt tension, prevent slippage, and ensure long service life.

Idler/trough
support:

Proper spacing of idlers, troughing sets, return sets, impact bars at loading zones. Ensure belt tracking and minimize belt sag.

Pulley design:

Pulley diameter relative to belt thickness for metal belt conveyors, ratio ≥ 625:1 to maximize belt life.

Straight vs incline
vs pipe vs sandwich conveyors:

Depending on path and elevation changes.

Standards:

Design codes such as IS 11592:2000 (India) give guidance for belts 300-2000 mm width, referencing ISO 5048 for belt conveyor calculations.

Technical Specifications

Belt
width

500 mm – 3000 mm+Based on capacity, lump size

Belt
speed

≈1.5 – 6 m/s (bulk)Higher speeds increase dust/spillage risk

Top cover thickness

3 mm – 10 mm+Depends on abrasiveness

Carcass tensile strength

Fabric: e.g., 200–1000 N/mm; Steel-cord: up to 5000 N/mmFor long distances/high tension

Drive
power

Varies widelyDepends on load, length, elevation change

Idler
spacing

Carry: ~1–2 m; Return: ~2–4 mDepends on belt width/weight

Maximum incline angle

18°–23° in bulk duty; steeper use cleated/pipe beltsMaterial and lubrication
dependent

Important Considerations:

  • Belt tracking & sag:

    Poorly tracked belts cause edge wear, spillage and downtime — skirtboard and sealing design influences this.

  • Upgrade allowance:

    Design should allow future capacity upgrades; simply increasing belt speed without adjusting belt width or chute design often fails.

  • Return side maintenance:

    Returning belt must be cleaned of carryback; accessories like return idlers, skirting, scrapers, dust control are important.

  • Material impact at loading:

    At the feed chute, belt damage from impact/lump size/density must be mitigated (impact bars, smooth chute design).

  • Dust and spillage management:

    Especially in mineral processing, controlling dust and material spillage is key for safety, environment and maintenance cost.

  • Energy efficiency:

    Belt conveyors are more energy-efficient than trucks/place of transport over long distances (some sources indicate belt over 1 km may cost 1/10th of truck haulage).

  • Maintenance cost rules of thumb:

    Especially in mineral processing, controlling dust and material spillage is key for safety, environment and maintenance cost.

  • Smart monitoring:

    Emerging practice includes condition monitoring sensors, anomaly detection on idlers, splices and belt surface for predictive maintenance.