Alat Transport di Industri

1
Alat Transport di Industri

Pipa Conveyor
Cair / Gas Padat
Cair + Padat Curah Padat
Gas + Padat

2
Conveyor

3
 Design of
Material Handling Equipment
Belt Conveyor System
for Crushed Limestone
Using 3 Roll Idlers
I. A. Daniyan, A. O. Adeodu and O. M. Dada
Department of Mechanical & Mechatronics Engineering
Afe Babalola University

4
1. ABSTRACT
• In the process or manufacturing industry, raw materials and products
need to be transported from one manufacturing stage to another.
• Material handling equipment are designed such that they facilitate
easy, cheap, fast and safe loading and unloading with least human
interference.
• For instance, belt conveyor system can be employed for easy handling
of materials beyond human capacity in terms of weight and height.

5
1. ABSTRACT
• This paper discusses the design calculations and considerations of
belt conveyor system for limestone using 3 rolls idlers, in terms of
size, length, capacity and speed, roller diameter, power and tension,
idler spacing, type of drive unit, diameter, location and arrangement
of pulley, angle and axis of rotation, control mode, intended
application, product to be handled as well as its maximum loading
capacity in order ensure fast, continuous and efficient movement of
crushed limestone while avoiding halt or fatalities during loading and
unloading.
• The successful completion of this research work has generated design
data for industrial uses in the development of an automated belt
conveyor system which is fast, safe and efficient.
6
2. INTRODUCTION
• Different methods such as fork lifting, use of bucket elevators,
conveyors systems, crane, etc. has been identified for lifting or
transporting bulk materials or products from one place to another in
the manufacturing industries depending on the speed of handling,
height of transportation, nature, quantity, size and weight of
materials to be transported.
• However, occasional halt or fatalities encountered while loading and
unloading in the industry are source of concern.

7
2. INTRODUCTION
• The objective of this research work is to provide design data base for
the development of a reliable and efficient belt conveyor system that
will reduce cost and enhance productivity while simultaneously
reducing dangers to workers operating them.
• Conveyor system is a mechanical system used in moving materials
from one place to another and finds application in most processing
and manufacturing industries such as: chemical, mechanical,
automotive, mineral, pharmaceutical, electronics etc.

8
2. INTRODUCTION
• It is easier, safer, faster, more efficient and cheaper to transport
materials from one processing stage to another with the aid of
material handling equipment devoid of manual handling.
• Handling of materials which is an important factor in manufacturing is
an integral part of facilities design and the efficiency of material
handling equipment add to the performance level of a firm [1].
• Conveyor systems are durable and reliable in materials transportation
and warehousing.

9
2. INTRODUCTION
• Based on different principles of operation, there are different
conveyor systems namely: gravity, belt, screw, bucket, vibrating,
pneumatic/hydraulic [2], chain, spiral, grain conveyor systems etc.
• The choice however depends on the volume to be transported, speed
of transportation, size and weight of materials to be transported,
height or distance of transportation, nature of material, method of
production employed.
• Material handling equipment ranges from those that are operated
manually to semi-automatic systems and to the ones with high degree
of automation.
• The degree of automation however depends on handling
requirements.
10
2. INTRODUCTION
• Material handling involves movement of material in a manufacturing
section. It includes loading, moving and unloading of materials from one
stage of manufacturing process to another.
• A belt conveyor consists of an endless and flexible belt of high strength
with two end pulleys (driver and driven) at fixed positions supported by
rollers.
• In this work, 3 roll idlers are required for adequate support of materials
transported and protection of the belt along its length.
• Pulleys are used for providing the drive to the belt through a drive unit gear
box powered by an electric motor. It also helps in maintaining the proper
tension to the belt.

11
2. INTRODUCTION
• The drive imparts power to one or more pulleys to move the belt and
its loads.
• Materials are transported over the required distance as a result of
friction generated between the roller surface and the moving belt set
in motion by a rotating pulley (drive pulley).
• The other pulley (driven or idler pulley) acts as a wheel around which
the material rotates and returns in a continuous process.
• Continuous processes are characterized by non-stop motion of bulk
or unit loads along a path without halt for loading and unloading [3].

12
2. INTRODUCTION
• The peculiarities of a belt conveyor is that it is easy and cheap to
maintain, it has high loading and unloading capacity and can
transport dense materials economically and at very high efficiency
over long distance allowing relative movement of material [4].
• Belt conveyor can also be used for diverse materials: abrasive, wet,
dry, sticky or dirty material.
• Only a single roller needs to be powered by driver pulley and the
roller will constantly spin causing the materials to be propelled by
the driving roller.
• Material handling equipment such as belt conveyors are designed to
load and unload materials from one stage of processing to another
in the fastest, smoothest, most judicious, safest, and most
economical way with minimum spillage.
13
2. INTRODUCTION
• Belt conveyors are employed for conveying various bulk and unit
loads along horizontal or slightly inclined paths and for transporting
articles between various operations in production flow lines [3].
• A belt conveyor can be horizontal, incline or decline or combination of
all.
• With the aid of pneumatic cylinder, the height of the conveyor is
adjustable so as to load and unload at different height.

14
2. INTRODUCTION

15
3. Design Considerations
• According to [1], the design of an effective and efficient material
handling system which will increase productivity and minimize cost,
the guidelines normally followed are:
1. Designing the system for continuous flow of material (idle time should be
zero);
2. Going in for standard equipment which ensures low investment and
flexibility;
3. Incorporating gravity flow in material flow system; and
4. Ensuring that the ratio of the dead weight to the payload of material
handling equipment is minimum.

16
3. Design Considerations
• The transportation route affects the overall cost of material
handling.
• An efficient material handling equipment will reduce cost per
volume of material transported and ensure that materials are
delivered to the production line safely.
• The design of belt conveyor system involves determination of
the correct dimension of the belt conveyor components and
other critical parameter values so as to ensure optimum
efficiency during loading and unloading conditions.
• Some of the components are: Conveyor belt, motor, pulley and
idlers, rollers, pneumatic cylinder etc.
17
3. Design Considerations
• The design of a belt conveyor system takes into account the followings:
i. Dimension, capacity and speed
ii. Roller diameter
iii. Belt power and tension
iv. Idler spacing
v. Pulley diameter
vi. Motor
vii. Type of drive unit
viii. Location and arrangement of pulley
ix. Control mode
x. Intended application
xi. Maximum loading capacity

18
 4. Belt Dimension, Capacity and Speed
• The diameter of the driver and driven pulley is determined by the type and
dimension of conveyor belting.
• The diameter of the pulley must be designed such that it does not place undue stress
on the belt.
• The length of a belt conveyor in meter is the length from the centre of pulley parallel
to belt line.
• Belt length is dependent on both the pulley diameters and center distances [4].
V = d × Π x n / 60 (1)
Where:
• V = Belt speed (m/s);
• d = diameters of rollers; and
• Π = pi
• n = rotation per minute (rpm)

19
 4. Belt Dimension, Capacity and Speed

• Capacity is the product of speed and belt cross sectional area

• Generally, belt capacity (BC) in kg/s is given as:
BC = A x ρ x V (2)
• Where:
• A= transported material sectional area (m2);
• ρ = material density (kg/m3); and
• V= belt speed (m/s)

20
 4. Belt Dimension, Capacity and Speed

• The mass of material (live load) per meter (kg/m) loaded on a belt
conveyor is given as: Mm = C / (3.6 x V) (3)
Where:
• C = Conveyor capacity (355 tonnes/h); and
• V = belt speed (1.25 m/s).
• Mm = 78.88 kg

21
 4. Belt Dimension, Capacity and Speed

• The magnitude of belt speed V (m/s) can be determined from

equations 1, 2, 3 or 6 and can as well be gotten from the catalogue
for standard belt.
• Belt speed v (m/s) depends on loading, discharge and transfer
arrangement, maintenance standards and lump size [5].
• The determination of belt width is largely a function of the quantity of
conveyed material which is indicated by the design of the conveying
belt [6].
• The value of belt capacity from equation 2 determines the value of
lump size factor.
22
 4. Belt Dimension, Capacity and Speed

• Another important factor in determining the belt capacity is the

troughing angle.
• Belts are troughed to allow the conveyor load and transport
materials.
• As trough angle increases, more materials can be transported.
• For standard 3 idler rollers of equal length the most common trough
angle is 35°.
• The belt width must be wide enough to deal with the material lump
size.

23
 4. Belt Dimension, Capacity and Speed
• Angle of surcharge is one of the most important characteristics in
determining the carrying capacity as it directly governs the cross
sectional area of material in the belt and hence the volume being
conveyed [5].
• The surcharge angle depends on friction between the belt and the
material and how the material is loaded.
• The steeper the conveyor, greater the belt capacity and the lesser the
surcharge angle.
• Since the limestone to be handled is abrasive, heavy, with specific
gravity between 1.5-2 tonnes/m3 and lump size up to 75 mm, a belt
of minimum width of 1200 mm and speed of 1.25 m/s is preferred
according to design values [7].
• For 3 equal roll idlers with surcharge angle of 25° and troughing angle
of 35° the capacity factor is 1.08 [5].
24
 4. Belt Dimension, Capacity and Speed

• The capacity in tonnes/h of a conveyor consisting of 3 equal roll idler

is given as
C = (CT x ρ x Cf x V) / 1000 (4)
• Where:
• C = Capacity in tonnes/h of a belt conveyor consisting of 3 equal roll idler;
• CT = Capacity of troughed belts for 3 roll equal length idler (175);
• ρ = material density in kg/m3 (1500);
• Cf = Capacity factor (1.08); and
• V = Belt speed in m/s (1.25)
• From equation (4), the overall capacity of the belt conveyor consisting
of 3 equal roll idler is 355 tonnes/h.

25
 4. Belt Dimension, Capacity and Speed

• For belts running horizontally and loaded evenly, the volumetric belt
load also is given as:
VL = LC / W (5)
Where:
• VL = Volumetric belt load (m3/h);
• LC = Load capacity of the belt conveyor (tonnes/h); and
• W = Specific Weight of the conveyed material (tonnes/m3)

26
 4. Belt Dimension, Capacity and Speed

• As belt tend to wander a bit in operation, the overall face width of the
pulley should exceed the belt width by 150 mm [6], if serious edge
damage is to be avoided.
• For haulage efficiency, conveyors should be operated fully loaded at
the maximum recommended speed and capacity.

27
5. Roller diameter
• The roller support belt and facilitates easy as well as free rotation of
the belt conveyor in all direction.
• The correct choice of roller diameter must take into consideration the
belt width [7].
• The relationship between the maximum belt speed, roller diameter
and the relative revolution per minute is given as:
n = (V x 1000 x 60) / (D × Π) (6)
Where:
• n = no of revolution per minute (rpm);
• D = roller diameter (mm); and
• V = belt speed (m/s)

28
5. Roller diameter
• The belt width is designed as 1200 mm, the belt speed is 1.25 m/s,
the roller diameter is therefore designed as 108 mm [7].
• From equation (6), the no of revolution per minute n = 220 rpm.
• The conveyor lengt
= horizontal distance / inclination angle θ (7)
• The inclination angle is 10°, the conveyor length is 100 m, and the
conveyor height is 10 m.
• Belt basic length = 2 x length a long conveying route (8)
• From equation (8), basic belt length = 2 x 100 = 200 m
29
5. Roller diameter
• The roll diameter for belt is given as
D = {d2 + (0.001273 x L x G)}0.5 (9)
Where:
• D= Overall diameter (m);
• d= Pulley ccore diameter (m);
• L= Belt length (m); and
• G= Belt Thickness (mm)

30
5. Roller diameter
• The length of a belt on roll is given as:
L = d + {(D - d) / 2} x N x π (10)
Or
L=HxNxπ (11)
Where:
• D = Outside diameter of the roll (m);
• D = diameter of the roll centre (m);
• N = no of wraps of the belt
• H = Height of the centre core (m); and
• π = 3.1416

31
6. Belt Power and Tensions
• The longer the length of the belt, the more the power required for
the conveyor and the higher the vertical distance of the lift, the
higher the magnitude of power required.
• The power PP (kW) at drive pulley drum is
PP = (FU x V) / 1000 (12)
Where:
• FU = Total tangential force at the periphery of the drive pulley (N);
• V = Belt speed (1.25 m/sec); and
• Or FU = (Pp x 1000) / V (13)

32
6. Belt Power and Tensions
• Power required for the conveyor to produce lift can also be calculated
as:
P = (3.75 x C x L) / 1000 (14)
Where:
• P = power required for conveyor (kW);
• C = conveyor capacity (355 tonnes/hr) = (98.6 kg/sec); and
• L = Lift (10 m)
P = 3.7 kW.

33
6. Belt Power and Tensions
• The belt of the conveyor always experience tensile
load due to the rotation of the electric drive, weight
of the conveyed materials and due to the idlers.
• The belt tension must be great enough to prevent
slippage between the drive pulley and the belt [8].

34
6. Belt Power and Tensions
• Belt tension at steady state is given as:

Where:
• Tss=Belt tension at steady state (N);
• f= Coefficient of friction (0.02)
• L=Conveyor length (100 m);
• (Conveyor belt is approximately half of the total belt length)
• g=Acceleration due to gravity (9.81 m/sec2);
• Mi=Load due to the idlers (570 kg);
• Mb=Load due to belt (577.5 kg);
• Mm=Load due to conveyed materials (78.88 kg);
• θ = Inclination angle of the conveyor (10°); and
• H=Vertical height of the conveyor (10 m).
• Tss= 71 kN

35
6. Belt Power and Tensions
• During the start of the conveyor system, the tension in the belt will be
much higher than the steady state. The belt tension while starting is
Ts = Tss x Ks (16)
Where:
• Ts= Belt tension while starting (N);
• TSS=Belt tension at the steady state (71KN); and
• KS=Start up factor (1.08).
Ts=76.68 KN

36
6. Belt Power and Tensions
• For inclined belt, the drive at head pulley is:
Tmax = Te + T2 (17)

• While the drive at tail pulley is

Tmax = Te + T2 (18)

• OR
Tmax = Te + T2 + belt tension-return side friction (19)
• Te is effective tension (KN)
• T2 = total empty friction load+ friction load+ slope tension

37
6. Belt Power and Tensions

Where:
• Fe = Equipment friction factor (0.0225);
• C = Belt Conveyor Capacity (355 tonnes/hr);
• V = Belt speed (1.25 m/sec);
• Tf = Terminal friction constant (60 m);
• W = Weight of material and belt in (656.38 kg/m);
• L = Length of conveyor (100 m); and
• H = Height of conveyor (10 m)

38
6. Belt Power and Tensions
• From equation 21, total empty friction is 965.86 N.
• From equation 22, load friction is 163.24 N.
• From equation 23, return side tension is 5.795N
• From equation 24, load slope friction is 12.09 N
• The effective tension Te according to equation 20
is 965.86 + 163.24 + 12.09 = 1.141 KN.
• For horizontal and elevating conveyors, the terminal friction constant Tf,
expressed in meter of centre to centre distance up to 300 m centre = 60 m
• And the equipment friction factor Fe = 0.0225 [5].

39
6. Belt Power and Tensions
• Maximum tension (Tmax) is the belt tension at the point where the
conveyor experiences the greatest stress. Tmax can be found at
different sections in the belt.
Tmax = (1 + K) × T (25)
Where:
• K = Drive factor
• T = Tension at a particular point (KN)

40
6. Belt Power and Tensions
• However, unitary maximum tension TUmax (N/mm) of the belt is
defined as:
TUmax = (Tmax × 100/ b (26)
Where:
• Tmax = Tension at the highest stress point of the belt or steady state tension in a conveyor
(71 KN); and
• B = Belt width (1200 mm).
TUmax=0.59 kN/mm.

41
6. Belt Power and Tensions
• The belt power (kW) is given as
Pb = Te × V (27)
• Te= effective tension (1.141 KN)
• V= Belt speed (1.25m/sec)
Pb= 1.43 kW

• Belt tension of a conveyor system is of a varying value along the system

flight and is governed by the following influencing factors: length and track
of the system, number and arrangement of pulley, characteristics of the
driving and braking equipment, type and location of the belt take up
devices and operating and loading state of the system [9].

42
7. Idler Spacing
• Idlers are installed at graduated spacing to ensure that the
sag as a result of load varies inversely with the tension in the
belt.
• Live load is calculated as 78.88 kg from equation 3
• Total live load (kg):
TL = LL x LC (28)
• LC is conveyor length (100 m)
• TL= 7.88 KN

43
7. Idler Spacing
• Dead load is the load consisting of weight of roller, belt and drive
pulley.
• The idler spacing at any point can be obtained from:
IS = (8 x T x Sg) / (Mρ x 9.81)e−3 (29)
Where:
• Mρ = Mass of belt and live load (656.38 kg/m);
• T = Tension at a particular point (kN); and
• Sg = Percentage of the idler spacing (0.01)
• An idler spacing of 1.0 m is recommended for a belt conveyor system
conveying a material of 1500kg/m3 and on a belt width of 1200 mm
[6].

44
8. Pulley Diameter
• Pulleys are manufactured in a wide range of sizes.
• The selection of pulley takes into account the wrap angle (180°),
belt speed (1.5 m/sec), method of belt strain, belt tension T, belt
width (1200 mm) and type of splice of the conveyor belt.
• The pulley diameter is obtained from standard value from the
catalogue.
• Once the pulley diameter is determined, the size of the coupling
can also be decided from the catalogue.
• Pulley wraps length at terminals:
2 x Π× D (30)
Where:
• Diameter of pulley (800 mm) [6].
• Pulley wraps length at terminals= 5 m.
45
8. Pulley Diameter
• Drive pulley can be lagged to increase friction and
improve transmission between belt and pulley [10].
• Elastic lagging helps to keep pulley clean so as to
increase duration of friction while grooved lagging
helps in removal of moisture so as to improve friction.

46
8. Pulley Diameter
• The effective pull FU (N) is given as

47
8. Pulley Diameter
• Recall from equation 12, the power PP (kW) at drive pulley drum is

PP = (FU x V) / 1000 (12)

Where:
• FU = Total tangential force at the periphery of the drive pulley (2.9 KN);
• V = Belt speed (1.25 m/sec); and

From equation 31,

PP= 3.62 kW.

48
8. Pulley Diameter
• The acceleration of the conveyor belt is given as:

Where:
• Ts = Belt tension while starting (76.68 N);
• TSS = Belt tension at the steady state (71 N);
• L = Conveyor length (100 m);
• Mi = Load due to the idlers (570 kg/m);
• Mb = Load due to belt (577.5 kg/m);
• Mm = Load due to conveyed materials (78.8 kg/m);
The acceleration A (m/sec2) of the conveyor belt is 2.39e-5 m/sec2.

49
9. The Conveyor Belt
• Belt breaking strength can be calculated as:
Bbs = (Cr x Pp) / (CV x V) (33)
Where:
• Cr = Friction factor (15);
• Cv = Breaking strength loss factor (0.75);
• Pp = Power at drive pulley (3.63 kW); and
• V = Belt speed (1.25m/sec)
The breaking strength is 58.08 N

50
10. Motor
• The minimum motor power for sizing of the motor is
Pmin = Pp / η (34)
Where:
• Pmin=Minimum motor power (kW);
• Pp=Power at drive pulley (3.62 kW); and
• η = Efficiency of the reduction gear (0.9)
• Pmin = 4.022 kW.
• The next standard motor greater than Pmin will be sufficient [11], [12].
• A standard motor of 5.0 kW is chosen.

51
10. Motor
• Alternatively, to determine the motor horse power hpmin
Hpmin = HPreq / η (35)

Where
HPreq = Hpe + HPm + HPj (36)
Where:
• HPe = Horse power required to drive the conveyor empty
• HPm = Horse power required to move material horizontally
• HPj = Horse power required to elevate material.

52
10. Motor
• Torsional moment is given as
Mt = ½ x D x (F + μ x W x g) (37)
Where:
• D = Diameter of pulley (m);
• F = Force (N);
• μ = Coefficient of friction;
• W = Weight of material and Belt (kg/m); and
• g = Acceleration due to gravity (m/s2)

53
10. Motor
• The number of revolution per minute (n) of the motor is given as
n = (9550 x 1000 x P) / Mt (38)
Where:
• P = Power (kW); and
• Mt = Torsional moment (N/mm)

54
10. Motor
• The cycle time of conveyor is given as:
Ct = 2 x L / V (39)
Where:
• L = Length of conveyor (100 m); and
• V = Belt speed (1.25m/sec)
The cycle time of the conveyor is 160 s-1

55
10. Motor
• Torque (kNm) is calculated as:
T = 9.55 x P / Pulleyrpm (40)
Where:
• P = power required for the conveyor (3.7 kW)
• Pulleyrpm = 26.2
• T = 1.35 kNm

56
11. Shaft Design
• Shaft diameter that will ensure satisfactory rigidity and strength when
the shaft is transmitting motion under different operating and loading
conditions.
• The values of belt width and pulley diameter helps in selecting the
size of shaft diameter from different conveyors hand book.

57
12. Control
• Compact Programmable Controllers otherwise known as application
controllers can be used for the control of the system.
• These controllers can e used for time control and supervisory
functions such as: conveyor speed control, speed control of individual
drives, speed and belt slip control, load equilibration between two
driving drum and speed difference control between two motors on
one driving drum [13].

58
13. RESULTS
• The followings are designed values were obtained for belt conveyor
system for limestone using 3 roll idlers.
• The following Table describe Design Values for Belt Conveyor System

59
13. RESULTS

60
13. RESULTS

61
13. RESULTS

62
14. Limitation of Study
• The construction of a belt conveyor system requires high capital base.
• This is a major constraint that limits this work to design only and as
such performance evaluation cannot be carried out on the belt
conveyor system.
• However, the research work provides design data for development of
belt conveyor system for industrial uses.

63
15. CONCLUSION
• Using the designed values above, a belt conveyor system
with 3 roll idlers can be developed for conveying crushed
limestone efficiently without belt spillage and fatalities.
• A PN 450 double weave standard rubber belt with the
specifications above will sufficiently convey the crushed
limestone.
• The belt conveyor system is designed with high degree of
automation, loading, movement and unloading efficiency.
• It is also very flexible, safe, with low initial, operational
and maintenance cost while eliminating repetitive short
distance movement in the manufacturing industry.

64
16. REFERENCES

1. Ogedengbe, T. I. (2010). Lecture Note on Applied Techniques of Production

Management. pp. 16-20.
2. Richardson, J. F., Harker, J. H. and Backhurst, J. R. (2002). Particle Technology and
Separation Process. Vol., 2, 5th Edition, Elsevier publisher, New Delhi, India. Pp. 29-35.
3. Vanamane, S. S., Mane, P. A. and Inamder, K. H. (2011). Design and its Verification of
Belt Conveyor System Used for Mould Using Belt Comp Software. Int. Journal of
Applied Research in Mechanical Engineering. Vol. 1(1) pp. 48-52.
4. Taiwo, A., Jekayinka, S. O. and Onawumi S. A. (2005). Mechanical Maintenance and
Repairs. Orsome Ventures Ltd, Ibadan. Pp. 50-70.
5. Anath, K. N. and Rakesh, V. (2013). Design and Selecting Proper Conveyor Belt. Int.
Journal of Advanced Technology. Vol. 4(2) pp. 43-49.
6. Fenner Dunlop “Conveyor Handbook” (2009). Conveyor Belting Australia. Pp 1-70.

65
16. REFERENCES

7. Rulmeca. Technical information. Project and Design Criteria for Belt conveyors.
Pp. 1-50.
8. Besser Service Bulletin. (2006). Conveyor Belt Basic Rules and Procedure for
Tracking. pp. 1-7
9. Phoenix Conveyor Belt Systems. (2004). Design Fundamentals. Hamburg pp. 1-
16.
10. Sandvik (2000). Conveyor Components. Pp. 1- 8.
11. Orthman Conveying System (2004). Belt Conveyor Catalogue. pp.1-21.
12. Conveyor Equipment Manufacturers Association (CEMA). “Belt Conveyors for
Bulk Materials” 6th Edition, pp. 200-205.
13. ABB-Process Industries (2000). Variable-speed drives for Belt Conveyor
Systems. Pp. 1-7.
66
Contoh Soal Belt Conveyor
67
Berapa torsi (Nm) yang bisa didapat dari motor listrik, jika dayanya
adalah 100 kW, putaran nominalnya adalah 1500 rpm dan
efisiensinya adalah 90% ?

• Motor listrik: daya = 100 kW, putaran = 1500 rpm, efisiensi = 90%
• Daya Mekanik (Pm) = eff x Daya Listrik (PL) = 0,9 x 100 kW = 90 kW
• Torsi Mekanik (Tm) = Pm/ (2 x 3,14 x n / 60) = 90.000 / (2 x 3,14 x
1500 / 60) = 573,2 Nm

68
Jika motor listrik di atas dipergunakan untuk memutar puley
penggerak belt conveyor yang berdiameter 50 cm dan tebal beltnya
adalah 1 cm melalui roga gigi reduksi putaran, sehingga putarannya
menjadi 20 % dari putaran motor penggerak, berapa kecepatan gerak
beltnya (km/h) ?
• Diameter puley (d) = 50 cm
• Tebal belt = 1 cm, mengelilingi ½ puley → Diameter puley + belt (D) = 50 +
1 + 1 = 52 cm = 0,52 m
• Reduksi putaran → 20%, putaran = 20% x 1500 = 300 rpm
• Keliling = 3,14 x D = 3,14 x 0,52 = 1,63 m
• Putaran = 300 putaran/menit
• 1 Putaran = 1 Keliling
• Kecepatan (Vb)= 300 x 1,63 m/menit = 489,84 m/menit = 29,39 km/jam
69
Jika efisiensi roda gigi reduksi adalah 90 % berapa torsi maksimum
(Nm) yang bisa dipergunakan untuk menggerakkan belt ?

• Efisiensi gearbox = 90%

• Daya mekanik motor listrik = 90% x daya listrik
• Daya listrik = 100 kW
• Daya keluaran gearbox (Pgb) = 90% x 90% x 100 kW = 81 kW
• Putaran = 300 rpm
• Torsi tersedia (Tt) = 81 / (2 x 3,14 x 300 / 60) = 2,579 kNm

70
Jika belt conveyor panjangnya 200 m mendatar (tidak ada
kemiringan) dengan bentuk belt datar saja dan di atas belt ada
tumpukan batu bara membentuk gunungan berpenampang segitiga
sama kaki dengan lebar alas 80 cm dan tinggi 30 cm, serta densitas
batu bara 0,87 ton/m³, berapa kapasitas conveyor (ton/h) ?
• Panjang conveyor (Lc) = 200 m
• Volume batubara (Vbb) = alas x ½ tinggi x panjang = 0,8 m x 0,5 x 0,3
m x 200 m = 24 m³
• Massa batubara (Mbb) = Vbb x densitas = 24 m³ x 0,87 ton/ m³ =
20,88 ton
• Kecepatan belt conveyor (Vb) = 29,39 km/jam = 489,84 m/menit
• Kapasitas conveyor = (Lc / Vb) x Mbb = (200 m / 490 m/menit) x 20,88
ton = 8,52 ton/menit = 511,3 ton/jam

71
Jika berat belt dengan lebar 120 cm dan tebal 1 cm adalah 13,4
kg/m, berapa torsi (Nm) yang dibutuhkan untuk menjalankan
konveyor jika koefisien gesek belt dan roller adalah 0,02 ?
• Massa Belt (Mb) = Lc x densitas = 200 m x 13,4 kg/m = 2,68 ton
• Massa di atas roller = Mbb + Mb = 20,88 ton + 2,68 ton = 23,56 ton
• Berat di atas roller (Wdr) = (Mbb + Mb) x g = 23,56 ton x 9,8 m/s² =
230,9 kN
• Koefisien gesek belt – roller (f) = 0,02
• Gaya gesek (Fg) = f x Wdr = 0,02 x 230,9 kN = 4,62 kN
• Diameter puley – belt (D) = 0,52 m
• Torsi yg dibutuhkan (Tb) = Fg x D/2 = 4,62 kN x 0,52/2 = 1,201 kNm

72
Apakah conveyor tersebut dapat befungsi dengan baik ?

• Torsi yang tersedia (Tt) = 2,579 kNm

• Torsi yan dibutuhkan (Tb) = 1,201 kNm
• Tt > Tb → conveyor dapat bergerak untuk mentransport barubara
dengan kapasitas 511,3 ton/jam

73
Sebuah “belt conveyor 3-rollers” dipergunakan untuk mensuplai kebutuhan batubara bagi sebuah
PLTU:
1. Jika daya yang dibangkitkan PLTU adalah 200 MW pada efisiensi 35% dengan nilai kalor batubara
17,8 MJ/kg, berapa “ton/jam” kebutuhan batubara PLTU tsb ?
2. Jika densitas batubara adalah 1800 kg/m³ berapa “m³/h” batubara yang harus disuplai ?
3. Jika batubara di atas conveyor membentuk penampang trapesium di bagian bawah dan segitiga
sama kaki di bagian atas, dimana panjang alas trapesium adalah 20 cm, panjang sisi atas trapesium
adalah 40 cm, tinggi trapesium 5 cm, dan tinggi segitiga adalah 10 cm, berapa kecepatan gerak belt
conveyor agar kebutuhan batu bara di atas terpenuhi dengan pas ?
4. Jika diameter puley adalah 40 cm, tebal belt adalah 2 cm, berapa “rpm” putaran puley yang sesuai ?
5. Jika motor yang dipergunakan memiliki nominal putaran 1500 rpm, berapa “%” reduksi yang
diperlukan ?
6. Jika lokasi pulverizer adalah 100 m dari coal yard dan tinggi pulverizer adalah 20 m di atas
permukaan tanah, berapa panjang conveyor yang harus dibuat ?
7. Berapa panjang belt yang diperlukan untuk membuat conveyor tersebut ?
8. Berapa besar berat batubara yang ada di atas conveyor tersebut ?
9. Jika koefisien gesek belt dan roller adalah 0,05 berapa gaya gesek yang terjadi ?
10.Berapa “HP” daya motor yang diperlukan jika efisiensinya adalah 90% ?
74
1. Jika daya yang dibangkitkan PLTU adalah 200 MW pada efisiensi 35%
dengan nilai kalor batubara 17,8 MJ/kg, berapa “ton/jam” kebutuhan
batubara PLTU tsb ?
• Daya = 200 MW
• Eff = 35 %
• Kebutuhan Heatrate dari Batubara = 200 MW / 0,35 = 571,4 MW
• NK = 17,8 MJ/kg
• Kebutuhan Batubara = 571,4 MW / 17,8 MJ/kg = 32,1 kg/s = 115,6
ton/h

75
2. Jika densitas batubara adalah 1800 kg/m³ berapa “m³/h” batubara
yang harus disuplai ?

• Kebutuhan Batubara = 32,1 kg/s

• Densitas batubara = 1800 kg/m3
• Kebutuhan Batubara = 32,1 kg/s / 1800 kg/m3 = 0,018 m3/s = 64,2
m3/h

76
3. Jika batubara di atas conveyor membentuk penampang trapesium di
bagian bawah dan segitiga sama kaki di bagian atas, dimana panjang
alas trapesium adalah 20 cm, panjang sisi atas trapesium adalah 40 cm,
tinggi trapesium 5 cm, dan tinggi segitiga adalah 10 cm, berapa
kecepatan gerak belt conveyor agar kebutuhan batu bara di atas
terpenuhi dengan pas ?

• Penampang Batubara = {(20 + 40) x 5 / 2} + (40 x 10 / 2) = 350 cm2 =

0,035 m2
• Kebutuhan Batubara = 0,018 m3/s
• Kecepatan Belt conveyor = 0,018 m3/s / 0,035 m2 = 0,51 m/s = 1,85
km/h

77
4. Jika diameter puley adalah 40 cm, tebal belt adalah 2 cm,
berapa “rpm” putaran puley yang sesuai ?
• Diameter puley = 40 cm
• Tebal belt = 2 cm
• Diameter total = 40 + 2 + 2 = 44 cm
• Keliling puley & belt = pi x diameter = 3,14 x 44 cm = 138,16 cm = 1,38
m
• Kecepatan belt = 0,51 m/s
• Putaran puley & belt = 1,38 m / 0, 51 m/s = 2,7 putaran/s = 162,4
rpm

78
5. Jika motor yang dipergunakan memiliki nominal putaran
1500 rpm, berapa “%” reduksi yang diperlukan ?
• Putaran motor = 1500 rpm
• Putaran puley & belt = 162,4 rpm
• Reduksi putaran = (162,4 rpm / 1500 rpm) x 100% = 10,8 %

79
6. Jika lokasi pulverizer adalah 100 m dari coal yard dan tinggi
pulverizer adalah 20 m di atas permukaan tanah, berapa
panjang conveyor yang harus dibuat ?
• Lokasi pulverizer = 100 m
• Tinggi pulverizer = 20 m
• Panjang conveyor = (1002 + 202)1/2 = 102 m

80
7. Berapa panjang belt yang diperlukan untuk membuat
conveyor tersebut ?
• Jarak sumbu puley = 102 m
• Diameter puley % belt = 44 cm = 0,44 m
• Puley = 2 buah
• Panjang belt = 2 x 102 m + 2 x (0,5 x 3,14 x 0,44 m) = 205,4 m

81
8. Berapa besar berat batubara yang ada di atas conveyor
tersebut ?
• Panjang conveyor = 102 m
• Luas penampang batubara = 0,035 m2
• Densitas batubara = 1800 kg/m3
• Massa batubara di atas conveyor = 102 m x 0,035 m2 x 1800 kg/m3 =
6.426 kg = 6,43 ton
• Berat batubaa = 6.426 kg x 9,81 m/s2 = 63.039 N

82
9. Jika koefisien gesek belt dan roller adalah 0,05 berapa gaya
gesek yang terjadi ?
• Berat batubara di atas conveyor = 63.039 N
• Koefisien gesek belt & roller = 0,05
• Gaya gesek = Berat batubara x koefisien gesek = 63.039 N x 0,05 =
3.152 N

83
10. Berapa “HP” daya motor yang diperlukan jika efisiensinya
adalah 90% ?
• Gaya gesek = 3.152 N
• Kecepatan belt = 0,51 m/s
• Daya untuk menggerakkan belt conveyor = 3.152 N x 0,51 m/s =
1.607,5 W
• Efisiensi motor listrik = 90 %
• Daya motor listrik = 1.607,5 W / 0,9 = 1.786 W = 1,8 kW = 1,8 kW x
1,341 HP/kW = 2,4 HP
• Catatan: berat belt diabaikan.

84
TERIMA KASIH

85