Pipe Conveyor Belt

A: As with a troughed belt conveyor, the loading section or feeder of a pipe conveyor is open in order to be able to take on the bulk material. Special rollers then form the belt into a closed tube – diameters of 150 to 650 millimetres are possible. From this point on, metal plates with hexagonal cut-outs and staggered rollers with large support spans keep the tube in shape and closed over the entire conveying distance. Once the conveyed material has reached its destination, the belt opens automatically due to the positioning of the rollers and ejects the material. A deflection system now guides the belt into the lower run, where the conveyor belt is brought back into the tube shape and runs back to its starting point. For dual pipe systems it is also common to build and install walkways between the pipes for inspection and maintenance.
A distinct design feature of the Pipe Conveyor Belt is the round shape of the belt. There are two design variants: oval and circular. Each shape has its unique advantages. The oval shape seals the overlap of the belt a little better, because the angle of the overlap is flatter. On straight sections and across long distances the oval shape performs well – here the belt runs steady with little twisting or deviation. This is also due to the aerodynamics, there is less surface for wind resistance. On the other hand, the circular or round tube shape requires less reinforcement, and the cable construction has greater stability. The service life of the lower rollers are also extended, as they do not have to carry as much weight and endure less wear and tear as a result.
Whether short distances for alternative fuels, cement, or clinker or kilometre-long transport of ores, limestone and gravel – our technical expertise will help ensure proper planning at the beginning of your project. Our knowledge of horizontal, inclined and ascending routing and proprietary calculation programs are what make the realisation of big projects possible in the first place. With extensive feasibility studies and elaborate simulations of loading conditions and throughput rates, we develop the right system solution for you with the appropriate belt width and drive power for conveying your goods.

A: If you make a brief comparison between Pipe Conveyor Belt and traditional rubber belts, it is clear that the first mentioned ones can now easily face and overcome past unsolved logistic and environmental protection problems, such as:
• Horizontal and vertical curves with reduced bending radius
• Little space requirement by compact plant design
• Reduced spillage of materials loaded from the belt
• Dust free transportation
• Low maintenance
The Pipe Conveyors show several advantages if compared with conventional conveyor: the belt is rolled, after the loading point, into a pipe shape, containing the material inside with a very limited envirnment impact.
The Pipe Conveyor can negotiate much tighter curves than a flat belt as well as it can negotiate steep inclines and this will facilitate complex routing requiring less space than a conventional conveyor.
This advantage of being able to run tight curves is an essential aspect, since it can eliminate transfer points that are normally necessary when there is a relative sharp change in belt direction.
A Pipe Conveyor can transport the same volume of material as a conventional conveyor belt which is typically approx. double the width of the Pipe Conveyor, this is an important factor where space is limited, such as inside a tunnel.
The environmental regulations introduced in the last years require the industries to redraw the use of the plants for the transportation of dusty materials; the tubular belts plants are the most suitable for those materials handling where a special care to the environmental protection is needed.
Hence, it becomes evident that Pipe Conveyor Belt can be considered an environmental friendly products since they are used to prevent dust or material spillage to avoid polluting the surrounding areas. Nonetheless, some products affected by the presence of humidity, such as cement, meet in the tubular conveyor belt system the right technology for their transport in open areas such as loading and unloading wharfs.
At the very beginning, you have been informed that pipe conveyors are perhaps SIG most iconic products for cement industry where these tubular shape items can guarantee astonishing performances.
What can be surely claimed is that Pipe Conveyor Belts give the maximum of their potential in the fields of: cement factories, power plants, ports and steel making plants.

A: Pipe Conveyors are as the name implies the belt is wrapped into a cylinderical pipe form, guided by six hexagonally arranged idlers along the conveyor route.This allows the conveyor to negotiate inclines of upto 30 deg. and curve in both, the vertical and the horizontal directions, enabling it to negotiate obstacles that would obstruct a conventional straight conveyor. With the product completely enclosed within the belt pipe, spillage is eliminated along the conveyor run on both the carrying and the return side. The conveyor is being used to convey Copper Concentrate, Rock Phosphate, Coal from the jetty to the plant.
In a Pipe Conveyor system the belt runs flat over the head, tail and snub pulleys. The belt is troughed by idlers at the feeding point. Once the belt is loaded, it is formed into a pipe by overlapping its edges. At the discharge end the belt opens out to a troughed belt running flat over the pulleys. Material can be transported on the return belt.Intermediate loading can be provided at any point by opening and closing the belt at the required feed point.Pipe conveyors are an environmental friendly solution for conveying bulk material with zero spillage and ability to cover terrain difficult to negotiate by conventional conveyors.
Advantages
Unlimited capability for direct transfer of materials between two points which is not possible with conventional means.
Enclosed, clean and environment friendly transportation eliminating all spillage, scattering and return dropping of materials.
Elimination of transfer points and non-exposure to atmosphere results in retention of material properties while conveying.
Curvature possible in both horizontal and vertical planes associated with steeper angle of inclination.
Possibility of transporting second material through the return side pipe of the system, thereby reducing capital and operating cost.
Overall savings in space requirement, structural and foundation cost, thereby making the investment decisions easier.
Even a horizontal angle of 90 degree possible with the current technology.

A: Pipe conveyors provide effective solutions for a variety of problems faced in the industry, this includes
Spillage free transportation of material is obtained due to the enclosed belt.
Material build-up on idlers is reduced, decreasing maintenance, as no material is spilled during transit.
Pipe conveyors fit into narrow areas and save space in congested areas. This is possible due to a circular belt profile, allowing the gantry width to be reduced.
Can negotiate tight horizontal and vertical curves because the material is enclosed within the pipe and cross belt slip is reduced by the idler configuration.
Greater rate of elevation is obtained due to the increased contact between belt and material.
Has better belt edge damage control, due to improved belt training.
Weather resistance to wind and rain is improved as the material is enclosed, therefore gantry does not require covers.
Ecologically/environmentally friendly as it is able to pass around sensitive areas and negotiate remote terrain.

A: The Pipe Conveyor Belt is suitable for use in tougher conditions and requires application of special tubular-type conveyors. Due to its special carcass construction the belt runs like a tube which opens only when loaded and unloaded. The system remains closed and dust-tight even when bulk solids are conveyed in horizontal or vertical curves.
FEATURES
Prevents transport materials from flying, spilling or mixing with foreign substances as transported in a sealed pipe.
Consumes less energy than ordinary conveyor lines.
3-dimension layouts are available with openings at top, bottom, left or right.
Allows for maximum 30 degree incline transport, much steeper than ordinary conveyor belts.
Occupies minimum installation space.
Generates much less noise than ordinary conveyor lines.
APLICATION GROUPS
Cement and concrete plants.
REA - or gypsum plants.
Lime industry.
Tunnel construction.
Conveying dusty and fine-grained material.
Material of lower density and environmentally hazardous material
Silo conveyors.
Conveyors crossing roads (bridge conveyors).
Heating stations, power stations, garbage incinerating plants.

A: Pipe Conveyors are an environment friendly solution for conveying bulk material with zero spillage. They have the ability to cover difficult terrain which conventional conveyors would find difficult to negotiate.
Pipe conveyors are similar to a conventional belt conveyor at the material receiving area and discharge area. Thereafter the flat belt is slowly shaped to trough belt through transition and carrying idlers. At the end of loading zone, the conveyor belt gradually takes on a pipe formation with the help of variable off set rollers, finger rollers and pipe forming idlers.
The bottom three rollers at the carrying side of a Pipe Conveyor support the belt and material load whereas the top three rollers maintain the belt in its pipe shape. At the horizontal and vertical curved sections, rollers surrounding the belt support the load depending on the direction of the resultant force. The same applies to the bottom or return belt side of the pipe conveyor which may be utilized to transport a second material, thereby reducing capital and operating cost.
Development of suitable high resilient flexible belting has acted as a catalyst for the growth and popularity of pipe conveyor installations for several industries.
Pipe Conveyer's advantages over conventional conveyors:
Enclosed, clean and environment friendly transportation eliminating spillage, scattering and return dropping of materials.
Non-exposure to atmosphere resulting in retention of material properties.
Curvature possible in both horizontal and vertical planes associated with steeper angle of inclination.
Option of transporting second material through the return side pipe of the system.
Overall savings in space requirement, structural and foundation cost.

A: Moderate rigidity for tubing and bend easily, with the ability to maintain stability of the roundness.Pipe conveyor belts can be bent horizontally, vertically or diagonally, making them suitable for complex layouts and limited-space environments. This makes it possible to implement more flexible transmission lines within limited space.
The sealing is good at the overlap edge, fatigue resistance, abrasion resistance, with stable bearing capacity.
As enclosed conveying, the materials won’t float in the sky or fall, and will not affect the environment, especially for the fine materials such as powder or paste.
To protect the material from wind, rain, snow and some other environment.
Compared with traditional flat conveyor belts, pipe conveyor belts consume less energy during transportation. This is because the tubular structure can reduce the resistance and friction of the material and reduce the energy required for transportation.
Due to the unique structure and applications of pipe conveyors, they require higher technical specifications compared to conventional conveyor belts. For example, the requirements for EP (ethylene propylene) and NN (nylon) fabrics include enhanced flexibility in the latitudinal direction, thicker skim rubber, and stronger adhesion between fabrics and cover. Consequently, the production of pipe conveyors imposes greater demands on conveyor belt manufacturers’ capabilities, necessitating them to possess stringent production management and quality testing capabilities.

A: The core of Pipe Conveyor Belt is composed of high canvas or steel cord carcass, with high strength and wearable rubber as this top and bottom cover. During operating, the rubber belt is gradual changing from the plane to U-size, while the belt is rolled into tubular size for hermetic conveying.
Pipe Conveyor Belt is using for conveying materials required environment protecting and three-dimensional bend conveying in coal, mine, port, electric power, metallurgy, architecture, food industry. During hermetic conveying, the materials do not fly upwards and fall off, do not influence by environment, can be bend, big obliquity, out and home conveyed.

A: Pipe conveying system is recently developed system and has several advantages over traditional conveyor system.
Its application is versatile to carry all type of material in all kinds of industry.
Advantages of pipe conveyor over conventional conveyor are
A flat belt turns in to a shape of pipe and carries material.
Pipe shape gives protection to material being handled against weather such as wind and rain.
Reduction in transfer points.
Reduces Spillage of Costly Material during transportation from one point to another.
Compact design results in to space saving, works in any terrain, permits steep inclination angle and sharp bend.
Special Features about our PIPE CONVEYOR BELTS are as under:
Special pipe conveyor fabric is used to keep tension on the rollers & preventing collapsing of pipe.
Special fabric construction is given to reduce stress on the carcass during running & pipe formation.
Supplied in longer length to reduce no of joints in the pipe conveyor.
For high temp grade application, special top cover layer is given to sustain heat trapped inside the pipe
Special bottom cover is given to withstand the impact & rubbing from any rollers.

A: The alignment of the pipe conveyor belt is important in order to prevent the belt fouling with the structures, chute work. etc. which will result in permanent damage to the belt and the affected structures. In addition, belt alignment is crucial to prevent product being spilled from the pipe conveyor along its length due to the overlap being in the incorrect position.
The correct alignment / training of the belt must be checked for operation under no-load, partial load and full load conditions. For the initial alignment check i.e. for the initial new belt and for subsequent replacement belts, the conveyor must be started only once all cheeks have been completed as per the Erection Cheek Procedures. The conveyor is then started without load, with suitable monitoring by personnel along the full length of the conveyor.
Once the conveyor is started, the belt overlap must be observed with reference to the rest of the structure. Also the alignment of the belt at the tail and head end must be monitored at start-up and should the 'overlap' move clockwise or anticlockwise in the structure beyond the 20 degrees indicated above, the belt requires training.
Training of the belt should preferably be performed by one individual only. This ensures that the there is no duplication of adjustment to the idlers, especially in this instance considering the length of this conveyor. In addition, training of the betting should commence at the tail-end of the conveyor beginning with the tail pulley, loading section, etc. and progressing along the carrying-strand belt. Once at the head-end, training follows the belt line through the drives, take-up and back to the tail pulley via the return-strand.
To train the belt, each of the pipe conveyors' idler panels are fitted with two training idlers, on the carrying and return strands respectively. These idlers are usually the bottom idlers of each set of six idlers, and are mounted on a bracket which has slotted adjustment holes. Where the conveyor negotiates a horizontal curve, the training idlers are usually off-set to the inside of the curve radius.
To adjust the belt training, first establish whether the belt is required to rotate either clockwise or anti-clockwise for the 'overlap' to be at the top (carrying-side) or bottom (return-side) of the idler set. Secondly, establish which idlers on which of the idler panels require adjustment. To do this, the source of the misalignment must be found i.e. where the belt begins to misalign, and these idlers must be adjusted.
The bolts on the identified adjusting idler brackets must then be loosened slightly, to enable the bracket to be turned.
To align the belt, the idler bracket must be turned in the correct direction. The effect which this training has on the alignment of the belt is identical to that experienced on conventional conveyors.
Care must be taken to prevent excessive adjustment -of the training idlers. Adjustments must be made in small increments, to three or four adjacent training idlers at one time followed by observation for approximately 5 minutes, to allow the adjustment to take effect before further adjustments are made.
Where idlers are adjusted, the panels should be marked for reference purposes.
Once the belt is running true in the panels, partial load should be conveyed, followed by full load testing. All training idler brackets must be re-tightened once training of the belt is complete.
If it is found that by adjusting a series of training idlers, the belt alignment is not improved, then the adjusted idlers must be re-set to their original positions before proceeding to the next series of panels to make further adjustments. In this way the belt training procedure is conducted in a logical, systematic way.

A: Conveyor frame
If your conveyor frame is crooked or slanted, it could be misguiding your belt. Check your framework from all angles to ensure the frame is level and square.
Snub rollers
These rollers create more tension in your belt and make contact with every pulley in the system. Tenison is crucial to tracking, so your snub rollers should align with your frame and apply enough tension to the belt.
Belt cutting
Conveyor belts can be cut incorrectly during manufacturing, making them crooked. No matter how well the rest of your system runs, a crooked belt will cause tracking errors.
Cleanliness
Buildup on the belt and pulleys can cause the belt to sway one way or another. Make sure all parts of your conveyor are clean to ensure a smooth run and prevent failure.
False crowns
Conveyor belts move a variety of items, and sometimes the material can snag or get stuck on a pulley. You can find crowns on the center of your end pulleys that distribute force to each side of the belt and help it stay on track. If a piece of debris gets lodged in another pulley, it can create a fake crown and redistribute weight where you don’t need it. Check to see if your pulleys are clear of debris to avoid this.