CONVEYOR TRANSFER CHUTE ANALYSIS

Prepared for

PORT WARATAH COAL SERVICES LTD

Kooragang Island Operations
PO Box 57
Carrington, Newcastle
NSW 2294

Ref - 115972

Prepared by
Helix Technologies Pty Ltd
PO Box 610
Morley WA 6943
Perth
Australia
Tel +61 8 9275 0635
Email: helix@helixtech.com.au
15/04/2016

TRANSFER CHUTE 05.32

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Table of Contents
INTRODUCTION.......................................................................................................................................
BASIC CONVEYOR AND CHUTE LAYOUT..............................................................................................
SITE OBSERVATIONS AND PHOTOGRAPHS.........................................................................................
BELT TRANSITION TROUGH TO FLAT....................................................................................................
4.1 Trough idler Drawing..........................................................................................................................
4.2 Trough idler Calculated Material Cross-section..................................................................................
4.3 Transition Idler - adjustable................................................................................................................
4.4 Transition idler Calculated Material Cross-section..............................................................................
4.5 Belt Transition Geometry....................................................................................................................
5 THEORETICAL DISCHARGE TRAJECTORY.........................................................................................
5.1 Discharge Trajectory at 5.2m/s and 3.286 degree incline.................................................................
5.2 Discharge Trajectory at 5.2m/s and 8 degree incline........................................................................
5.3 Discharge Trajectory at 5.2m/s and 15 degree incline......................................................................
6 DEM MODEL CALCULATIONS EXISTING AT 1000TPH.....................................................................
7 DEM MODEL CALCULATIONS EXISTING AT 10000TPH...................................................................
7.1 Overview of model existing conveyor............................................................................................
7.2 Side Elevation of model 10000tph - existing conveyor.....................................................................
7.3 Plan view of model - existing conveyor.............................................................................................
7.4 View of Impact area - existing conveyor...........................................................................................
7.5 Front view of model - existing conveyor...........................................................................................
7.6 Front view of model smaller particles 50mm..................................................................................
7.7 Particle Trace....................................................................................................................................
8 TRAJECTORY CALCULATIONS WITH RAISED IDLERS......................................................................
8.1 Trajectory Calculation with Transition idlers as per existing conveyor..............................................
8.2 Trajectory Calculation with Transition idlers raised 200mm..............................................................
8.3 Trajectory Calculation with Transition idlers raised 300mm..............................................................
9 DEM CALCULATIONS WITH RAISED TRANSITION IDLERS................................................................
9.1 DEM Calculation with Transition idlers raised 200mm......................................................................
9.2 DEM Calculation with Transition idlers raised 300mm......................................................................
9.3 Hump Pulley alternative method of raising belt at discharge............................................................
10
SUMMARY AND CONCLUSIONS.......................................................................................................
10.1
Existing Case................................................................................................................................
10.2
Case 1 Raise approach idlers 200mm.......................................................................................
10.3
Case 2 Raise approach idlers 300mm.......................................................................................
10.4
Other options................................................................................................................................
10.5
Conclusion....................................................................................................................................
11
REFERENCE DRAWINGS AND DOCUMENTS..................................................................................
12
DISCLAIMER.......................................................................................................................................
13
APPENDICES......................................................................................................................................
13.1
Trajectory Calculation Reports......................................................................................................
13.2
Particle Trace Reports..................................................................................................................
13.3
Helix DEM Model movie file download links..................................................................................
1
2
3
4

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1 Introduction
Conveyor 05.32 at Kooragang Island has a transfer chute at the discharge pulley onto
conveyor 07.04. The transfer chute has a sample cutter arrangement fitted which is designed
to take a cut through the material stream after it discharges over the drive pulley and before it
impacts onto a curved impact plate in the chute. The impact plate has a top support bar and
hinge arrangement which allows adjustment of the lower portion of the impact plate. The
sample cutter has an arc of movement which clears the top support bar of the impact plate.
The material trajectory from the discharge pulley is currently impacting the top support bar of
the impact plate and some material is also clearing the top of this bar and impacting on the
un-lined chute wall behind it. This material has caused damage to the support bar and unlined
chute walls.
A simple remedy would be to move the impact plate higher in the chute but this is not possible
due to the sample cutter arc of movement.
Site investigations and surveys have shown that the equipment and impact plate, discharge
pulley and transition idlers have been installed as per the original design drawings.
Theoretical discharge trajectory calculations (by others) have been made but the reason for
the high impact points is not evident from these calculations.
Helix Technologies have been contracted to build a Discrete Element Method (DEM) model of
the transfer and to run this model to determine the predicted trajectory and impact of the
material in the chute.
The software used to make this model is the Helix DEM Chute design program, details of
which are available from www.helixtech.com.au
This report details the results of the DEM modelling.

2 Basic Conveyor and Chute Layout

The 05.32 conveyor belt is 2500mm wide running at 5.2m/s. Trough angle is 45 degree with
three roll idlers. The discharge pulley is 1240mm diameter with 20mm lagging and belt
thickness is 20mm.

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Elevation of the chute showing pulley, theoretical trajectory, curved impact plate, sample
cutter and arc of movement.

3 Site Observations and Photographs

The following photographs illustrate the material impact on the support bar and spillage over
the top of the impact plate.

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Coal over shooting the deflector plate at 9,000 tph

Tile repairs to rear wall due to abrasion from coal over shooting deflector plate

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Repairs to top pipe of deflector plate worn away from abrasion

4 Belt Transition Trough to Flat

The idler trough angle is 45 degrees with a centre roll face width of 900mm as per drawing
below.

4.1

Trough idler Drawing

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4.2

Trough idler Calculated Material Cross-section

The following drawing is calculated and drawn from the Helix delta-T Conveyor design
software. A bulk density of 800kg/m3 and an angle of repose of 28 degrees have been used.
4.2.1

Capacity 7000tph, Trough 45 degree

Capacity input is 7000tph. Burden Depth is 442mm.

4.2.2

Capacity 10000tph, Trough 45 degree

Capacity input is 10000tph which is the maximum system capacity. Burden Depth is 565mm.

4.3

Transition Idler - adjustable

Transition idlers with wing roll angles varying from 35 degrees down to 5 degrees have been
installed over a transition length of 15m. The incline angle of the stringers is 5.742%.
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Transition Idler spacing is 1.25m except for the two idlers closest to the pulley; these are 1.15
and 1.35m respectively. Note centre roll face width remains at 900mm throughout, ensuring a
constant width centre trough section. This constant width trough ensures that the material
burden maintains most of the original burden depth formed during the normal trough right
through the transition from trough to flat. A detailed model of this was built in Helix DEM
program.

4.4

Transition idler Calculated Material Cross-section

The following drawing is calculated and drawn from the Helix delta-T Conveyor design
software at an intermediate and at the last idler before the discharge pulley.
4.4.1

Capacity 10000tph, Trough 20 degree

Capacity input is 10000tph. Burden Depth is 472mm.

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4.4.2

Capacity 10000tph, Trough 5 degree

Capacity input is 10000tph which is the maximum system capacity. Burden depth is 394mm.

4.5

Belt Transition Geometry

The above angles and RLs have been entered into Helix DEM as shown below:

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Note the constant width centre section of the transition.

5 Theoretical Discharge Trajectory

The following calculations show the theoretical discharge trajectory calculated using the
CEMA methods and performed using the Helix delta-T software.

5.1

Discharge Trajectory at 5.2m/s and 3.286 degree incline

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The trajectory calculation above is for the belt running at 5.2m/s and a burden depth of
500mm. The belt incline angle is the theoretical incline of the belt at transition. The deflector
plate pivot is located 3.351m from pulley centre and 0.095m below pulley centre and is shown
in the graph. The front faces of the tiles on the deflector plate are 3.209m from pulley centre
and this is the location of the lines drawn above.

5.2

Discharge Trajectory at 5.2m/s and 8 degree incline

The trajectory calculation above is for the belt running at 5.2m/s and an assumed burden
depth of 500mm. The belt incline angle is the belt sag incline of the belt at transition, assumed
to be an angle of 8 degrees. The Deflector plate pivot is located 3.351m from pulley centre
and 0.095m below pulley centre. The front faces of the tiles on the deflector plate are 3.209m
from pulley centre and this is the location of the lines drawn above

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5.3

Discharge Trajectory at 5.2m/s and 15 degree incline

The trajectory calculation above is for the belt running at 5.2m/s and an assumed burden
depth of 500mm. The belt incline angle is the belt sag incline of the belt at transition, assumed
to be an angle of 15 degrees.
None of the three theoretical calculations above show the material impacting the top of the
deflector plate, even with the extreme sag approach angle of 15 degrees.

6 DEM Model calculations existing at 1000tph

The first DEM calculation was run at a reduced capacity of 1000tph. The impact of material on
the chute impact plate is acceptable as it is below the top of the impact plate.

7 DEM Model calculations existing at 10000tph

This model has been run using 100mmm particle diameters in order to enable manageable
number of particles at 10000tph. The model inputs have been adjusted to compensate for the
larger particle than actual particle sizes which are -50mm.

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7.1

Overview of model existing conveyor

Isometric view of model running at 10000tph. Green particles are moving slowly and red
particles moving fast

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7.2

Side Elevation of model 10000tph - existing conveyor

This view shows the material spilling over the top of the impact plate. It also shows the
upwards curvature in the trajectory after the material leaves the pulley. This upwards velocity
is caused by the material and belt sag before the pulley ensuring a steeper approach angle to
the pulley than the theoretical angle if no belt sag occurred.

Belt Sag
approach

on

Upwards
trajectory

Impact above top of

plate and on back
wall of chute

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7.3
7.3.1

Plan view of model - existing conveyor

Using friction 0.2 and co-efficient of restitution e = 0.2

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Less
material
towards edges
Material build up in
centre area

Note that the material spilling over the top lip of the deflector plate is concentrated at the
centre of the deflector plate with little or no spillage towards the outside edges of the plate.
This model used low friction (0.2) and normal co-efficient of restitution e (0.2)

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7.3.2 Using friction 0.9 and co-efficient of restitution e = 0.01

The following image is for a high friction and low co-efficient of restitution. In this case the
material cannot slide down the chute rapidly and loses its energy on impact, so a pressure or
standing wave forms near the top of the impact plate.

More
material
towards edges

Material build up in
centre area green
colour means slow
moving material.

This model used high friction (0.2) and normal co-efficient of restitution e (0.2)
7.3.3

Actual View of impact from Video

View below is from video of actual transfer.

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Note nearly stationary material at top of plate and on sides. Fast moving material is blurred.
Spillage in centre.

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Standing Wave forms near top of plate and

materials flows over top of plate

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Nearly stationary
material is shown in
green colour with
spillage over centre
portion.

Top of Impact plate

Note nearly stationary material shown in green at top and side edges of deflector plate. Actual
video of the transfer confirms this behaviour.

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7.4

View of Impact area - existing conveyor

Top of Impact plate

Impact above top of
plate and on back
wall of chute
Spillage over top
of deflector

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Spillage over top of

deflector

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7.5

Front view of model - existing conveyor

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7.6

Front view of model smaller particles 50mm

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7.7

Particle Trace

The image below is trace of a single, randomly chosen particle in the model.
The velocity of the particle after discharge is 5.21m/s. At impact with the plate it is 6.91m/s.

The particle reaches a speed of 5.18m/s in the X direction before the discharge pulley and is
moving at a velocity 7.62m/s when it impacts the deflector plate. Refer to the Particle trace
report in the appendix for details.
7.7.1 Impact location particle number 0
X,Y,Z location at time of impact with the plate is as follows (from file Helix PWCS Chute 0532
Particle Trace Existing Rev 02.pdf):
Particle No 0, time = 3.205 seconds, X = 3.049m, Y = 0.188, Z = -0.847. This means the
particle is 847mm below the centre line of pulley. The centre of the pivot plate is 95mm below
pulley, so the impact point is 752mm below top of plate. If this particle was at the top of the
burden depth of 394mm (see section on cross-section above) then the impact would have
been about 752-394 = 358mm below the top of deflector.
7.7.2 Impact location particle number 8
X,Y,Z location at time of impact with the plate is as follows (from file Helix PWCS Chute 0532
Particle Trace Existing Rev 01.pdf):
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Particle No 8, time = 2.765 seconds, X = 2.99m, Y = -0.469, Z = -0.432. This means the
particle is 432mm below the centre line of pulley. The centre of the pivot plate is 95mm below
pulley, so the impact point is 337mm below top of plate. If this particle was at the top of the
burden depth of 394mm (see section on cross-section above) then the impact would have
been about 337-394= 57mm above the top of deflector.

Large angle of approach due

to belt sag

Note the distinct upward trajectory after initial contact with the pulley. This is due to the steep
angle of approach which is more than the theoretical angle of 3.2863 degrees (5.742% grade
of stringers). The upward trajectory of the particles in contact with the belt is imparted to the
layers of particles on top of the lowest layer, causing material to spread to a degree.

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8 Trajectory Calculations with Raised Idlers

The following three cases are Trajectory calculations performed with the approach angle
altered by raising the idlers at approach to the pulley.

8.1

Trajectory Calculation with Transition idlers as per existing

conveyor

Approach angle is +3.286 degrees as per stringer angle.

At the distance of 3.209m from pulley centre (impact plate tiles), the top of the trajectory is
-0.6m or 600mm below pulley centre.

8.2

Trajectory Calculation with Transition idlers raised 200mm

The transition idlers have been raised initially by 200mm except the last transition at the head
pulley is raised 100mm and the discharge pulley kept at its existing location. This 200mm
raising of the idlers reduces the approach angle by ATan (200 / 2500) = 4.57 degrees so the
approach angle is -1.28 degrees (declined).

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At the distance of 3.209m from pulley centre, the top of the trajectory is -0.7m below pulley
centre, so the trajectory has dropped 100mm from the existing case.

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8.3

Trajectory Calculation with Transition idlers raised 300mm

The transition idlers have been raised initially by 300mm except the last transition at the head
pulley is raised 150mm and the discharge pulley kept at its existing location. This 300mm
raising of the idlers reduces the approach angle by ArcTan (300 / 2500) = 6.84 degrees so the
approach angle is -3.56 degrees (declined).

At the distance of 3.209m from pulley centre, the top of the trajectory is -0.8m below pulley
centre, so the trajectory has dropped 200mm from the existing case.

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9 DEM calculations with raised transition idlers

The following set of DEM calculations has been performed with the same input data as for the
above model of the existing chute and detailed in section 7 above.

9.1

DEM Calculation with Transition idlers raised 200mm

The transition idlers have been raised initially by 200mm except the last transition at the head
pulley is raised 100mm and the discharge pulley kept at its existing location. The effect of
additional loads on idlers due to belt deviation caused raising the idlers has not been
considered.

All
other
idlers
raised 200mm

Last idler
100mm

raised

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9.1.1

DEM Model General View (raised idlers 200mm)

This model is with the idlers raised 200mm and it shows a big improvement over the existing
installation, but with a few particles going over the top of the impact plate.

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9.1.2

Front View (raised idlers 200mm)

Standing wave is below top of deflector plate, but there are still some particles going over the
top of the deflector plate.

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9.1.3

Impact zone view (raised idlers 200mm)

Material is not overtopping the deflector except for occasional waves of material.

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9.1.4

Top View of impact area

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Note standing wave is present but does not overflow the deflector plate as much as the
existing design.

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9.2

DEM Calculation with Transition idlers raised 300mm

The transition idlers have been raised initially by 300mm except the last transition at the head
pulley is raised 150mm and the discharge pulley kept at its existing location. The effect of
additional loads on idlers due to belt deviation caused raising the idlers has not been
considered.

All
other
idlers
raised 300mm

Last idler
150mm

raised

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9.2.1

DEM Model General View (raised idlers 300mm)

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9.2.2

Front View (raised idlers 300mm)

Standing wave is below top of deflector plate. There is still spillage over the top of the
deflector plate.

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9.2.3

Impact zone view (raised idlers 300mm)

Material is still overtopping the deflector.

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9.2.4

Top View of impact area (raised idlers 300mm)

Note the build up at the top edge of the deflector plate is present but does not overflow the
deflector plate as much as the existing design. However there are still some particles which
impact the back plate of the chute.
As a general observation the raising of the idlers by this amount of 300mm will not definitely
ensure that material does not impact above the top of the deflector plate, but it will improve
the spillage from existing case.

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9.3

Hump Pulley alternative method of raising belt at discharge

An alternative method of raising the belt and reducing the approach angle at the discharge
would be to install an additional pulley ahead and slightly above the main drive pulley. This
will ensure that the material discharges off the hump pulley and so will impact the deflector
plate at a lower level due to the further distance from the discharge point to the plate.

The above sketch illustrates the concept of a hump pulley, however due the large belt width
and large diameter pulleys required, it is not very practical, as can be seen from the sketch.
The hump pulley shown above is 800mm diameter and it needs to be located 1.1m back and
0.6m above the centre of the existing pulley in order for all the material to clear the discharge
pulley. This does not seem practical as the whole conveyor approach will have to be raised by
this amount. Also, the sample cutter will probably not be able to move low enough to get
below the bottom of the material stream in order to get a proper sample.
This system will also reduce the wrap angle on the drive pulley which may be detrimental to
drive traction.

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10 Summary and Conclusions

It is clear from observation and the chute liner and back plate wear patterns that material
flows over the top of the deflector plate.

10.1 Existing Case

Examination of the Trajectory and DEM modelling shows the following:

Conventional Trajectory calculations using the CEMA method show that at a capacity of
10,000tph the top of the material discharge stream should not flow over the top of the
deflector plate.

Discrete Element Method (DEM) modelling of the same trajectory shows divergence of
the trajectory stream and that some particles will overshoot the top of the deflector plate.

DEM modelling also shows that due to material build-up caused by slowing of the
discharge stream at the impact area on the deflector plate, a pressure wave builds up
and flows over the top of the deflector plate.

Actual video movie footage of the impact area confirms the flow of material over the top of
the deflector plate and also the presence of the pressure wave can be clearly seen in the
video.

Belt sag before the discharge pulley increases the effective transition approach at the
discharge pulley angle from the theoretical angle of 3.286 deg at the stringers.

Further modelling was undertaken to determine if raising the approach idlers of the conveyor
by certain amounts will lower the trajectory sufficiently to prevent material flowing over the top
of the deflector plate. The following points are a summary of this modelling.

10.2 Case 1 Raise approach idlers 200mm

A Trajectory calculation shows that the top of the material stream will be lowered by
100mm.

DEM modelling shows a definite reduction in material flowing over the top of the deflector
plate but there is still some material overtopping it.

10.3 Case 2 Raise approach idlers 300mm

A Trajectory calculation shows that the top of the material stream will be lowered by
200mm from existing case.

DEM modelling shows a definite reduction in material flowing over the top of the deflector
plate but there is still some material overtopping it.

10.4 Other options

There are many other options for preventing material over topping the deflector plate such as
moving the plate further away from the discharge or raising the deflector plate, but these
option have not been considered due to the proximity of the sampler cutter swing arc and the
fact that there are sample chutes and conveying equipment installed in and around the chute,
which would make modifications such as this very costly.
The inclusion of a Hump Pulley installed in front of the existing drive pulley was considered
but there are height constraints which would make this type of system impractical, at first
inspection.

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10.5 Conclusion
It is clear from the above that the raising of the idlers will lower the trajectory but it will not be
sufficient to keep all the material on the correct side of the deflector plate. The DEM model
shows that even with the idlers raised 300mm there will still be some spillage over the back of
the deflector plate.

11 Reference Drawings and Documents

Description

Drawing Number

PWCS Kooragang 05.32 Belt Profile 2500 wide

conveyor mechanical arrangement

KL41831/7

PWCS Kooragang 06.301 Sample Station Elevations

KL42729/3

PWCS Kooragang 06.301 Sample Station Elevations

KL42718/2

PWCS Kooragang 05.32 Check Survey

Cad file 09/008

PWCS Kooragang 06.301 Sample Station External View

KL42730/4

PWCS Kooragang 05.32 Conveyor Chute Deflector Plate

KL41839/2

PWCS Kooragang 05.32 Conveyor Head End Chute

Details

KL41836/4

PWCS Kooragang 05.32 Conveyor Head End Chute

Details

KL41840/2

PWCS Kooragang 05.32 Conveyor Head End Elevation

KL41833/5

PWCS Kooragang 05.32 Conveyor Data Sheet 2

KL41309/5

PWCS Kooragang 05.32 Conveyor Drive Pulley

KL41384/4

PWCS Kooragang 00.01 Mechanical Standards 3 Roll

Retractable Idler

KL57923/8

PWCS Kooragang 00.01 Mechanical Standards 3 Roll

Adjustable Transition Idler

KL57920/5

12 Disclaimer
This report and its appendices have been compiled from information supplied by PWCS and
other parties. The information has been used in the Helix delta-T software to perform various
calculations relating to conveyors, and the results of these calculations have been presented.
No guarantee is given that the data presented here is one hundred percent accurate and the
recipient uses this report entirely at their own risk.

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13 Appendices
The following files in electronic file format make up the appendices to this report.

13.1 Trajectory Calculation Reports

The following are the Trajectory Calculations and calculated co-ordinates for the trajectories
used in this report.
13.1.1 Helix PWCS Chute 0532 Trajectory at +3-286 degrees as existing conveyor.pdf
This is to simulate no belt sag before the pulley
13.1.2 Helix PWCS Chute 0532 Trajectory at +8 degrees.pdf
This is to simulate belt sag before the pulley
13.1.3 Helix PWCS Chute 0532 Trajectory at +15 degrees.pdf
This is to simulate excessive belt sag before the pulley
13.1.4 Helix PWCS Chute 0532 Trajectory at -1-28 degrees.pdf
This is with idlers raised 200m.
13.1.5 Helix PWCS Chute 0532 Trajectory at -3-56 degrees.pdf
This is with idlers raised 300m.

13.2 Particle Trace Reports

13.2.1 Helix PWCS Chute 0532 Particle Trace Existing Rev 02.pdf
Particle trace report from DEM calculations.
13.2.2 Helix PWCS Chute 0532 Particle Trace Existing Rev 01.pd
Particle trace report from DEM calculations.

13.3 Helix DEM Model movie file download links

13.3.1 Helix DEM Model Movie Existing Conveyor
Click the following link to download a Windows AVI movie file of the conveyor operating at
10,000tph with the idlers in the existing location. The file is packaged in an exe file with a built
in media player.
http://www.helixconveyor.com/ChuteAvi/HelixDEM_PWCS_0532_at_10000tph_Existing_Idlers.exe

13.3.2 Helix DEM Model Movie Conveyor Idlers Raised 200mm

Click the following link to download a Windows AVI movie file of the conveyor operating at
10,000tph with the idlers raised 200mm. The file is packaged in an exe file with a built in
media player.

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http://www.helixconveyor.com/ChuteAvi/HelixDEM_PWCS_0532_at_10000tph_Idlers_raised_
200mm.exe

13.3.3 Helix DEM Model Movie Conveyor Idlers Raised 300mm

Click the following link to download a Windows AVI movie file of the conveyor operating at
10,000tph with the idlers raised 300mm. The file is packaged in an exe file with a built in
media player.
http://www.helixconveyor.com/ChuteAvi/HelixDEM_PWCS_0532_at_10000tph_Idlers_raised_
300mm.exe

314167457.doc
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