Bateman Engineered Technologies has designed a Japanese Pipe Conveyor system of more than 7 100m for a privately owned Brazilian energy provider. The system, sold and manufactured by Bateman Engineered Technologies' Brazilian representative and solution partner for the Mercosur countries, TMSA Tecnologia em Movimentação S/A, is part of a 14 000 m conveyor system, which takes coal from the Port of Pecém, Brazil, to the power station.
Assisted by Bateman engineers, TMSA has successfully manufactured, installed and commissioned the system, which comprises four conveyors in series, the longest being just over 2 500 m in length.
(Seen here: Bateman Engineered Technologies-designed Japanese Pipe Conveyor winds its way from Pecém Port to local power station.)
Bateman Engineered Technologies' Richard Späth says that belting for the conveyor, which handles 2 400 t/hour in 600 mm diameter pipes, was shipped from Japan to Pecém in 32 separate ‘reels' weighing up to 44 t each. Other components, such as the idlers, for example, were also imported. "Japanese Pipe conveyors are particularly suitable for coal. Being totally enclosed, spillage and dust are eliminated, which is a significant environmental advantage," says Späth.
He adds that another advantage of Bateman Engineered Technologies' Japanese Pipe Conveyors over conventional trough belt conveyors is that they are able to curve horizontally with much smaller radii. "This reduces the need for multiple transfer points, which helps in the reduction of dust generation, and also, reduces both costly chute liner replacements and the number of drive units required."
The drive units of the Pecém system are standardised and interchangeable and are located at ground level for ease of maintenance. "This is an important feature of the system", Späth says. "Spare part stock-holding is optimised and downtime is minimised."
The take-up mechanisms are equipped with ‘braked capstans', which were included in the design to prevent damage caused by dynamic forces resulting from a power failure during start-up, when the belt is tensioned to its maximum. "Safety is, of course, our number one priority and forms part of the design consideration for each and every component, as well as of the complete system," Späth says.
Another significant advantage of the unit is its ability to perform steep-inclined conveying. Increased friction between the material and the ‘pipe' shape, allows for inclines of up to 50% greater than conventional belt conveyors. This means significant overall savings as the length of a conveyor system can be reduced and plant footprints can be smaller. Further cost savings can be made due to Japanese Pipe Conveyor's being narrower than conventional conveyors. Importantly, the return belt, which is also formed into a pipe shape, can in special circumstances, transport material.
Japanese Pipe Conveyors resemble conventional troughed conveyors at their tail-ends where the material is loaded. The open belt then passes through a series of transition idlers to form a ‘pipe' shape, which is maintained for the length of the conveyor. Just before the discharge pulley, the belt opens up again and the material is discharged in the normal fashion.
The conveyors are installed on a turnkey basis with the design done in-house by Bateman Engineered Technologies', backed up by specialized and dedicated after-sales, spares and service teams. "Also, we are continuously kept up to date with latest technology improvements and developments in this ever dynamic technology," says Späth.
Bateman Engineered Technologies is licensed through Bridgestone to exclusively sell its Japanese Pipe Conveyor system in Southern Africa and Brazil. The company has installed more than 60 systems in these regions in a wide range of applications, transporting an equally wide range of commodities and products. Through an ‘Individual Project License Agreement' with Bridgestone, the company may also sell the conveyor system in the countries of Argentina, Uruguay and Paraguay.