19-05-2015

Welcome

BEVCON AT A GLANCE
Very Promising professionals with well
planned Vision to achieve 500Crores by
2016.

Advanced Bulk Material Conveying

Technologies in Cement Industry

Three different manufacturing set-ups

with latest Technology two in Hyderabad
& one at Raipur are ISO Certified.
Only company in India to have all kinds
of
material
handling
products
manufactured under one common roof.
Marketing, Constructions & After Sales
Service Offices at all regions.

S.A.K.JEELANI
May 15th 2015

Export business with SAARC, E. Africa,

S. Africa, South East Asia & UAE.

19-05-2015

FOCUSSED AREAS

OUR PRESENCE
Bevcon Wayors is the industry leader in providing highquality and technologically advanced Bulk Material
Handling & Processing Solutions Crushing, Screening,
Conveying, Dust Extraction, Pneumatic conveying and
Special Conveying Systems.

BEVCON

Bevcon Wayors Leadership Areas:

Comprehensive Range of Bulk Material Handling &
Processing Solutions
Innovation Excellence & in-house Fabrication
Track Record & Credentials
World-Class Technology Partnerships
Vast Domain Expertise

ADVANCED CONVEYING SYSTEMS

A Total Solutions Provider to
Your business needs
Bevcon Wayors is engaged in
providing End to End solutions to
Power, Steel, Cement , Ports and
Mines with an experience of over
than 20 years on Turnkey basis
which include Design, Engineering,
Manufacturing, Installation and
Servicing.
Bevcon Wayors is the industry
leader in providing high-quality and
technologically advanced Bulk
Material Handling & Processing
Solutions

Advanced Conveying Systems

to
Simplify the Cement Plant Operations

Steep Angle Cleated Belt Conveyor

Overland Troughed Belt Conveyor

Overland Pipe Conveyor

Sandwich Belt Conveyor

19-05-2015

STEEP ANGLE CONVEYOR

CONVENTIONAL / STEEP ANGLE CONVEYOR COMPARISON

STEEP ANGLE CONVEYOR

STEEP ANGLE CONVEYOR

FEATURES
INCLINE ANGLES UP TO 90 DEGREES.

LIMITATIONS

NO TRANSFER POINTS.

NO SPILLAGE.

LUMP SIZE IS SOMEWHAT LIMITED PARTICULARLY IN HIGH ANGLES OF INCLINE

MAXIMUM UTILISATION OF SPACE.

THE BELT IS MORE DIFFICULT TO CLEAN THAN STANDARD CONVEYOR BELTS.

MINIMUM MAINTENANCE, LONG BELT LIFE.

WIDE RANGE OF MATERIALS CAN BE HANDLED.
LOW POWER REQUIREMENT, QUIET AND SMOOTH RUNNING.
HIGH/MEDIUM CAPACITY, HIGH LIFTS CAN BE ACCOMPLISHED.

19-05-2015

JK Cement - Jhajjar

STEEP ANGLE CLEATED BELT CONVEYOR

Steep Angle (90o) Sidewall Cleated Belt Conveyor

Case Study JK Cement - Jhajjar

CASE STUDY JK CEMENT - JHAJJAR

19-05-2015

Case Study JK Cement - Jhajjar

Belt Width

2000mm

Capacity

1650TPH

Material

Clinker

Lift

19 Meters

Bulk Density

1700 kg/m3

Feed Size

: (-)50mm

Power Sector

Handling Ferro
Alloys at
Vatvedt
Technologies

SAC Installations
Handling
Dolomite,
Limestone & DRI
at Kamachi
Steel & Power

SAC Installations
Handling
Coal at
Malabon Oil & Soap

Handling
Coal
at Phoenix
Commodities

Handling
Ferro Alloys
at Kalyan Garuda

Handling Dolomite
& Lime mixture at
Viraj Profiles Ltd.

Handling
Municipal Solid
Waste at
Selco Intl.

Handling
Raw Sugar
at Silkroad Sugar

Handling Coal
& Husk at
Mylan
laboratories

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SAC Installations
Handling Granite
power at Restile
Ceramics

SAC Handling
Coal

OVERLAND PIPE CONVEYOR

Working Operation Process

Transition zone Loading / Unloading

Conventional belt and pipe conveyors are
loaded and unloaded in exactly the same
way; being opened for a conventional belt
feed system from the tail pulley and again
opening out at the head pulley for
discharging.
In the material loading area, the conveying
belt is open. The conveyed material is
supplied in the same way as in a
conventional belt conveyor. Then special
devices enclose the belt carrying the
conveyed material. The diameter of the
closed pipes can be selected depending
on the material conveying capacity.

At this point, the belt forms a sealed pipe for

the entire conveying line. Thus, the content
is protected against external influences
while the environment is protected against
any potential material losses.

At this point, the belt

opens on its own
before the material
discharge point and
the
material
is
discharged.

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Working Principle - Overland Pipe Conveyor

SUPERIOR FEATURES OF PIPE CONVEYOR

Dust free with minimal noise emissions.

Pipe Conveyor is as similar as conventional belt conveyor

system, and comprises a head and tail pulley, one of
which is driven, over which an endless conveyor belt is
spanned.
The belt is tensioned in a similar manner to conventional
belt conveyors. Beyond the loading point, the belt passes
through a series of pipe forming idlers which effect the
transition from conventional to rolled form. This transition
takes place over a distance calculated to minimize belt
stresses.
Once formed the pipe shape is maintained by six idlers set
in a hexagonal pattern at each idler frame. Idler frame
spacing depends on pipe diameter and ranges from 1 to
3.5 m

No spillage or scattering of material from loaded belt.

Any desired horizontal and vertical curves with
minimal radius upto 45 meters.
Material can be conveyed on the feed and as

well as on return belt even with different materials.

No build up on Idlers.
Can elevate vertically 50% more than conventional
conveyors.
Conveying angle up to 30 degree.
Has excellent belt edge damage control.

Unaffected by wind and rain thus requires no covers.

Reduced structural costs by eliminating walkways.

SHREE CEMENT -PIPE CONVEYOR

SHREE CEMENT -PIPE CONVEYOR

PROJECT HIGHLIGHTS
TYPE

Overland Pipe Conveyor

LOCATION

Khapradih, Raipur, CG

SYSTEM

3150TPH Limestone Handling System (Ongoing Project)

SCOPE OF WORK

Engineering, Manufacturing, Supply

EQUIPMENT Details
Material to be conveyed
Pipe Conveyor Length
Lift
Lump Size
Pipe Dia
Belt Width
Capacity
Belt Speed
STATUS

:
:
:
:
:
:
:
:

Limestone
1.4 Kms
10.5 Mtr
60 mm
600 mm
2100 mm
3190 TPH
3.5Mtr/sec

Under Commissioning Stage

19-05-2015

SHREE CEMENT -PIPE CONVEYOR

Sandwich Belt Conveyor

What is a Sandwich Belt Conveyor?
Simply, Sandwich Snake Belt Conveyor consists of two endless belt conveyors that share a
common load carrying path. The top and bottom belts are independently driven and
tensioned. Along the carrying path the top and bottom belts are alternately supported
against closely spaced toughing idlers. Radial pressure, due to belt tension and the curving
profile, continuously hugs the material that is Sandwiched between the two belts. Internal
friction is developed and bulk material can be conveyed at any high angle up to Vertical.
Sandwich Snake Belt Conveyor uses all and only conventional conveyor components and
smooth surfaced belts that can be continuously
scraped clean.
Sandwich Conveyor Profiles
Snakes are available in widely ranging profiles of C and S-Shape. In any case, a long
bottom belt approach is possible to the sandwich entrance, and discharge may be on the
high incline or may be after the extension of the carrying belt beyond the mouth of the
sandwich

Basic Profile

SANDWICH CONVETOR
FEATURES

Increased angle of lift including vertical lift.

Uses standard belting.
Some environmental protection.
Good for sticky material.
LIMITATIONS

Difficulty to handle large lumps, dry fines or spherical material.

Extended Profile

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Typical Layout

Installation
Dos Santos Sandwich Belt High Angle Conveyor, Majdanpek Copper Mine, Serbia.
Part of an IPCC (In-pit Crushing and conveying) system

Applications & Installations

Limestone Quarry, Midwest, USA
Material Density Size
Conveying Rate
STPH)
Conveying Angle
Belt Width
(42)
Belt Speed
(500 FPM)
Lift
Length
Drives
- Top Belt - Bottom Belt
HP)

Limestone
1.60 t/cu-m (100 PCF)
76 mm (3) minus
762 t/h (800
-

60 degrees
1067 mm

2.54 m/s

48,000 mm (158)
79,000 mm (258)
168 kW (125 HP)
168 kW (125

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Applications & Installations

Applications & Installations

Aceralia Steel Mill, Spain

Material
Density
Size
Conveying Rate Conveying Angle
Belt Width
Belt Speed
Lift
Length
Snake Drives
Top Belt
Bottom Belt
-

Coal
0.8 t/cu-m (50 PCF)
50 mm (2) minus
250 t/h (276 STPH)
75 degrees
1200 mm (47)
2.29 m/s (450 FPM)
35,100 mm (115)
45,065 mm (148)
30 kW (40.2 HP)
30 kW (40.2 HP)

DSI Snake Sandwich Conveyor Shiploader

for
Cortex Resources at Port Adelaide, Australia
Inflection 2

Inflection 1
Curve 2

Loading
Curve 1

Material
-Density
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Snake Drives
- Top Belt
- Bottom Belt

- Titanium Ore
- 2.4 t/cu-m (150 PCF)
- 1000 t/h (1102 STPH)
- 50 degrees
- 1200 mm (47)
- 2 m/s (394 FPM)
- 21,805 mm (71.5)
- 56,656 mm (185.9)
- 55 kW (74 HP)
- 55 kW (74 HP)

Applications & Installations

Applications & Installations

Hamilton Ontario, Canada

Continental CN at INCO Voiseys Bay Proj

Material
- Pebble Ore
Density
- 2.25 t/cu-m (140
PCF)
Size
- 60 mm (2.4) minus
Conveying Rate
- 102 t/h (112 STPH)
Conveying Angle - 90 degrees
Belt Width
- 762 mm (30)
Belt Speed
- 1.02 m/s (200 FPM)
Lift
- 13,010 mm (42.7)
Length
- 23,500 mm (77.1)
Snake Drives
Top Belt
- 7.46 kW (10 HP)
Bottom Belt
- 7.46 kW (10 HP)

Steel Mill Project

SNAKE CONV. ELEVATION

Material
Density
Size
Conveying Rate
STPH)
Conveying Angle
Belt Width Belt Speed Lift
Length
Snake Drives
Top Belt
Bottom Belt -

Various
4.16 t/cu-m (260 PCF)
75 mm (3) minus
188 t/h (200
70 degrees
914 mm (36)
1.02 m/s (207 FPM)
35,235 mm (115.6)
48,768 mm (160.0)
18.64 kW (25 HP)
18.64 kW (25 HP)

10

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AN INTRODUCTION - OVERLAND TROUGHED BELT CONVEYOR

LATEST DEVELOPMENTS
Belt Conveyor and Pipe

Overland troughed belt conveyors (also known as long distance or cross country
conveyors) are belt conveyors that have been designed to carry high tonnage
loads over long distances. Overland conveyors can be applied in many different
industries and can range from just a few thousand feet to several miles in length.
Industries such as mining, power, paper, waste and cement require reliable
conveying of large quantities of material to long distances day in & day out.

Over land troughed belt conveyors have been proven to be an efficient method of
transporting bulk material over long distances and costs are often lower than with
truck & rail transportation.
These overland troughed belt conveyors can follow most terrains and have little or
no impact on the environment. Operating and maintenance costs are low and they
are extremely safe to operate and doesnt produce loud sounds.

Conveyor Systems
System Design
Energy Efficiency
Distributed Power

Analysis and
Simulation
Advanced Controls

11

19-05-2015

Model Project
Complex Overland Conveyor

Reference List
(Overland Troughed Belt Conveyor)
19.1km center-to-center length. 3 meter lift from head to tail
11 horizontal curves with radius ranging from 2100m to 3500m
Many Vertical Curves
Conveying ~1100 mtph of Lignite Coal
Real Installed Application

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Material
Capacity (TPH)
Length (km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Horizontal Curves
Radii (M)

Installation & Application

:
:
:
:
:
:

Aker Solutions
Peru Copper- Toromocho
Peru, South America
Under Construction (2012)
Designer
Surface Copper Mine

Client
Mine
Location
Commissioned
Role
Application

:
:
:
:
:
:
:
:
:
:
:
:
:
:

Copper
10,292
4.93
+196, -276
1800
ST5200
6.00
10,000
CST
4x2,500
0
Winch
2
5000

Material
Capacity (tph)
Length(km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Lycopodium
Rio Tinto- Western Turner Syncline
Western Australia
Pre-Feasibility Design in Progress
Design Auditor
Surface Iron Ore Mine

:
:
:
:
:
:
:
:
:
:
:
:
:
:

Iron Ore
5,000
15.16
+106
1500
ST3800
4.00
8,000
VFD
5x1,600
1
Gravity
2
5000

12

19-05-2015

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Consulting Engineer
Typical Project
Installed 2005, USA
19 km Centers
10 Horizontal Curves
Intermediate Drive

R10000

R6900

23

Head

R10000

31
5

14

R12000

R9750

Capacity: 1200 tph

Length: 62,791 ft
Lift: 11 ft
Belt Width: 36 in
Belt Speed: 1400 fpm

31
R8500

FREEPORT MCMORAN
Henderson PC-3
Climax, CO USA
1999
Design Team
Underground Molybdenum
Mine

Capacity (tph)

Molybdenum

2500

Length (km)

6.4

Lift (m)

76

Belt Width (mm)

1200

ST2500

R8000 R10000
R10000

:
:
:
:
:
:

Material

R12000

Tail

Installation & Application

Belt Spec

Belt Speed (mps)

4.5

Power Attached (kW)

3,000

No of Drive

2x1500

Drive Type

VFD

Intermediate

10

33

Take-up

Gravity

Horizontal Curves

1524

Radii (M)

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

:
:
:
:
:
:

Peabody Energy
NARM
Gillette WY, USA
2006
Designer
Surface Coal Mine

Material

Coal

6000

Capacity (tph)

Length(km)

3.70

Lift (m)

-14

Belt Width (mm)

1830

ST2500

Belt Spec

Belt Speed (mps)

4.87

Power Attached (kW)

4400

Drive Type

VFD

No of Drive

4x1100

Intermediate

Take-up

Gravity

Horizontal Curves

Radii (M)

NA

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Material
Capacity(tph)
Length(km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Gravity
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Metso Brazil
Vale- Sossego
Brazil
2002
Designer
Surface Copper Mine

:
:
:
:
:
:
:
:
:
:
:

Copper Ore
3000
3.50
+65
1200
ST2500
4.80
1050
VFD
3x350
0

:
:

0
NA

13

19-05-2015

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Material
Capacity(tph)
Length(km)
Lift (m)
Belt Width(mm)
Belt Spec
Belt Speed(mps)
Power Attached(kW)
Drive Type
No of Drive
Intermediate
Take-up
Horizontal Curves
Radii (M)

:
:
:
:
:
:

ThyssenKrupp Robins
Barrick- Cortez Hills Mine
Elko, NV, USA
2010
Designer
Surface Gold Mine

:
:
:
:
:
:
:
:
:
:
:
:
:
:

Gold
1100
11.6
-216
900
ST1400
4.50
1200
VFD
2x600
0
Winch
1
5000

Installation & Application

Sichuan, China

7.8 miles (12.5 km) Long

1500 TPH Limestone
48 Belt Width
800 FPM
8 Horizontal Curves
Built by Beumer

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Material
Capacity (tph)
Length(km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Freeport McMoran
Henderson PC-2
Climax, CO USA
1999
Design Team
Underground
Molybdenum Mine

:
:
:
:
:
:
:
:
:
:
:
:
:
:

Molybdenum
2500
16.8
474
1200
ST6800
6.0
10,000
VFD
4x2500
0
Gravity/Winch
0
NA

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

PC 3

PC 2

Material
Capacity (tph)
Length(km)
Lift (m)
Belt Width(mm)
Belt Spec
Belt Speed(mps)
Power Attached(kW)
Drive Type
No of Drive
Intermediate
Take-up
Winch/Storage Unit
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Continental Conveyor England

UTE Guadarrama
Spain
2004
Designer
Tunnel Boring Much Removal

:
:
:
:
:
:
:
:
:
:
:

Muck
1150
13.4 and 15.0
-78
900
ST1000
3.55
1085 and 1280
VFD
7x160 and 8x160
3 and 3

:
:

4
800

14

19-05-2015

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Material
Capacity (tph)
Length(km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Gravity
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Continental Conveyor Australia

Tiangin Port Authority
Tiangin, China
2003
Design Auditor
36
Coal Ship Loader

:
:
:
:
:
:
:
:
:
:
:

Coal
6000
8.98
8
1800
ST3500
5.6
6,000
VFD
3x2000
0

24

Head

R4000

R3000

Capacity: 6000 mtph

Length: 8980 m
Lift: 8 m
Belt Width: 1800 mm
Belt Speed: 5.6 mps

Tail

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

: 2
: 3000-4000

Material
Capacity (tph)
Length(km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Gravity
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Black Hills Energy

Wyodak
Gillette, WY, USA
2004
Designer
Surface Coal Mine

:
:
:
:
:
:
:
:
:
:
:

Coal
1950
1.0
12
1200
ST800
4.57
750
VFD
1x750
0

:
:

1
1500

Installation & Application

Client
Mine
Location
Commissioned
Role
Application

Material
Capacity (tph)
Length(km)
Lift (m)
Belt Width (mm)
Belt Spec
Belt Speed (mps)
Power Attached (kW)
Drive Type
No of Drive
Intermediate
Take-up
Horizontal Curves
Radii (M)

:
:
:
:
:
:

Hatch
Xstrata- Koniambo Nickel
New Calidonia
In Construction 2010
Design Auditor
Surface Nickel Mine

:
:
:
:
:
:
:
:
:
:
:
:
:
:

Nickel Ore
700
11.41
-757
1050
ST1600
4.50
1575
VFD
5x315
0
Gravity
4
1500-2000

15