Memahami Biaya Sistem Konveyor Overland: Faktor Utama & Panduan Harga
Biaya sistem konveyor overland terkait dengan jarak yang harus ditempuh, tetapi hanya sebagian: ada faktor lain yang terlibat juga. Di sini kami akan menjelaskan apa yang termasuk dalam paket konveyor overland dan bagaimana karakteristik aplikasi mempengaruhi biaya.
KAPAN & MENGAAPA KONVEYOR OVERLAND DIGUNAKAN
Tujuan konveyor overland adalah untuk mengangkut agregat seperti pasir, bijih, kalium, dan kerikil dari satu lokasi ke lokasi lain. “Overland”, atau alternatifnya, “surface” menunjukkan bahwa konveyor ini mengikuti medan dan tidak dirancang untuk ruang tertutup seperti tambang.
Di quarry dan operasi lain di mana agregat harus dipindahkan antara dua lokasi tetap, sabuk konveyor adalah alternatif untuk menggunakan truk. Setiap situasi berbeda, tetapi konveyor overland seringkali lebih hemat biaya dan memiliki dampak lingkungan yang lebih kecil daripada menggunakan armada kendaraan. Plus, dengan desain yang tepat, ini dapat diterapkan ke lokasi baru sesuai kebutuhan situasi.
ELEMEN SISTEM KONVEYOR OVERLAND
Sabuk konveyor membawa agregat yang dipindahkan tetapi ini hanya satu bagian dari sistem lengkap. Elemen esensial lainnya adalah:
- The drive unit — Merupakan motor(s), reducer, dan fluid coupling yang memutar drive pulleys, alignment-free drive biasanya yang ditentukan.
- Take-up unit — Ini (atau ini, konveyor panjang mungkin membutuhkan beberapa) memelihara tegangan dan meminimalkan lesung sabuk di antara roller idler.
- Tail section — Ini adalah tempat material dimuat ke sabuk. Tail section memastikan troughing sabuk yang sesuai untuk distribusi beban merata.
- Starter — Butuh banyak daya untuk memindahkan sabuk yang terbeban. Starter mengelola daya ke motor untuk memastikan awal yang mulus dan efisien.
- Structure — Ini adalah rangka yang memegang roller idler yang mendukung sabuk.
COST DRIVERS
Poin utama yang perlu dipertimbangkan saat menentukan spesifikasi sistem konveyor overland adalah:
- Tons per hour (TPH) to move
- Material properties — Density determines the volume to be transported and hence belt width.
- The nature of the material – Wet or dry, abrasive or sharp-edged, determines what type of belt cover is appropriate.
- Elevation changes — This can add significantly to the load on the motor, especially if moving material uphill.
- Distance/belt length — This determines total load to be moved, the quantity of belt structure needed, and the number of take-up units.
- Belt width — Another factor that determines load and capacity, and also influences the cost of belt, structure, and all other system elements.
- Belt speed — Determined in conjunction with belt width and capacity, this gives the reduction needed by the drive system along with torque and power.
DRIVE UNIT COST & OPTIONS
Establishing how much work this system is to do, (TPH and belt speed) leads directly to sizing the motor, starter, and drive unit. For a representative application, consider a 1000 ft. system moving sand at 300 TPH on a belt 30” wide at 450 feet per minute.
A suitable alignment-free drive could use two 300 hp motors for a total of 600 hp. New motors could be $20k-$25k apiece, although using rebuilt motors would cut this significantly. There’s also a reducer, or two reducers, plus the starter.
There are several options for motor starters. Some users prefer a variable frequency drive (VFD) for the control it provides over motor speed and current draw, (and hence energy savings,) but these do come at a significant cost. A VFD starter for the system described could cost $50k-$60k. In the case of complex systems, (where the savings from VFDs are greatest,) a control panel is needed, at an additional $20k.
A popular alternative is an across-the-line starter. This is less expensive ($15k-$25k) but uses more energy and can cause more wear and tear at start up. In between the two, there are soft/slow start starters. These reduce wear but don’t maximize energy savings.
STRUCTURE CONSIDERATIONS
Structure is sized for belt width and load. West River Conveyors uses the CEMA B to E+ standard for idler rollers.
CONVEYOR BELT OPTIONS
The conveyor belt must be appropriate to the material being conveyed. It needs a cover that will resist sharp or abrasive edges while troughing as needed to avoid spills. The construction must be strong enough to handle the loads, including those imposed at loading. West River Conveyors uses plied or steel cord belts as required. Overland belt runs from $10 – $40 per foot, depending on width of the belt, PIW and whether two-ply, three-ply or four-ply is needed.
SHIPPING
West River Conveyors manufactures in Oakwood, VA. From here everything must be transported to the quarry, port, power plant, or another facility. Shipping costs depend on the size of the equipment and how far it must be moved, but for budgeting assume $5k-$10k.
OVERLAND CONVEYOR SYSTEM COST ESTIMATES
Every application is different and West River Conveyors would welcome the opportunity to propose a solution to your conveyor needs. However, to indicate what a system might cost let’s return to the sand conveying application.
In this case, the system was to carry 300 TPH of sand on a belt 30” wide moving at 450 feet per minute for a distance of 1,000 feet. For such an application, a conveyor package including alignment-free drive, take-up unit, tail section, starter, structure, and belt would cost in the region of $250k – $350k.
WHY CHOOSE WEST RIVER CONVEYORS?
The team at West River Conveyors has experience that’s hard to match. Since the early 1980s we’ve engineered and built systems for conveying a wide range of materials in the most difficult and challenging environments. We are also specialists in replacement equipment and can extend the life of your existing conveyor systems with new or rebuilt components.
For us, every project starts by listening to and understanding what our clients want. Only then can we develop a proposal that provides the performance, quality, and durability needed at an affordable price.
