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Thread: Energy Saving Idlers

  1. #1
    Steve Davis

    Steve Davis, B.Eng., P.Eng., CEng, CPEng, FIMechE, FIEAust

    Principal Advisor

    RioTinto

    RioTinto

    Energy Saving Idlers

    I have recently been approached regarding the potential benefits of using these idlers to reduce energy consumption on long conveyors.

    The idler is essentially a standard 3-roll troughing arrangement but with two centre rolls giving the appearance of a dual offset. The centre rolls have a tilting load equalisation feature. This apparently spreads the load more evenly across the idlers reducing roll and bearing size and indentation losses.

    Would anyone like to comment on this arrangement or relate an actual saving in power or capital cost through the use of this product.

  2. #2
    D Kwiatkowski Guest
    Dear Steve,

    You can find more infromation in the following articles:

    Bulk Solids Handling Vol 20 No 4 October/December 2000
    This sounds like the idlers you are referring to.

    In addition there is an article on Henderson Mine:

    Bulk Solids Handling Vol 20 No 3 July/September 2000
    These idlers do not have dual center rolls but have several unique features that reduced the rolling friction.

    Best regards,

  3. #3
    Lawrence K. Nordell

    Lawrence K. Nordell

    President and CEO

    Conveyor Dynamics Inc.

    Conveyor Dynamics Inc.

    Professional Experience 59 Years / 6 Month Lawrence K. Nordell has 59 Years and 6 Month professional experience

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    Mr.Davis,

    The answer to your question is dependent on the ability to analyze the pressure and indention the rubber undergoes at the idler roll contact with the belt. See our website for a visual:

    http://www.conveyor-dynamics.com/about/power.htm

    There are times when the dual center roll has some effect. This usually occurs with higher tonnage and wide idler spacing.

    As the prior responder referenced, the Henderson Mine has larger center rolls which also gives a benefit.

    These points are factored when the rubbers rheological properties, and viscoelastic modeling is performed on the belt/idler interface.

    Here at CDI, we can analyze the differences from first principles.

    Lawrence Nordell
    Conveyor Dynamics, Inc.

  4. #4
    Join Date
    Sep 03
    Posts
    5
    This idea I think was originally developed by Stepson and Adamson or something, ne way - Svedala took them over which in turn has been taken over to become Metso. I have a *pdf which I can e-mail you into the research of these items.
    However my confidence with these working in arduous conditions is doubtful, the swivel units are prone to problems with build up of material.
    The concept I think is by eliminating "Idler offset" it tries to ensure the idler load is spread across all the toughing sets.

    The more components etc - four idlers and swivel units mean the cost is increased to begin with.

    The way forward is to improve affiance - I am yet to see any on site.

    e-mail: stuart.davies@virgin.net

  5. #5
    Lawrence K. Nordell

    Lawrence K. Nordell

    President and CEO

    Conveyor Dynamics Inc.

    Conveyor Dynamics Inc.

    Professional Experience 59 Years / 6 Month Lawrence K. Nordell has 59 Years and 6 Month professional experience

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    Stuart,

    Could you elaborate on this pivot arragement for dual center trough rollers?

    The Metso dual center roll I have seen does not pivot.

    The dual center roll benefit comes from the reduction of roll/ belt interface pressure. The reduction in pressure drops the power.
    Bothe dual roll and larger diameter rolls reduce the pressure. The formulation has already been published by many authors in Bulk Solid Handling myself included.

    Lawrence Nordell
    Conveyor Dynamics, Inc.

  6. #6
    Join Date
    Sep 03
    Posts
    5
    Yes I agree with above statement. The pivot feature I was talking about is as follows. The frame holding the two center rollers is known as the pivot frame and is allowed the rotate vertically. This compensates for any vertical misalignment between adjacent rollers ensuring an equal spread of load.

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