The compound fertilizer belt conveyor system is an efficient conveying equipment designed to safely and quickly transport various granular or block fertilizers with a bulk density of 5 to 25 tons/m from one place to another. The TD75 belt conveyor has six bandwidths: 500, 650, 800, 1000, 1200 and 1400 mm. By accurately controlling the speed and angle of the conveyor belt, the system can achieve large-scale continuous transportation. The tongli belt conveyor system uses acid and alkali resistant rubber rollers and 5 layers of oil-resistant, acid and alkali resistant rubber belts. It can withstand a conveying capacity of up to 540 cubic meters/hour. The working environment temperature is between -15C~+40°C. It is suitable for conveying materials with acidic, alkaline, oily substances and organic solvents. It is specially designed for the corrosive characteristics of compound fertilizer raw materials. It is equipped with a full range of dust covers to minimize dust emissions and prevent the spread of dust and impurities. It is suitable for fertilizer processing plants, agricultural enterprises and storage facilities. It can transport various bulk materials and finished goods with a density of 500~2500Kg/m3.
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Designed to handle the toughest environments and optimize material handling. Whether for transporting raw materials or finished products, our belt conveyors are engineered to provide smooth, continuous movement with minimal maintenance.
It can operate in various harsh working environments, such as high temperature, low temperature, humidity, dust, etc. For materials of different properties, such as block, powder, granular, etc., it can be effectively transported, can adapt to different terrains and space restrictions, and can transport horizontally, tilted, and even vertically lift materials. By rationally designing the layout of the conveyor, the space can be fully utilized to meet the needs of complex production processes.
It can continuously convey a large amount of materials, whether it is bulk materials or finished items, it can be efficiently conveyed. For example, in the conveying of bulk materials such as coal and ore, the belt conveyor can run for a long time at a stable speed to meet the needs of large-scale production. It can adapt to different material particle sizes and conveying volume requirements, and can flexibly meet various production conditions by adjusting parameters such as belt width and speed.
It consists of main components such as belts, rollers, drive devices, tensioning devices, etc. The structure is relatively simple and easy to install and maintain. The manufacturing technology of each component is mature and reliable, which reduces the probability of equipment failure. As a conveying medium, the belt has good flexibility and wear resistance and can adapt to different terrains and working environments. During operation, the rolling friction between the belt and the roller is small, which reduces energy loss and equipment wear.
Productivity (tons/hour) | 500 mm | 650 mm | 800 mm | 1000 mm | 1200 mm | 1400 mm |
Speed: 0.8m/s | 78 | 131 | - | - | - | - |
Speed: 1m/s | 97 | 164 | 278 | 435 | 655 | 891 |
Speed: 1.25m/s | 122 | 206 | 348 | 544 | 819 | 1115 |
Speed: 1.6m/s | 156 | 264 | 445 | 696 | 1048 | 1427 |
Speed: 2m/s | 191 | 323 | 546 | 835 | 1284 | 1748 |
Speed: 2.5m/s | 232 | 391 | 661 | 1033 | 1556 | 2118 |
Speed: 3.5m/s | - | - | 824 | 1233 | 1858 | 2528 |
Speed: 4m/s | - | - | - | - | 2202 | 2996 |
1. Conveyor belt deviation
Conveyor belt deviation is usually caused by the tensioning device not being adjusted properly or the uneven force on both sides of the belt during use. Especially when one side is used for a long time to transport materials, the belt will gradually lean towards the side with a larger load. To solve this problem, the tensioning device can be adjusted to a suitable degree, and the material can be placed evenly in the middle of the conveyor belt as much as possible to avoid eccentric loading.
2. Conveyor belt slippage
The reason for the belt slippage may be that the tensioning device is too tight or the pulley of the push roller is damaged. In addition, if too much material is transported, it may also cause the belt to slip. In addition, if dirt accumulates on the surface of the belt, it will also cause slippage. This problem can be solved by adjusting the tensioning device to ensure that it is in the appropriate tension range, controlling the amount of material transported, and cleaning the belt regularly to keep its surface clean.
3. Conveyor belt breakage and damage
The conveyor belt may break because the transported goods contain sharp objects or the belt is unevenly stressed during use. When the conveyor belt deviates, causing the belt to be stressed in a certain part, it is also prone to breakage. In addition, long-term use in a high temperature environment will also cause the belt to become brittle, thereby increasing the risk of breakage. To avoid such failures, it is recommended to wrap sharp objects, solve the belt deviation problem in time, check the equipment regularly to ensure that there is no jamming, and avoid using the conveyor in a high temperature environment.
4. Abnormal noise in the conveyor
Abnormal noise usually occurs when the roller is severely eccentric or the two shafts of the coupling are not concentric. Abnormal matching between the redirection roller and the drive roller may also cause noise. In addition, the failure of the reducer can also cause noise. In order to solve these problems, it is necessary to replace or repair the roller in time, adjust the driving direction of the roller, and replace the roller if necessary. At the same time, check the position of the reducer to ensure that it has not failed due to incorrect position, and regularly check whether the reducer is short of oil or loose parts.
5. The conveyor belt does not run
The conveyor belt may not run because the motor loses power or the redirection roller is stuck. In addition, if the equipment does not reset the button after stopping, or the pull-wire switch or deviation switch is not reset after actuation, the conveyor belt will fail to start. The solution to this problem is to replace the motor, choose a more powerful motor, and clean the equipment regularly to avoid material jamming. It is also necessary to check the power supply voltage, the circuit and switch of the drive motor to ensure that the motor is working properly.
6. Insufficient conveyor belt tension
The reason for insufficient tension may be insufficient friction between the belt and the roller, or the tensioning device does not tighten the belt to the appropriate degree. Insufficient motor power may also cause the tension to fail to meet the requirements. To solve this problem, the position of the driving wheel or the driven wheel can be adjusted to balance the tension of the belt. If the adjustment is ineffective, the belt can be re-joined or replaced. At the same time, increasing the motor power can also effectively increase the tension of the belt.
7. Conveyor belt slack
Conveyor belt slack may be caused by a bad working environment or long-term high-load operation. The tensioning device is not adjusted properly during installation, which may also be one of the reasons for the slack. To solve this problem, you can control the working time of the equipment and use the equipment in rotation to avoid long-term overload operation. In addition, improving the use environment and adjusting the tension of the belt and traction roller can also effectively prevent the belt from slack.
First of all, in terms of conveying capacity, belt conveyor usually has higher conveying capacity and can handle larger flow of materials. For example, belt conveyor can convey up to 1,000 tons of materials per hour, which is suitable for long-distance, large-capacity continuous conveying, while bucket elevator has relatively small conveying capacity, usually between tens of tons and hundreds of tons per hour. This makes belt conveyor more suitable for large-scale industrial applications, especially places such as mines and ports that require large-flow material conveying.
In terms of adaptability, belt conveyor can handle a variety of materials of different properties, especially high-humidity and high-viscosity materials. For example, in the conveying of wet and viscous materials such as fertilizers, fertilizers, and mud, belt conveyor has better adaptability. It can run smoothly in a humid environment, while bucket elevators have difficulty handling such materials because high humidity and high viscosity will cause the material to adhere to the inside of the conveyor, resulting in stagnation and low conveying efficiency.
Regarding maintenance and care, belt conveyor is relatively easy to maintain due to its simple structure. Replacing belts, cleaning troughs, and checking drive systems are relatively straightforward, usually requiring only a few hours to a day or two of maintenance time. Bucket elevator maintenance is relatively complex, especially when the chain or bucket wheel is damaged, requiring maintenance personnel to disassemble more parts, and the entire process may take several days, increasing downtime and repair costs.
In terms of corrosion resistance, belt conveyors usually use corrosion-resistant materials such as rubber belts and stainless steel structures, which can effectively cope with corrosive materials and harsh working environments. For example, when handling chemical fertilizers, belt conveyors can resist corrosion well. However, bucket elevators have poor corrosion resistance, especially when handling materials with high moisture and high pH, the metal parts of bucket elevators are prone to rust, which in turn affects their service life.
Regarding floor space and dust issues, belt conveyors take up a large amount of space when conveying over long distances. For example, a conventional belt conveyor may require tens or even hundreds of meters in length, and often requires multiple conveyor belts to be arranged in parallel, resulting in a large floor space. At the same time, when handling some fine-grained materials, belt conveyors will generate a lot of dust, which places higher demands on factory layout and environmental hygiene. In contrast, bucket elevators have a small footprint due to their vertical conveying structure, making them suitable for use in places with limited space. They can also effectively prevent materials from flying and reduce dust pollution. The vertical design of bucket elevators usually makes them occupy less than one-third of the area of belt conveyors, making them particularly suitable for plants with limited height space.
Overall, belt conveyors are more suitable for conveying materials with large flow, long distance, high humidity, and high viscosity, especially when high conveying capacity and long working cycle are required. It is easy to maintain and has strong corrosion resistance, but due to its large footprint and easy generation of dust, it may not be suitable for places with high requirements for space and environment. Bucket elevators provide a more compact solution in limited space, suitable for places where vertical conveying is required. Although their conveying capacity is small and maintenance is slightly complicated, they have obvious advantages in controlling dust and saving space. According to different material characteristics and plant layout requirements, choosing suitable conveying equipment can greatly improve work efficiency and reduce operating costs.
When choosing a compound fertilizer conveyor, you need to consider multiple factors, including material properties, production capacity, plant size, budget, etc. Each factor is closely related to the selection, design, and ultimate operating efficiency and economic benefits of the conveyor.
1. Material properties:
First of all, material properties are one of the key factors in choosing a suitable conveyor belt. Compound fertilizer is a multi-component fertilizer, usually composed of nitrogen, phosphorus, potassium and other trace elements. Since the particles of compound fertilizer are usually hard and may have different humidity and viscosity, this requires the selection of conveyor belts to handle different types of materials. For compound fertilizers with larger particles, the conveyor belt needs to have a strong load-bearing capacity and good material friction to prevent the material from sliding or falling during transportation. If the compound fertilizer has a high humidity, the belt material of the conveyor belt should have strong anti-slip and moisture resistance. Assuming that the humidity of the compound fertilizer is between 10% and 15%, the conveyor belt should be made of moisture-resistant rubber or synthetic materials to ensure stability and efficiency during transportation.
2. Output demand
Output demand is also an important factor affecting the selection. The output of compound fertilizer production lines is usually large, especially in large-scale production. For example, if the annual output of the production line is 100,000 tons of compound fertilizer, the hourly production is about 12 tons to 15 tons. In order to ensure efficient production, the belt conveyor needs to have a certain conveying capacity. In this case, it would be ideal to choose a belt conveyor that can convey 30 tons to 50 tons of materials per hour, which can adapt to the high-speed production process and ensure the continuous supply of materials.
3. Conveying distance and inclination angle:
The length and inclination angle of the conveyor have a direct impact on the selection. For longer distances, it is necessary to select a belt with higher tension and durability. For example, if compound fertilizer needs to be transported from one end of the workshop to the other end, and the conveying distance reaches more than 150 meters, it may be necessary to consider a belt conveyor with tension adjustment function to avoid the belt from running or slipping due to excessive length. If the conveyor has an inclination angle, it must be ensured that the belt can work stably at a larger inclination angle. Generally, the maximum inclination angle of the belt conveyor is 15 to 20 degrees. Exceeding this angle may cause the material to slip or unstable conveying, so it is necessary to select the appropriate angle and equipment design according to the specific situation.
4. Material flow characteristics and conveying speed:
Compound fertilizer particles of different types, especially compound fertilizers containing multiple fertilizer components, may have different fluidity. Materials with poor fluidity may get stuck on the bends or conveyor belts of the conveyor, thus affecting the conveying efficiency. Therefore, choosing the right conveying speed is also very critical. Generally, the conveying speed of the belt conveyor is between 1 m/s and 3 m/s. Lower speeds are suitable for fragile or easily damaged materials, while higher speeds are suitable for large flow and harder materials. In order to avoid excessive wear or jamming problems, a moderate speed and appropriate conveyor belt width can be selected to ensure that the material can pass smoothly.
5. Ambient temperature and humidity:
The storage and production environment of compound fertilizers is usually humid, so the belt conveyor needs to have good waterproof and corrosion resistance. A working environment with heavy humidity may cause the metal parts of the conveyor to rust, thereby shortening the service life of the equipment. In this environment, you can consider choosing a belt conveyor made of anti-corrosion coating or stainless steel. In addition, too high or too low temperature will affect the elasticity and durability of the belt. For example, in a high temperature working environment, rubber belts may become brittle, while low temperature environment may cause the belt material to harden. Therefore, when choosing a belt conveyor, you should consider the local climate conditions and choose suitable belt materials and structural designs to extend the service life of the equipment.
6. Plant size
The size of the plant directly affects the layout of the belt conveyor and the choice of conveyor length. Compound fertilizer production lines usually require longer conveying channels to connect various production equipment and storage areas. Assuming that the production area of the plant is 3,000 square meters, and 3 conveyor belts need to be arranged in the workshop to connect each production section respectively, it is particularly important to choose the appropriate belt conveyor length. For long-distance transportation requirements, the length of the belt conveyor can reach 100 meters or even longer. When designing, it is necessary to ensure that the direction of the conveyor belt is not restricted by the layout of the plant, avoid wasting space and ensure smooth passages.
7. Investment budget
When considering the budget, the selection should be combined with the long-term use cost and initial investment of the equipment. The price of compound fertilizer belt conveyor varies with the conveying capacity, conveying length, and belt material. For example, the initial investment of a standard belt conveyor with a conveying capacity of 50 tons/hour may be RMB 50,000 to 80,000. If the budget is tight but the demand for efficient conveying still needs to be met, an economical belt conveyor can be selected and combined with a reasonable maintenance plan to reduce long-term operating costs. In addition, choosing the right belt material (such as wear-resistant or corrosion-resistant materials) can reduce equipment wear and increase service life, thereby reducing the frequency of equipment replacement and further saving long-term costs.
8. Safety and environmental protection requirements:
During the production process of compound fertilizer, the material is prone to generate a certain amount of dust, especially during material unloading and conveying. Dust not only affects the production environment, but may also cause harm to the health of employees. Therefore, when selecting a belt conveyor, it is necessary to consider designs with closed structures, dust suppression functions or dust collection systems to reduce dust pollution and protect the health of workers. In addition, the operating noise of the belt conveyor is also an aspect that needs attention, especially during long-term and high-intensity operation. Choosing equipment with low noise operation can effectively improve the quality of workers' working environment.
9. System integration and automatic control:
Modern compound fertilizer production lines are increasingly dependent on automatic and intelligent control systems. In order to improve production efficiency and ease of operation, belt conveyors with automatic control systems can be selected. These systems can automatically adjust functions such as conveying speed, material distribution, and fault alarm according to the needs of the production line. For example, they automatically monitor the operating status of the conveyor, automatically adjust the belt tension, prevent the belt from deviating or excessive wear, and provide real-time operating data to help maintenance personnel find problems and take measures in time.
10. Equipment scalability and flexibility:
With the expansion of production scale, compound fertilizer production lines may need to transform or expand equipment. Therefore, when choosing a belt conveyor, it is necessary to consider the scalability and flexibility of the equipment. For example, choosing a belt conveyor with standardized modular design can easily increase the length of the conveyor or increase the number of conveying channels when needed in the future. Modular design makes it easier to upgrade and expand the conveyor and can adapt to changes in demand at different production stages.
Belt conveyors are widely used in various industries, including mining, agriculture, manufacturing, etc., to meet different material conveying needs. Common types of belt conveyors include flat belt conveyors, modular conveyors and trough belt conveyors.
1. Flat Belt Conveyor
Flat belt conveyors are the most common and are widely used in the transportation of light to medium-sized materials. It has a simple structure and is suitable for horizontal or slightly inclined conveying work. Flat belt conveyors are suitable for conveying granular, block or light materials. The belt width is usually between 500mm and 1200mm, and the conveying capacity can reach more than 100 tons per hour, depending on the type of material and the distance of conveying.
2. Modular Belt Conveyor
Modular conveyors are connected by multiple independent modules and have high flexibility and adaptability. It is particularly suitable for occasions where it is necessary to change direction and convey irregularly shaped materials. The modular design can quickly replace some components as needed to reduce maintenance costs. This type of conveyor is usually used in food processing, chemical industry and other fields. Its conveying speed is adjustable and suitable for precision-controlled conveying needs.
3. Trough Belt Conveyor
Trough belt conveyors are designed to stably convey loose granular materials at an inclined angle and are usually used in mines, coal mines and other heavy industrial fields. Since materials are easy to slip off the belt, the trough design effectively prevents the leakage of materials and has a strong carrying capacity. The conveying capacity usually ranges from tens of tons to hundreds of tons per hour, depending on the density of the material and the conveying angle.
The working principle of the belt conveyor is very simple, but its application is very wide. Basically, the belt conveyor consists of a drive device, a conveyor belt, a roller and a tensioning device. First, the motor drives the conveyor belt to run along the predetermined route through the reducer, and the material is pushed forward by the rotation of the roller.
The driving roller is connected to the driven roller through a belt, and the belt is driven to run smoothly under the action of tension. On the belt, the material will be transported forward along the conveying path driven by the roller. The design of the belt can be adjusted according to the type of material and conveying conditions. The material and thickness of the belt will also vary according to the conveying requirements. Wear-resistant rubber materials or special synthetic materials are usually used to ensure long-term service life.
Belt conveyor is also equipped with a tensioning device to maintain the proper tension of the belt to prevent the belt from deviating or slipping due to being too loose. The tension and speed of the belt can be adjusted according to the weight of the conveyed material and the requirements of the conveying speed to ensure smooth material transportation without jamming or blocking problems.
Although we have introduced some of the characteristics of Tongli belt conveyor above, we still summarize them here.
1. High efficiency
Belt conveyors can efficiently transport large amounts of materials, especially in long-distance or high-volume transportation. Taking a conveying capacity of 100 tons per hour as an example, a belt conveyor can run continuously for 24 hours and handle a large amount of materials, greatly improving the efficiency of the production line. Whether in mines, fertilizer plants, or large storage and logistics centers, belt conveyors can maintain efficient transportation capabilities.
2. Low energy consumption
Belt conveyors are relatively energy-efficient, especially when handling heavy or bulk materials. Compared with other types of conveying equipment (such as bucket elevators or screw conveyors), belt conveyors generally have lower energy consumption. Its main energy consumption comes from the rotation of the motor-driven belt, so choosing the right motor power and optimizing the transmission system design can effectively reduce energy consumption. For large production lines that need to run for a long time, the energy-saving advantage is more obvious.
3. Easy to operate and maintain
Belt conveyors have a relatively simple structure, easy operation, and low employee training costs. Daily maintenance is also relatively convenient. Just check the belt wear regularly, adjust the tensioning device, and clean the debris on the belt surface. Compared with other types of conveying systems, belt conveyors have a lower failure rate, and the cost of replacing belts, cleaning or repairing some components is relatively low. For some simple faults, operators can easily solve them by adjusting and replacing some parts.
4. Wide applicability
Belt conveyors are suitable for all kinds of materials, including granules, powders, block materials, etc. Especially for materials with high humidity and high viscosity, such as compound fertilizers, ore, coal, etc., belt conveyors can convey them smoothly. This system is particularly suitable for occasions that require continuous and large-volume material transportation, greatly reducing manpower and time costs.
Powdered fertilizers, including phosphate and potash, are easily conveyed by belt conveyors. These systems prevent segregation of fine particles and maintain the homogeneity of the product, crucial for plant uptake and efficiency.
Belt conveyors are ideal for transporting granular fertilizers, such as urea or ammonium sulfate. Their consistent speed and ability to handle bulk loads ensure that fertilizers reach the appropriate storage or application areas without damage.
Clay is often used in the cement industry for its plasticity and bonding properties. Belt conveyors effectively transport clay in its moist or powdery form without degradation, facilitating efficient mixing with other raw materials.
In cement production, sand is mixed with other raw materials to achieve specific properties in the final product. Belt conveyors provide a steady flow of sand, reducing the need for manual handling and ensuring consistent quality throughout the production process.
Fly ash is commonly used as a pozzolanic material in cement production. Belt conveyors can transport this fine, powdery material effectively, ensuring uniform mixing with other components and maintaining the required quality standards.
Gypsum is crucial for regulating the setting time of cement. Its crushed form is easily conveyed by belt conveyors, allowing for precise dosing and integration into the final product without contamination.
In the final stages of cement production, cement clinker is transported from kilns to storage or packing areas. Belt conveyors provide an efficient means to move clinker, reducing handling time and minimizing environmental impact.
Limestone is a key raw material in both cement and fertilizer production. Its fine powder form is transported easily by belt conveyors, allowing for consistent supply to the grinding mills. The durability of the belts ensures minimal wear, even when handling abrasive materials like limestone.
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