Since 1972 the Magaldi Superbelt has been
used to handle hot, heavy, abrasive and sharp materials in
the following applications:
Cement
Hot clinker transportation
Hot clinker weighing
Coal, limestone and slag extraction from
hopper
Foundries
Castings, hot sands and burrs, risers and
molds transportation
Castings cooling
Risers removal (also by manipulator)
Scraps pre-heating and furnaces charging
Cupola's slag dry removal
Sand extraction from hoppers
Steelworks
Hot sinter weighing
Briquettes handling and cooling
Dangerous fines handling (lead and zinc oxides)
Scraps handling
Forges
Hot forgings transportation (1260 °C)
Forgings transportation after shot blasting
machines
Power Plants
Bottom ash dry handling and cooling
Bottom ash post-combustion directly under
the boilers
In traditional apron conveyors a chain can
break in its weakest point and maintenance is immediately required.
The Magaldi Superbelt is made up by the assembly of a high tensile
steel fabric belt onto which a series of steel pans, partially
overlapped, is fixed.
Even if one or more wires of the fabric breaks, it is not necessary
to stop immediately the conveyor. The belt can keep on operating
till the next planned stoppage of the plant.
As witnessed from the running installations,
the belt has a life of more than 10 years.
This is demonstrated by the fact that the Magaldi Superbelt
(e.g. the assembly of mesh and plates) comes with a 3 years
guarantee.
Abrasive materials do not affect Magaldi Superbelt
life because there is no relative movement between handled
material and Superbelt pans during conveyance. Abrasive materials
have no effect on the life of the Magaldi Superbelt.
The Magaldi Superbelt withstands higher temperatures
than standard chain conveyors, because the belt components
are free to expand in any direction without distortion. The
take-up device automatically compensates for thermal expansions.
The mesh construction ensures very fast heat dissipation.
The Superbelt's pans fit so tightly that there
is no clearance between adjacent pans. Constant tension through
the tensioning device ensures a very high contact pressure
in the overlapping area. As consequence no leakage of fines
can occur.
Depending on the application:
Pneumatic
Pneumo-hydraulic
Counterweight
The most common is the pneumatic system, made
by two pneumatic cilinders that push the tail trolley.
Big conveyors or feeders under big hoppers can require the pneumo-hydraulic
or the counterweight system.
Magaldi Superbelt belt is completely supported
by idlers across its entire width. These idlers can be closely
spaced in impact areas so that stresses are distributed over
a large area; the plates are not subjected to any bending
moments and no deformation can occur.
Specific tests performed in Japan shows that the mesh belt has
a fine characteristic to absorb impact loads.
Critical failure during special impact conditions could cause
bending of rollers. These can be very easily replaced during
scheduled maintenance periods because a few bent rollers do
not affect the normal operation of the conveyor.
The design of the Magaldi Superbelt is very
similar to traditional conveyors. It can be easy to fit the
carrying idlers and return rollers on existing frames of rubber
belts or apron conveyors, turning the old equipment into a
very dependable conveyor.
Often it is also possible to reuse the head and tail drums,
pillow blocks and bearings the drive.
The Magaldi Superbelt undergoes negligible
wear and tear and unscheduled maintenance shutdowns are not
required. Replacement of idlers is very easy and quick, just
like in rubber belt conveyors.
It has no chains and no sprockets that are the critical components
of traditional apron that need frequent maintenance.
The bearings of the idlers of the Superbelt are life lubricated;
the bearings of the head and tail pulleys need lubrication only
after 4000 hours of operation.
Anyway the easy maintenance can be performed during scheduled
plant shutdowns.
Technically it is possible to replace an idler
without stopping the conveyor, using adequate safety precautions.
Anyway an accidental failure of one or several idlers is not
a critical event that compromise the operation of the conveyor.
This concept is related to the absolute dependability
of the Magaldi Superbelt.
The steel wire fabric is over-designed and
has a service factor of 20 - 50 times the breaking load (depending
from the application).
A failure of one or several idlers do not
compromise the operation of the conveyor
All the other components (motor, gearbox,
bearings etc.) are "heavy duty" type designed to survive
to the most catastophic event.
The diameter of the head and tail pulleys
is very large compared to the overlap pitch of the pans. Consequently
while passing over the drums, the pans open out only about
few degrees. The side walls are constructed in such a way
to ensure that they always overlap during this passage.
Technically, it is possible to run the belt
in the reverse direction; anyway this must be done only under
no load conditions or for a few seconds during accidental
jamming. On load the belt must be run only in the designated
direction, to prevent trapping of material between pans at
tail section.
Yes, it is. Infact, any part of the belt can
be changed very easily. The two transverse rods bordering
the section to be changed, can be removed easily and the belt
piece can be taken out. The new piece can be immediately installed
using the same transverse rods.
On the contrary, it is not possible to replace few links in
a chain of an apron conveyor, because of the change in the pitch
of the chain links and of the sprocket teeth due to wear.
In this case the entire chain along with the head and tail sprockets
have to be replaced.
The minimum width is 400 mm (16 in).
Regarding the maximum width there are running installations
2.000 mm (78 in) wide. It is possible to provide 2.400 mm (95
in) wide pans.
The Magaldi Superbelt "E" type,
provided with vertical cleats, installed in SOCOCIM cement
plant, is 54° inclined .
It is used for the transportation of 120 t/h of red hot clinker
@ 650°C (1200°F).
The Magaldi Superbelt "P" type installed
in Teksid Hua Dong foundry, is 107 meters long.
It is used for the trasportation of 8 t/h of sprues @ 650°C
(1200°F).
It depends on the application. However to
ensure the belt longevity, we do not recommend to operate
at speeds greater than 0.3 m/s (60 ft/min).
All idlers, rollers, pulleys and bearings
are standard type. Magaldi Industrie selects the heavy-duty
ones with oversized shaft, shell, bearings etc.
The belt (mesh + pans) is the only special component as it is
a patented by Magaldi Industrie.
One of the particular features of the Magaldi
Superbelt conveyor is its very silent operation; noise level
is below 65 dB like rubber conveyor belts.
The Magaldi Superbelt does not leak fines
and does not shake, ensuring that no dust can contaminate
environment.
Moreover there is a version of the Magaldi Superbelt that we
call Ecomag that is completely enclosed in a dust-tight housing.
It depends on the application.
The pans, 5 or 8 mm tichness (1/5 in or 1/3 in) can be made
of carbon steel, manganese steel or stainless steel; the mesh
can be made of carbon steel or stainless steel.