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QUALITY CONVEYOR COMPONENTS

BRYANT PRODUCTS, INC.ANATOMY OF THE AGGREGATES INDUSTRY

INTRODUCTIONThe aggregates industry is in the business of mining and processing rock. The aggregates industry encompasses rock quarries, sand and gravel plants, concrete manufacturing and asphalt processing facilities; their end products include crushed stone,sand & gravel, cement and asphalt. These products are used in applications ranging fromroad and bridge construction to building construction. The industry produced over 1.7 bil-lion tons of crushed stone and 1.4 billion tons of sand and gravel per year; it representsover 90% of the non-metallic mining production in the United States. The industry is keyto the growth of world economies, since its products are used in developing the infrastruc-ture required to support economic growth. In addition, a recent development in thisindustry is the recycling of asphalt and concrete. Today, many states require that a percentage of new asphalt and cement contain recycled material.

In non-technical terms, the aggregates industry “turns big rocks into little rocks". In a typical aggregates processing plant, belt conveyors are the transportation systems,moving the rock products between feeder/breakers, crushers, screens, classifiers, storage piles and load-out terminals. An aggregates plant cannot operate efficiently and cost-effectively without belt conveyors providing the material handling.

In this article, we will review the following topics:

a) Products of the aggregates industry

b) An overview of a typical aggregates quarry

c) The applicability of the Bryant Telescoper‚ take-up assemblies to the conveyors in an aggregates quarry

AGGREGATE PRODUCTSThe basic product of the aggregate industryis “rock”. Aggregate is defined as any combi-nation of sand, gravel and crushed stone intheir natural or processed state. The basictasks of this industry are to: (1) mine the aggregate (2) size the material (3) classify the materials

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Some of the primary products of this industry include:

Coarse Aggregate: This is typically defined as aggregate materials that are retained bya #4 sieve with a 0.187" square opening.

Fine Aggregate: This is aggregate that passes a #4 sieve (0.187" square opening) but ispredominately retained by a #200 sieve.

RipRap: This aggregate product has an average size of between 6" and 30". It is large,irregularly shaped rock and is often used to stabilize slopes or shorelines.

Gravel: This is a granular, pebbly material that results from natural disintegration ofrock. Usually coarser than 1/4" diameter, it is found intermixed with fine sand and clay;it can be classified as bank, river or pea gravel. Its rounded character is normally created by the stream action of water.

Base Aggregate: This is crushed rock that is sized for use as the foundation for pavement.

Ballast: This is broken stone or gravel that is often used to stabilize a road or rail bed.

Boulders: Material that is greater than 8" in diameter.

The National Stone Association (NSA) provides the material classification definitions forthe aggregates industry. The above listing is just a sampling of the many categories definedby NSA.

The construction industry is the largest user of aggregate products. Road, bridge, airport and dam construction account for over 50% of all aggregate products produced inthe United States. Aggregate products are used for sub-base and base materials, concrete and asphalt for road construction. Building construction, both commercial andgovernment, represents about 30% of aggregate product usage. The remaining 20% isspread out among residential construction, erosion control and railroad construction.

THE FLOW OF A TYPICAL QUARRYAs stated earlier, the basic process of an aggregates plant is to turn “big rocks into littlerocks". Although the processes to do that are quite technically sophisticated, the basic flowof an aggregates quarry includes A) Mining of the natural rock deposits, B) Feeding, C) Crushing, D) Screening, E) Classifying, F) Storage, G) Load-out, and H) Conveying.

Figure 1 is a schematic of a typical aggregates plant. It shows the flow of the materialthrough the various processes in the plant. The symbols shown are used in the aggregatesindustry to display each operation.

It is obvious from reviewing the plant layout that conveyor systems are the “transportationsystems” of an aggregates plant, moving the material from process to process. They are themost efficient method available for this transportation task.

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MINING:The mining of the rock is normally done by “blasting” out thenatural deposits. This blasting operation is a science in itself,developed by specialists who consider the consistency of the rock,the depth and the surrounding terrain. The basic process is a) todrill (bore) a series of deep holes in a specific pattern, b) to fill theholes with explosive material, and c) to detonate the explosives ina controlled manner.

This blasting process will create a pile of large rocks which mustthen be processed into more usable product. Front-end loaderstypically load huge dump trucks, which transport this blastedmaterial to the processing plant.

In many western states, mining is accomplished by dredging orscraping riverbeds, as this is the source of their aggregate prod-ucts.

FEEDING:The blasted material is delivered to the processingarea of the plant via the large dump trucks. Thismaterial is dumped into feeder-breakers that preparethe material for the primary crushers. These feeder-breakers are extremely heavy-duty devices since theyare subjected to tremendous forces from the impact ofthe dumped rock. They can be static or vibratory, hori-zontal or inclined. Their job is to feed the rock into thecrusher at the proper rate so as not to overload thecrusher. They are often designed to do some prelimi-nary “sorting", so that smaller pieces of rock canbypass the crushing operation. The most commonfeeder ahead of the primary crusher is a “Grizzly” barfeeder.

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Different types of crushers have been developed for the variety of crushing applications.The selection of the proper crusher design for a given application is a function of the mate-rial size, material composition (hardness and abrasiveness), the reduction in size requiredand the volume of material to be processed.

JAW CRUSHERS are the most universally applicable primary crusher. It is an eccentric jaw,compression machine that works within a 6 to 1 reduction ratio range, accepting rock up toabout 20” in size.

IMPACT CRUSHERS are typically used for limestone or lower abrasive applications. Workingin the 20 to 1 reduction range, these crushers utilize single or double impact impellers.

GYRATORY CRUSHERS are typically used as a primary crusher when high production isrequired.

CONE CRUSHERS are the crushers of choice for most secondary and tertiary crushing applications, although they can be used as primary crushers in smaller operations.Generally operating in the 6 to 1 reduction ratio range, they generally accept materialup to 4" in size.

HORIZONTAL SECONDARY IMPACT CRUSHERS utilize the benefits of impact crushing toprovide a tighter tolerance product. With reduction ratios of up to 12 to 1, these machinescan handle the more abrasive materials.

ROLL CRUSHERS are compression type machines that are limited to 2-1/2 to 1 reductionratios. They are capable of producing material sizes within close tolerances.

VERTICAL SHAFT IMPACT CRUSHERS combine impacting benefits with high chromemetallurgy. Typically used as a “finish” crusher, they accept material up to 3" in size andwith high abrasive makeup.

HAMMERMILLS (LIMEMILLS) are typically used in a secondary crushing application withmaterial size up to 8" and provide a reduction ratio of up to 20 to 1.

CRUSHING:Crushing is the operation of “sizing” the rock. In a typicalaggregates plant, material may go through three crushingstages, depending on the material to be produced. Eachcrushing step further reduces the size of the material. Thecrushing operations are typically defined as

a) Primary Crushing of the mined rock,

b) Secondary Crushing, and

c) Tertiary (third stage) Crushing.

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CRUSHERS

GYRATORY CRUSHERS

JAW CRUSHERS

ROLL CRUSHERSROTARY BREAKER

IMPACT CRUSHERS

Dodge Blake(double-toggle)

Overhead Pivot(double-toggle)

Overhead Eccentric(single-toggle)

Hammer Mills Vertical SpindleCageDisintegrators

Impactors

ConeGyradisc

TrueGyratory

Single RollsDouble Rolls

SCREENING:Screens are the “sieves” that separate theaggregates by size. In their simplest form, theyare meshes that allow a certain size materialto drop through, while retaining material thatis too large to pass the mesh opening. They aretypically vibrating devices that are horizontalor inclined. They are often “multi-deck”designs with progressively smaller mesh sizeson each deck. There are many designs forthese vibrating machines, each attempting tomaximize material separation.

The screen itself can be made from a number of different materials and in a variety of patterns. Some of the most common are:

WOVEN WIRE CLOTH: This is the most common screening material and is used in all phasesof screening. It is designated by the clearance in the mesh or by its “square mesh” (definedas the number of openings in one inch). The openings are typically either square or rectan-gular, and can be “weaved” in a variety of manners. Wires used to manufacture woven wirecloth are usually steel alloys, copper alloys, nickel alloys or stainless steels.

PLASTICS: Plastics can we woven similar to wire cloth. They are commonly used in thechemical industry due to their corrosion resistance. They are best suited for light materialswith low abrasion.

PROFILE DECKS: This is a screening medium consisting of wires in various shapes, runningsubstantially parallel to each other. They are used primarily in dewatering applicationsand for small particle separation.

ROD DECKS: These decks are constructed of round rods arranged parallel to each other.They are designed to handle high volumes of wet or dry abrasive materials.

GRIZZLY BARS: This is a heavy duty screening surface consisting of spaced bar, rail or pipemembers running in the direction of material flow. The bars can be either cast or fabri-cated, and are used for sizing with openings greater than 1-1/2". They are primarily used inheavy-duty operations ahead of the primary crusher, where accuracy of separation is notimportant; they are extremely effective with very abrasive materials.

PERFORATED PLATE: These screens are used when the material being screened is heavy orhighly abrasive. They are available in a wide variety of opening shapes and sizes, and areconstructed from a variety of materials, including steel, bronze, brass, copper and alu-minum. They can also be cast rather than fabricated. Some applications require a rubbercladding for extra abrasion resistance.

PERFORATED RUBBER or POLYURETHANE DECKS: Similar to perforated plate decks, thesescreens are made from rubber or polyurethane materials. They both offer the advantage ofincreased abrasion and impact resistance.

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The major advantages of the standard Bryant Telescoper® are• Elimination of adjuster rod thread damage due to rust, corrosion and material build-up• Elimination of take-up assembly “freeze up” due to its truly “protected screw” design• Rigid structure due to the tube sizes utilized and close tolerances achieved• Allows utilization of standard pillow block bearings — both 2 bolt and 4 bolt types —

resulting in lower bearing cost, easier bearing change-out and, therefore, reducedmaintenance costs

• Longer life expectancy than other manual take-up devices• Simple mounting to the conveyor frame: standard feet, mounting studs or direct weld• Easily customized to customer's unique requirements• Powder coat finish for durability• Use of ACME threaded rod on Series 350HD, 400 and 500 units for high load and

thrust capacity • “Pinned Adjustment Nut” design on Series 350HD, 400 and 500 units for higher

adjustment torque and easier disassembly

SPRING COMPRESSION TELESCOPERS®

Bryant Products has developed a spring compression version of their popular BryantTelescoper® take-up assembly. The Bryant Spring Compression Telescoper®

automatically compensates for belt stretch and wear through a unique design utilizing acompression spring within the tube assembly. By selecting the proper spring size and rate,the thrust capacity of the Bryant Telescoper® can be matched to the customer's specificapplication. On Series 300, 350HD, 400 and 500, Bryant Spring CompressionTelescopers® are fitted with a “direct reading tension scale". This feature allows accuratedetermination of belt tension by relating the amount of spring compression and theselected spring compression rate.

Users specify a Bryant Spring Compression Telescoper® when they• Require automatic compensation for belt stretch and wear• Require constant belt tension under varying thermal conditions• Require accurate determination of actual belt tension at the tail pulley• Require absorption of shock and impact loads

The Bryant SpringCompressionTelescoper® provides amajor advantage overconventional manualtake-up devices: it canbe adjusted by the conveyor user to provide a specificslack-side belt tension.

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CLASSIFYING:Almost all aggregate products contain “fines” or “sands”. Classifying equipment isdesigned to separate the fines from the aggregates, dewater it and separate the fines bysize.

Water is used in the aggregate processing to “wash” the rocks/stones throughout the plant.The water cleans away the sand (fines) into classifying tanks. These systems are designedto separate (classify) the sand by size and to remove the water. There are a number of dif-ferent ways to perform this classifying; the most common method is to utilize a “screwtype” classifier. They are normally an inclined trough or box. The screw flight turns withinthe trough, conveying the material up the incline. The discs on the flight have holes inthem, which allows the water to separate and flow downhill. The sand is then separated bysize by running it through a series of sieves of varying size.

STORAGE:Once the aggregates and fines are sized, they are conveyed to storage areas to await deliv-ery to the end customer. Storage is typically done in (a) open piles, (b) silos or (c) bins. Theyare simply staging areas for the various materials.

LOAD OUT FACILITIES:Loading out the products of a typical aggregates plant entails (a) weighing/measuring thematerial and (b) conveying it into the transportation vehicle. Load out is typically accom-plished with a front-end loader, by bin release or by conveyor. Transportation vehiclesinclude trucks, trains, barges and ships.

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BELT CONVEYORS:As stated earlier, conveyors are the transportation systems of an aggregate plant. They movethe various materials along between the crushers, screens, classifiers, storage facilities andload out. An aggregates plant could not efficiently operate without conveyors.

Belt conveyors have attained a favored position in transporting bulk materials due to theireconomy, reliability, safety, versatility and almost unlimited range of capacities. They canconvey a wide variety of materials, from fine dusty chemicals to large lumpy ore. Belt con-veyors can operate continuously, offering an economy of scale dramatically superior totrucks or other forms of haulage.

The Conveyor Equipment Manufacturers Association (CEMA) has played an important rolein the development of standards for the design of conveyor systems. Their “Belt Conveyorsfor Bulk Materials” manual has become the accepted reference for conveyor designersworldwide. In addition, the technical committees within CEMA have developed rigorousstandards for the design and manufacture of many belt conveyor components, most notablyconveyor pulleys and idlers.

Belt conveyors can be designed to follow an almost unlimited number of profiles (paths of travel).They can be horizontal, inclined, or declined, and even incorporate curves. In addition, they canbe configured for a variety of loading and unloading conditions. The proper design of a belt conveyor requires an understanding of the characteristics of the material to be handled, since itsbehavior while being carried, loaded and discharged affects the conveyor's design.

In its simplest terms, a conveyor can be described by its rated capacity; that is, the totalweight of material that it can convey in one hour. This is commonly referred to as the conveyor's “Tons per Hour (TPH)” capacity; it assumes a conveyor belt carrying a uniformcross section of material and traveling at a uniform speed. This TPH capacity is a functionof the belt width, the troughing angle of the idlers/belt and the speed that the belt is moving, normally described in “feet per minute (FPM)". As any (or all) of these factorsincrease, the capacity of the conveyor will increase. However, there are limits for beltwidth, troughing angle and belt speed; they are both independent and interdependent. Theconveyor designer's task is to find the “best” combination of these factors for the optimumconveyor design for their given application. Sounds simple — but conveyor design becomesa series of iterations and compromises to find that “best” design.

Once the basic parameters of belt width, troughing angle and belt speed have beenselected, there are a number of other decisions that the designer must make. Included inthis process is the selection of

a) The conveyor belt,b) The idlers,c) The pulleys, shafts and bearing assemblies,d) The conveyor drive mechanism (motor, gear reducer, etc),e) The conveyor control system,f) The belt take-up system, andg) The miscellaneous equipment, such as belt cleaners, skirtboards,

loading chutes, safety devices, etc.

Most of these selections are inter-related; as such, modern conveyor design is an iterativeprocess. Many combinations of these components are evaluated, typically by high-speedcomputers, to “hone in on” the optimum package.

CONVEYOR TAKE-UP SYSTEMS:All properly designed conveyor systems require some type of take-up device. The purpose of a take-up system is

a) To insure the proper amount of slackside tension (T2) at the drive pulley to prevent belt slippage,

b) To insure proper belt tension at loading and other points along the conveyor, so as to prevent the loss of troughing contour of the belt betweenidlers, thus avoiding spillage of the material from the belt,

c) To compensate for changes in belt length due to belt stretch, and

d) To allow belt storage for making replacement splices.

Any conveyor can be expected to have stretch in the conveyor belt. Some belt stretch istemporary, often due to changes in the belt tensions caused by starting or braking conditions, or caused by changing thermal conditions. Other belt stretch is permanent,caused by elongation in the fibers and fabrics used in the belt construction. Take-up sys-tems allow the conveyor designer to compensate for these changes in overall belt lengthwithout having to cut out sections of the belt.

The required distance of take-up movement is a function of several factors, including

a) The type of starting or braking that is employed in the conveyor. Across-the-line motor starting requires more take-up movement than a controlled soft start,

b) The number of starts and stops with the belt fully loaded,

c) Elongation characteristics of the conveyor belt, and

d) The running tensions of the conveyor system.

The take-up system should provide sufficient movement to accommodate acceleration ordeceleration surges without having the take-up strike against its stops. It should also allowfor some storage of belting, in case the belt must be repaired. The design of the take-upsystem should ensure its smooth movement and even tension across the face of the belt.

There are two basic types of take-up systems used on belt conveyors:

(1) Manual take-up systems, and

(2) Automatic take-up systems.

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MANUAL TAKE-UPS:Typically used on conveyors up to 100 feet in length, manual systems have the advantageof compactness and low cost. Manual take-ups are recommended where an automatic take-up is not practical because of space limitations or because of cost.

The major limitation of most manual take-up systems is the infrequency of manual reten-sioning. This creates a situation where the belt is either tensioned too tight or too loosemost of the time. In addition, most manual take-up devices do not offer a way to monitorbelt tension, so the operator does not really know how much belt tension he has. Because ofthis limitation, most conveyor designers will apply a service factor of 1.3 to 1.5 when selecting tail pulley/shaft/bearing sizes. This is to compensate for the additional tensionthat commonly occurs with manual take-up systems.

The most common type of manual take-up is the screw take-up. They utilize a threaded rodthat moves the bearing or a bearing mounting surface through the take-up travel. Manualscrew take-ups are typically available in industry standard travel lengths, such as 12, 18,24, 30 and 36 inches. However, take-up manufacturers frequently build special screw take-ups in different travel lengths.

Most manual “screw type” take-up devices are prone to “freeze-ups” as material spillageand corrosion attack the adjusting screw mechanism; after a short period of operation,many frame designs become almost impossible to adjust due to damage to the adjustingscrew. In addition, most manual take-up devices require the use of special “take-up” bearings, which fit only into a particular manufacturer's take-up frame. These “guide rail”mounted take-up bearings are more expensive than the more common pillow block bearings used on most conveyor pulley assemblies in a belt conveyor.

As stated previously, the main problem with manual take-ups is that they require frequentattention from a trained maintenance person. Evaluation must be made as to whether theconveyor requires additional take-up action, and then the operator must adjust the manualtake-up to the proper tension. Most manual screw take-ups do not have a gauge or index toguide the operator in this tensioning process. It becomes a “hit or miss” process, and thetendency is to overtension the belt. This overtensioning, if severe enough, has the potentialto cause component failures in the conveyor; pulleys are especially susceptible to overten-sioning of the screw take-ups.

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Manual take-ups are almost always used at the tail end of the conveyor, at the oppositeend from the drive pulley. Most conveyors using screw take-ups are simple, two or threepulley systems.

There are a variety of screw take-up styles available from a number of manufacturers.These styles include:

a) Heavy Duty, Protected Screw Take-up Frames:These frames are typically of a welded and bolted steelconstruction, with an adjusting screw that is somewhatprotected under an angle iron member. They typicallyaccept a variety of pillow block bearing types, bore sizesand are available in various travel lengths.

b) Light Duty, Protected Screw Take-up Frames:Similar to heavy duty frames, they are designed as aneconomical frame for lighter conveyors. Accepting ball,tapered roller, spherical roller and sleeve pillow blockbearings, they offer an adjusting screw protected fromfalling material by an angle iron member.

c) Center Pull Take-up Frames:Center pull frames are of welded steel constructionwith reinforced steel end plates. The hinged cap railallows access for bearing installation. They require aspecial style bearing available from most major bearingmanufacturers.

d) Top Angle Take-up Frames:Top angle frames are of welded steel construction, withthe adjusting screw normally plated to resist corrosion.The screw is protected from falling material by the toprail. They accept a variety of manufacturer's specialtake-up bearings, with a typical bore range of 1-3/4"through 4".

e) Wide Slot Side Mount Take-up Frames:Used with ball bearings, this style frame provides acompact solution to belt tensioning. They accept a vari-ety of manufacturer's bearing cartridges, with a borerange of 1/2" through 3-1/2".

f) Bryant “Telescoper®‚” Take-up Frames:These frames utilize an adjusting screw enclosed withintwo or more telescoping steel tubes. Pillow block bear-ings are typically mounted to the “inner tube” which“telescopes” out of the “outer tube” via the action of theadjusting screw. This design virtually eliminates con-tamination reaching the screw assembly,due to the screw being completely“protected” within the telescoping tubes.

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AUTOMATIC TAKE-UPS:Automatic take-ups are the preferredmethod for maintaining belt tensionin most belt conveyors over 100 feetin length. They can be installed hori-zontally, vertically or on an incline.They are typically gravity operated,although there are power operatedsystems utilizing hydraulic, electricor pneumatic mechanisms. The mostcommon type of automatic take-upsystem is a gravity take-up, whichutilizes a heavy counterweight hang-ing from a take-up pulley carriage.

The conveyor designer has three key decisions to make relative to an automatic take-upsystem:

1) Location of the take-up system within the conveyor,

2) The amount of weight (or force) required for proper operation, and

3) The amount of take-up travel required.

Automatic take-ups can be located at almost any place on the return run of the conveyorbelt. The key factor in take-up system location is to try to keep belt tension at a minimum;this entails keeping the take-up system as close to the drive pulley as possible. Ease ofmaintenance access and economics are other considerations to take-up location.

On long, horizontal or inclined conveyors, the gravity take-up should be located near thedrive, where it will act quickly enough to prevent slippage of the belt on the drive pulleyduring acceleration at startup. An automatic gravity take-up system must provide a forceequal to twice the required belt tension at the location of the take-up. This force is usuallysupplied by a counterweight made of steel, concrete, cast iron or some other heavy mate-rial. If a system of wire ropes and pulleys are used to suspend this counterweight, theirmechanical effect must be factored into thecalculation of the hanging weight. Gravitytake-up counterweights are typically con-structed such that weight can be added orremoved as conveyor operating conditionschange.

Gravity take-up system movement (or travel) is determined by (a) the conveyor center-to-center distance, (b) the construction of the conveyor belt, (c) environmental conditions, and(d) amount of belt storage required. CEMA has developed some recommended values oftake-up movement for automatic take-up systems.

Not all automatic take-up systems utilize a counterweight. Systems utilizing electric cabledrum drives with tension sensing devices are often used in applications where verticalspace is at a premium. The take-up pulley is bolted to a sliding carriage that is attached tothe cable tensioning system. Based on outputs from the tension monitors, the cable drumdrive adjusts the cable length, thus increasing or decreasing the belt tension. Hydraulicand pneumatic automatic take-up systems utilize hydraulic or pneumatic cylinders toincrease or decrease the belt tension based on similar sensor information.

There are some manual take-up devices that deliver many of the advantages of an auto-matic take-up system. The Bryant Spring Compression Telescoper® and the BryantHydraulic Telescoper® are systems that meet this criteria. These devices provide theconveyor user with the ability to (a) set the belt slack-side tension at a specific value,(b) compensate for transient loads through their shock absorption capabilities, and(c) compensate for belt stretch.

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BRYANT TELESCOPER®

The Bryant Telescoper®‚ represents an innovative approach to manual belt tensioning.

The unique design eliminates the biggest shortcomings of other manual take-up devices:

• “freeze up” of the screw assembly,

• the need for special take-up bearings, and

• difficulty of bearing maintenance/replacement.

The Bryant Telescoper‚ utilizes a “tube within a tube” approach with the adjusting screwtotally enclosed within the tubes. This design virtually eliminates contamination reachingthe screw assembly. Fitted with the optional grease fitting, Bryant guarantees“no freeze up” conditions for five years.

STANDARD TELESCOPER®

The standard Bryant Telescoper®‚ consists of a three piece modular construction, including:

• The “outer tube” body assembly, which mounts to the conveyor frame,

• The “inner tube” slider assembly, which includes the floating adjuster nut assembly and the pillow block bearing mounting plate, and

• The “adjuster assembly” with the threaded adjusting rod factory treated with anti-seize compound prior to assembly.

The slider assembly telescopes within the outer body tube as the adjuster rod is rotated.Due to the close tolerances of the mating tubes, the Bryant Telescoper® offers a smooth,non-binding operation of the take-up over its entire adjustment range.

With the optional grease zerk fitting installed, the design provides a lubricant reservoirwithin the slider tube to provide additional protection for the threaded adjuster rod assem-bly. In addition, the slider tube is “ported” to allow grease to flow into the area of slider/body interface. This provides a grease barrier to the ingress of outside contaminants.Grease zerk fitted Bryant Telescopers® are recommended for those especially dirty envi-ronments typically found in many aggregates operations and/or where conveyorwashdowns are common.

THE HYDRAULIC TELESCOPER®

For the higher belt tension applications that are becoming more common in aggregatesmining applications, Bryant has developed a line of Hydraulic Telescopers®, utilizing theproven features of their dependable Telescoper® take-up assembly. Designed with a “noleak” hydraulic cylinder, the Bryant Hydraulic Telescoper® offers a compact design withthe cylinder totally enclosed within the tubes for safety and protection from contamination.All units are fitted with pressure gauges for accurate monitoring of hydraulic pressure andbelt tension. Bryant offers the Hydraulic Telescoper® as a stand alone unit, or with anengineered hydraulic power system.

Advantages of the BryantHydraulic Telescoper® include

• Remote actuation of the devices

• Accurate determination and monitoring of belt tension

• Automatic compensation for beltwear and stretch

• Easy tensioning of high tensionconveyor systems

THE TOP MOUNT TELESCOPER®

The Bryant “Top Mount” Telescoper® is the newest addition to their take-up line. TheBryant “Top Mount” Telescoper® places the pillow block bearing mount “over the tube”while the threaded adjustment rod remains completely protected within the body tube. Therod is protected from material build-up, rust, corrosion and thread damage common to

aggregate industry applications. In fact, the Bryant “Top Mount”Telescoper® was specifically devel-oped for the tough applications ofaggregate industry conveyor sys-tems. Available in models 350TM,400TM and 500TM, the Bryant“Top Mount” Telescoper® accom-modates pillow block bearings up to6" bore. The Bryant “Top Mount”Telescoper® is designed to mountwithin the side frame of mostaggregate industry conveyors.

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BRYANT TELESCOPERS® IN AGGREGATE APPLICATIONSAs we have seen from the information presented above, an aggregates plant is made up ofa multitude of processes, all connected by a material transportation system consisting oftrucks and conveyors. This transportation system moves the processed material around thefacility and eventually out to the customer. Conveyors are an important part of these facili-ties, and their trouble free operation is critical to the successful and profitable operation ofan aggregates quarry.

Referring to Figure 1, we can view schematically a typical aggregates quarry. It shows themovement and processing of the rock from the truck dump into the primary crusher (upperleft) through to the load-out of trucks carrying the finished products to the end customers(lower right). The conveyors utilized in this plant include:

48" Primary Conveyor takes the output of the Grizzly feeder and/or primary jaw crusher to asurge pile and/or the Rip-Rap storage pile. This will typically be the highest horsepowerconveyor in the facility, driven by a 100 horsepower or larger motor. It is an incline con-veyor, typically 150 feet or more in length, and is equipped with a gravity type automatictake-up system.

36" Conveyor “A” runs from under the primary crusher surge pile to the 6 x 16 2D screen.This is an inclined conveyor, normally between 25 to 100 horsepower, that utilizes a gravitytype automatic take-up system.

36" Conveyor “B” carries the output from the screen and/or the secondary cone crusher upto the 9 x 24 3D secondary screen. This is also an inclined conveyor, normally between 50 to 100 horsepower, that utilizes a gravity type automatic take-up system.

24" Conveyor “E-1” carries the output of the secondary screen to “the 24" Conveyor “E-5” that feeds onto Conveyor “D"; it also moves material to the overflow chute that feedsConveyor “E-2". This conveyor is under 100 feet in length, under 25 horsepower, and uti-lizes a manual screw type take-up system.

24" Conveyor “E-2” takes the overflow material from Conveyor “E-1” to the “fines” stock pile.This is an inclined conveyor, probably under 25 horsepower. It utilizes either a gravitytake-up system or a manual take-up system, determined by the traffic flow under this con-veyor.

24" Conveyor “E-5” also moves the overflow material from Conveyor “E-1” to Conveyor “D”for reprocessing through the secondary screen. This is a short inclined conveyor, less than25 horsepower, utilizing a manual take-up system.

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30" Conveyor “D” carries the sorted material from the secondary screen and the tertiary (third stage) crushers back up to Conveyor “B” for reprocessing through the secondary screen. This is likely an inclined conveyor of under 25 horsepower utilizing a gravity take-up system.

24" Conveyor “F” moves material from a feeder hopper into the surge bins adjacent to thesecondary screen. It is a relatively short conveyor, under 25 horsepower, equipped with amanual take-up system.

30" Conveyor “C” takes the output of the secondary screen to the third stage screen, forfinal sorting of the material before placement in the load-out bins. This conveyor is aninclined belt, with between 25 to 50 horsepower. It is equipped with a gravity type auto-matic take-up system.

24" Conveyors “E-3” and “E-4” move material from the overflow chute of Conveyor “E-1”through the screw classifier to the “washed screenings” stockpile. These conveyors are usu-ally under 100 feet in length, under 25 horsepower, and utilize manual type take-upsystems.

36" Load-Out Conveyors “LO-1” and “LO-2” run from the load-out bins to the transporttrucks. They are horizontal conveyors with 25 or less horsepower, utilizing manual take-up systems.

30" Conveyors “CR-1” and “CR-2” move material from the output of the primary screen to the“crusher run” storage pile. They are inclined conveyors, under 25 horsepower, which canutilize either automatic or manual take-up systems.

30" Conveyors “PM-1” and “PM-2” move material from either the “fines” stock pile or the“crusher run” stock pile into the pugmill for processing. These conveyors are normally short in length, under 25 horsepower, and utilize manual take-up systems.

All of the conveyors that utilize manual take-up systems are candidates for BryantTelescoper® take-up systems. The determination of which Bryant Telescoper® model isapplicable can be a function of the conveyor frame configuration, the bearing size, environmental and operational considerations and the operator's preference. The originalStandard Bryant Telescoper®, the Bryant Spring Compression Telescoper®, theBryant Hydraulic Telescoper® and the Bryant Top Mount Telescoper® have all beenused on aggregate industry conveyors.

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The aggregates industry has some of the most demanding applications for belt conveyors inindustry today. The production, environmental and cost requirements of the industryrequires careful selection of conveyor components that will meet their needs. The BryantTelescoper® is a product that continues to meet and exceed the challenges of the aggre-gates industry. The advantages of the Bryant Telescoper® are:

• Long life due to rigid, protected screw design

• Reduced maintenance costs through utilization of pillow block bearings

• Cost effective design

• Modular design offering customized configurations

• Spring Compression Model for accurate tensioning

• Hydraulic Model for extra tough applications

• Top Mount Model for fitment to most conveyor frames

• Backed by a “No Freeze Up” warranty

SUMMARYThe aggregates industry provides our economy with the raw materials required for infra-structure development, such as the construction of roads, bridges, railbeds, buildings and amultitude of other uses. Conveyors are the lifelines of aggregate processing plants, effi-ciently moving the mined rock between crushers, screens, classifying screws, surge piles,storage bins and load-out facilities. Bryant Products Inc. provides a high performance,dependable take-up system that insures long life and trouble free operation for the plantoperators.

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FINES STOCK PILE AND TUNNEL WITH

PAN FEEDER

CRUSHER RUNSTOCKPILE

DUMP POINT

PRIMARYGRIZZLYFEEDER

CONV. PM-2 24"

CONV. PM-1 30"

CEMENT SILOAND BAGHOUSE

CEMENT METERING

SYSTEM

PUGMILL

6X16 3DTERIARTYSCREENS

PRIMARYJAW CRUSHER

RIP - RAPCLASS 1

SURGE PILE AND TUNNELWITH FEEDER

PRIMARY CONV. 4

8"

600 TPH

CONV. CR-1 30"

CONV. A 3

6"

600 TPH

CONV. CR-2 30"

FINES STOCK PILE AND TUNNEL WITH

PAN FEEDER

TRANSPORTTRUCK

FIGURE 1

CONV. E-2 24"

6X16 2DPRIMARYSCREEN

SECONDARYFEEDER

SECONDARYCONE CRUSHER

FINESSTOCK

PILE

CONV. E - 24" 160TPH

CONV. E - 5 24"250 TPH

300 TPHTERTIARY CRUSHERS

CONV. D 30"

200 TPH

9X24 3DSECONDARY

SCREEN

FEEDER HOPPER

CONV. F .24"250 TPH

54 X 32 SCREWCLASSIFIER

CONV. E - 4 24"

WASHEDSCREENINGSSTOCK PILE

CONV. LO - 1 36"

CONV. LO - 2 36"

SURGEBIN

CONV. B

36

"

1000

TPH

CONV. C 400 TPH 30"

CONV. E - 3 24"

160 TPH

SURGE BINSFEEDER HOPPER

OVER FLOW

CHUTE

TERTIARY FEEDERS

TRANSPORTTRUCKS

LOAD OUTBINS

400 TPH

Table of Contents- Introduction PG. 1-2

- Flow of a Typical Quarry PG. 3-7

- Belt Conveyors PG. 8

- Conveyor Take-up Systems PG. 9-13

- Bryant Telescoper PG. 14-16

- Bryant Telescoper inAggregate Applications PG. 17-19

- Aggregate Chart PG. 20-21

NEW! AirFormTM Tapered SteelConveyor Rollers

• Greatly improved TIR, angle of taper and bearing pocket accuracy.

• Diameters to 8", lengths to 60", up to 10 gauge material with or without drive belt grooves.

• Our tapered steel rollers require no tooling so special profiles and tapers are available.

TeletrackTM Conveyor Rollers

• Thermoplastic designs available in PVC, Nylon, Polypropylene, and UHMW (some materials available with steel reinforcing for higher load capacities).

• Low carbon steel, pre-plated steel and stainless available in a variety of wall thickness and pipe sizes - diameters from 11/16" to 6".

• All common bearing options - plastic race, sealed precision, UHMW or wood sleeve, stamped steel/full complement - available with or without axles in a variety of sizes and forms.

Telescoper® Takeups

•Available in low carbon or stainless steel.

•Only takeup with a fully protected adjustment rod.

•Guaranteed to adjust in any environment for up to 5 years.

•Simple modular design allows for a wide range of readily available options.

•Standard products shipped same day from factory.

•Optional constructions and special designs available in one week lead time or less.

TeletrackTM Custom Conveyor Frame Components

•All components engineered and built to order.

•Available in one week lead time or less.

•Side rails, leveling feet, belt and drive guards.

Our Products, Services and Tradenames....

FOOD PROCESSING (FIELD HANDLING, PREPARATION, PACKAGING), AGGREGATES, CONCRETE, ASPHALT, MINING, ORE CARRYING, UNIT HANDLING CONVEYORSYSTEMS, WASTE MANAGEMENT & RECYCLING, CONVEYOR TURNS, FERTILIZER & PHOSPHATE PRODUCTION, CHEMICAL PROCESSING.

Custom Machining & Fabricating

•Full CNC machining and programming - CAD and solid modeling capabilities.

•CNC Lathes - bar feed and chucking-lengths to 60", diameters to 14", tolerances to .0004".

•CNC Vertical Machining - 20" by 48" swing, tolerances to .0004".

•MIG and TIG Welding - low carbon, stainless and aluminum.

•Tube forming and fabricating, press and CNC sawing.

TeletrackTM Conveyor Pulleys• Available in PVC, UHMW, stainless or

low carbon steel in a wide array of tubing and pipe sizes.

• Diameters to 10", lengths to 60".

• Straight, crowned or trapezoidal face configurations - lagging in rubber, white rubber or polyurethane.

• Machined face or NEW high precision formed face process that meets machined tolerances without the cost. Bryant offers the only forming process capable of producing trapezoidal crowns.

• Fixed shaft, through hole precision bearing with or without labyrinth and dust seals, QD or XT type hubs.

fax: 920.206.6929 www.bryantpro.com email: inquiry@bryantpro.comP.O. Box 270 W1388 Elmwood Ave. Ixonia, WI 53036

800.825.3874QUALITY CONVEYOR COMPONENTS

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