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<p>Belt conveyors play an important role in an integrated steel plant. They are used to transport raw materials like Iron ore, coal, sinter, pellet, coke, lime and dolomite from storage areas or unloading points to Blast furnaces (BF), Coke ovens (CO), Direct reduced Irons (DRI) and Steel making shops (SMS). Any unplanned outage in belt conveyor system leads to major production loss due to high revival time. A belt conveyor system consists of belt, pulleys, idlers, drive mechanism, and supporting structure. Pulleys are key component of conveyor which is used to drive the belt and change the direction of belt in vertical plane, and to form endless loop for continuous operation. The reliability of the pulley is very important for conveyor availability. Snub pulley failure happened in critical belt conveyor and led to major production loss. Therefore, detailed failure analysis has been carried out to identify the root cause. Pulley key design parameters like pulley shell diameter and shell thickness have been calculated and addressed in this paper. The pulley shell failed as it was subjected to high stress due to less shell thickness. The same type of failures can be avoided in conveyor pulley by implementing the recommendations which have been addressed in this paper.</p>

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Failure Analysis of Snub Pulley Shell of Belt Conveyor

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • Aditya Jain,
  • Mukesh Kumar Vishwakarma,
  • Rama Satyanarayana Mulapuri,
  • T. Thirumurugan,
  • N. Rajesh Kumar,
  • Satyen Ojha

摘要

Belt conveyors play an important role in an integrated steel plant. They are used to transport raw materials like Iron ore, coal, sinter, pellet, coke, lime and dolomite from storage areas or unloading points to Blast furnaces (BF), Coke ovens (CO), Direct reduced Irons (DRI) and Steel making shops (SMS). Any unplanned outage in belt conveyor system leads to major production loss due to high revival time. A belt conveyor system consists of belt, pulleys, idlers, drive mechanism, and supporting structure. Pulleys are key component of conveyor which is used to drive the belt and change the direction of belt in vertical plane, and to form endless loop for continuous operation. The reliability of the pulley is very important for conveyor availability. Snub pulley failure happened in critical belt conveyor and led to major production loss. Therefore, detailed failure analysis has been carried out to identify the root cause. Pulley key design parameters like pulley shell diameter and shell thickness have been calculated and addressed in this paper. The pulley shell failed as it was subjected to high stress due to less shell thickness. The same type of failures can be avoided in conveyor pulley by implementing the recommendations which have been addressed in this paper.