TECO ExConTec
Conveyor Description
The C-6 dock conveyor at a transfer terminal in Southern Louisiana carries various types of coal and coke to a traveling ship loader. Material arrives from two sources: a bucket wheel type Stacker/Reclaimer (S/R) reclaiming from the storage yard, and a bucket ladder type continuous barge unloader (CBU) receiving from river barges. A belt tripper delivers material to the ship loader, which travels the length of the dock to position its loading boom over each of the ship's holds.
When the S/R and CBU operate simultaneously, peak feed rates can exceed 8,000 t/h — making precise tension management across all load conditions critical.
Why Dos Santos Universal
Aware that modern modeling, simulation, and analysis technologies were not in common use when the C-6 conveyor was designed in the early 1980s, the terminal operator decided to commission a complete re-analysis of the conveyor and determine the best solution.
The Dos Santos relationship with this transfer terminal dates to the mid-1970s, with continuous work through the late 1990s and beyond. Dos Santos' deep familiarity with the terminal and all of its equipment, combined with the company's reputation in high-technology conveying, made us the logical choice for this assignment.
ExConTec Analysis
Detailed conveyor analysis using the ExConTec Computer Simulation and Analysis Program enabled us to predict the slack belt condition through rigid body dynamics — determining the distribution of inertial forces and superimposing these on travel resistance forces as the conveyor drifts to a stop.
Key ExConTec capabilities applied to this project:
- No path or drive-location limitations — the program places no restrictions on material carrying path or the location of drive, braking, or take-up stations.
- Real-time load simulation — Load and Unload macro buttons permit real-time analysis of actual loading conditions, including loading-on, trailing-off, and any load discontinuities most likely to aggravate belt tension distribution.
- Curvature resistance equations — expanded equations account for increased belt-line resistance of induced curvature.
- Calibration to operating experience — discretionary factors permit calibration of the analysis model to reflect the terminal's operating experience and philosophy, including power monitoring data from the C-6 conveyor itself.
Conveyor Parameters
| Parameter | C-6 Dock Conveyor |
|---|---|
| Location | Transfer Terminal, Southern Louisiana, USA |
| Material | Various coals and coke |
| Design Rate | 6,187 t/h (6,820 STPH) |
| Peak Rate (Drives) | 6,845 t/h (7,545 STPH) |
| Maximum Instantaneous Rate | To 8,000 t/h (8,800 STPH) |
| Belt Width | 1,829 mm (72") |
| Belt Speed | 4.55 m/s (895 FPM) |
| Lift | 8.0 m (26.3') |
| Length | 430 m (1,409') |
| Drive Power | 522 kW (700 HP) |
| In Service Since | 1983 |
Key Highlights
- One of the highest-capacity dock conveyors analyzed with ExConTec — peak instantaneous rates exceeding 8,000 t/h
- Traveling tripper configuration adds complexity to tension analysis as tripper position varies along the dock
- ExConTec's rigid body dynamics modeling accurately predicted the slack belt failure mode
- Analysis calibrated against actual power monitoring data from the C-6 conveyor
- Long-term Dos Santos relationship with this terminal spans from the mid-1970s through continuous present-day involvement
- Demonstrates ExConTec's ability to solve legacy conveyor problems that predate modern analysis methods