Our expertise for designing of long and high speed belt conveyors involves systematic approach to optimize the tension distribution along the conveyor belt which will be consuming less power comparably and helps in saving considerable CAPEX and OPEX. We design conveyors by analysing its various characteristics under steady state & stalled scenarios and do dynamic analysis at every point of interest by using powerful softwares such as Helix, Beltstat etc.
In a plant consisting of large scale bulk material handling transportation the critical issue during operation and maintenance is bad transfer chute design. This may result in huge productivity loss, hence having significant impact in system's success. Ficus got powerful resources such as "Discrete Element Modelling" software to simulate the transfer chute's design to analyse the flow of materials and to arrive at a best possible geometry. This approach ensures prompt design of chutes for large scale bulk material transportation in mines and ports.
ROM hoppers are crucial in Mines. There are possibilities for causing blockage of materials during loading if the power requirements are inadequately calculated for actual required pull-out force. This is a common mistake done by Engineers during design of ROM stations. We design ROM stations in an integrated manner and we developed a worksheet internally in which the hopper's geometrical parameters are interlinked and simulated numerically with belt feeder to design the hopper's optimum geometry. Also the ease of flow through hopper is ensured by designing hoppers with V - shedder plates and drafted openings. This design approach enabled our clients to operate ROM stations in fairly less down time.
Tripper's profile is designed by designers similar to belt conveyor profile and a hold down pulley is used inherently as a common design practice to prevent belt lift off during empty running condition. This design approach is being followed by significant number of designers globally. The disadvantage of having a hold down pulley includes increased belt resistance, ultimately higher power consumption and reduced belt life due to the belt constantly in contact with hold down pulley. Ficus possesses a well researched and proven paper by industrial design experts to effectively design tripper's belt profile. We follow this design approach which will prevent the belt lift off during empty running case and avoids a hold down pulley in tripper.
Two dimensional designs are becoming outdated and also have its limitations in clarity of details. Ficus possesses softwares such as solid works, StruCAD and Autodesk Inventor which is being used by our designers exclusively to design the critical systems such as material chutes, technological structures, transfer points etc., and even the entire layout of the system. This method enabled us to design the infrastructure with due diligence and minimized errors in the later stage of design engineering. Our design work flow and infrastructure is planned to suit the lifecycle of design in projects.