Study of the feasibility of classifying oversized lump material during conveyor transportation

Dmytro Popolov*, Oleksandr Uchytel, Serhii Shved, Ihor Zaselskiy, Serhii Henkulenko, Eduard Havrylov

popolov@duet.edu.ua

Received 05.12.2025, Revised 03.04.2026, Accepted 28.04.2026, Published 29.05.2026
Abstract

In the modern mining and metallurgical industry, the operational stability of preparatory processing equipment, such as crushers and mixers, is significantly dependent on the uniformity of the granulometric structure distribution of the feed material. The presence of oversized lump material leads to dynamic overloads, accelerated wear of working components, and increased energy consumption. Conventional classification methods using scalping screens are economically inefficient at low contents of oversized lump material, which necessitates the development of cost-effective classification methods directly on conveyor lines. The aim of this study was to provide a scientific justification for the design of a machine for the mechanical removal of large-sized inclusions from a flow of bulk material in the unloading zone of a belt conveyor, based on a previously developed segregation heterogeneity model. The study employs methods of mathematical modeling, theoretical mechanics, and particle dynamics, which made it possible to substantiate the design of a classification device in the form of a rotating rod comb positioned above the conveyor discharge pulley. It has been established that the rational operating regime is achieved by matching the linear velocity of the belt with the kinematic parameters of the rod tip rotation, thereby minimising energy losses due to sliding. It has been mathematically proven that a rod profile in the form of a clothoid ensures its penetration into the material bulk along the normal path, significantly reducing impact loads. A comprehensive dynamic model has been developed, describing three stages of interaction: particle extraction from the layer, its relative motion along the rod surface, and free flight, which makes it possible to determine the geometric boundaries of the oversized lump material dispersion zone. This enables precise positioning of receiving hoppers and deflector plates for oversized lump material. The obtained mathematical models and geometric relationships allow for the design of efficient pre-classification units integrated into existing conveyor systems, ensuring protection of process equipment from overloads without the need for bulky and energy-intensive machinery

Keywords:
belt conveyor; material segregation; mechanical classification; rotating rod comb; particle free-flight trajectory; size classification; discharge assembly

Retrieved from Volume 24, No. 1, 2026

Pages 8–20

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Popolov, D., Uchytel, O., Shved, S., Zaselskiy, I., Henkulenko, S., & Havrylov, E. (2026). Study of the feasibility of classifying oversized lump material during conveyor transportation. Journal of Kryvyi Rih National University, 24(1), 8-20. https://doi.org/10.31721/2306-5451-2026-1-24-08-20
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