Belt Conveyor Issues and Solutions in the Mining Industry

Belt conveyors are an integral part of the mining industry, facilitating the continuous transportation of large volumes of material. These systems are vital for operational efficiency but also come with their own challenges. From misalignment to material spillage, the performance of conveyor systems is often hampered by operational and maintenance issues. Addressing these challenges is crucial for ensuring the longevity of the equipment, minimising costly downtimes, and enhancing overall efficiency.

1. Misalignment: Belt misalignment occurs when the conveyor belt moves off-centre or deviates from the intended path. This can be caused by various factors such as incorrect installation, material build-up, or structural issues. Belt misalignment can cause uneven wear and tear on the belt, leading to frequent maintenance needs and even belt failure or damage to the conveyor system.

 

2. Belt Wear and Tear: Conveyor belts are subjected to continuous wear and tear from the abrasive nature of the transported materials . Over time, this can lead to belt degradation and failure if not properly maintained. Top cover wear is primarily caused by the abrasive action of the materials being conveyed, especially at the loading point and at the discharge point. Bottom cover wear is mainly caused by friction contact with pulleys and idlers. Tears and rips in the conveyor belt can be catastrophic, leading to significant downtime and costly repairs.

3. Material Build-up and Spillage: Spillage happens when materials fall off the conveyor, which can cause blockages, accidents, and environmental issues. Material that sticks to the conveyor belt (carryback) can cause misalignment or fall off and cause blockages, affecting performance and causing wear on both the belt and equipment.

1. Regular Inspections and Predictive Maintenance:

Implementing a rigorous inspection schedule and predictive maintenance practices can help identify and address issues before they escalate. Regularly inspect the belt for signs of wear and tear, and replace damaged sections promptly, or use rip-detection systems to detect small tears before they become major issues. Leverage data analytics and machine learning to predict when wear is likely to occur, allowing for maintenance to be scheduled proactively.

2. Automated Systems: Implementing automated tensioning systems ensures that the belt maintains optimal tension throughout its life, reducing the need for manual adjustments and improving cleaning efficiency​​. Additionally, installing automatic belt alignment systems, such as self-aligning idlers, can maintain belt positioning and reduce wear.

3. Advanced Materials and Monitoring Technologies:

• Installing skirting systems and adjusting loading areas can help contain material within the belt.
• Using advanced materials like lightweight composite rollers, belt cleaners or anti-slip pulleys can improve the reliability and lifespan of conveyor components.
• Installing energy-efficient motors and using regenerative drives can reduce energy usage and costs.
• Installing belt cleaners that are specifically designed for cleaning the type of material your conveyor handles will help prevent build-up problems.

Atlas Energy Solutions’s Duna Express project is a prime example of how innovative conveyor technologies can be implemented in large-scale operations. This project involves a state-of-the-art conveyor system designed to handle the demanding conditions of sand transportation in West Texas. Notably, the last conveyor flight, CV-004, will be the single longest conveyor in the world without a mid-drive or boosters, spanning 16.4 miles. The Dune Express has a low rolling resistance rubber compound and very wide idler spacing. It also has a unique mobile offload facility meaning it can take sand off the conveyor at any point wherever it makes sense on the ground.

1. High-Efficiency Belts and Drives: The conveyor system in the Duna Express project features high-efficiency belts and gearless drive systems, which reduce energy consumption and increase the system’s overall efficiency. These advanced components are designed to handle the abrasive nature of sand and the harsh environmental conditions of the region. For the belt itself, ContiTech is providing its CONTI MultiProtect system to monitor belt condition. This is a permanent magnetic system that detects belt rips by monitoring embedded rip inserts that are magnetised. The system can monitor for steel cord damage and splice integrity in addition to rip monitoring.

 

2. Automated Monitoring and Control: The project incorporates automated monitoring and control systems that allow for remote management of the conveyor operations. This includes the use of advanced software for data analysis and predictive maintenance, ensuring that the system operates at peak efficiency. Cameras are deployed along the entire length of the conveyor system to provide continuous monitoring and enhance security.

Belt conveyors are indispensable in the mining industry, but they face a number of challenges that can hinder operational efficiency. Common issues such as misalignment, belt wear and tear, material spillage, and roller failures can lead to significant downtime and costly repairs. However, mining operations can dramatically reduce these challenges by implementing predictive maintenance strategies, leveraging advanced materials and technologies, and integrating automated monitoring solutions like Smart-Idler® systems.

The success of the Duna Express project serves as an inspiring example of how innovations can be effectively integrated into large-scale mining operations and set new standards for operational efficiency and reliability in material handling. Understanding and implementing advanced conveyor technologies and maintenance strategies is crucial for mining operations looking to enhance productivity and reduce operational costs.