Case Study: Ore Processing Facility

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Case Study: Ore Processing Facility

Product - Poly Urethane Rollers
Location - Pilbara Western Australia
Conveyed Material - Iron ore
Belt Width - 1800 mm
Belt Speed - 3.7 metre per second
Bulk - 10 000 tonnes per hour

Previous problem:

The sheer volume of ore being transported over this belt and the natural of the material was creating extreme carry back issues. Consequently the operations where having unscheduled shuts to replace failed rollers before they damaged the conveyor belt, but at an enormous cost. A more cost effective strategy was to change all rollers in these areas every 12 weeks during the scheduled maintenance shutdowns. The 6mm Steel return rollers where lasting between 15-36 weeks depending on the location.

Particles that make up carryback typically have a higher moisture content than the overall conveyed material. As the belt rolls over the idlers the belt vibrates creating a setting action. The smallest moisture rich fines sift to the bottom of the pile, where they can create an adhesive mixture that clings to the belt beyond the discharge point of the head pulley, accounting for most of the fugitive material present in conveyor systems. Material fines become dislodged along the return run of the conveyor and build-up beneath the belt. Carryback build-up on rolling components reduces efficiency, increases maintenance costs, reduces plant safety, shortens belt life and leads to premature roller failure. 

The CPS Solution

The CPS Sales & Engineering team recommended that the first 10 return frames back from head pulley on all conveyors were changed out to PU disc rollers. The CPS PU ringed rollers resulted in achieved life of +2 years and are still running today. The initial trial/test data below as measured during shutdowns on a primary crushed ore overland belt. Wear data was collected across the face of the roller at the three ring locations over several incremental measurement dates.


Location
Date
Installed
Wear Rate
(mm/month)
Projected
C/O Date
Head Pulley Transition - Vee-Return Dec 2013 0.50 Oct 2055
Head Pulley Transition - Vee-Return Dec 2013 0.83 Jan 2039
Head Pulley Transition - Vee-Return Dec 2013 0.81 Aug 2039
Head Pulley Transition - Vee-Return Dec 2013 0.81 Aug 2039
Head Pulley Transition - Vee-Return Dec 2013 0.81 Aug 2039
Head Pulley Transition - Vee-Return Dec 2013 0.81 Aug 2039
Tail Pulley Transition - Vee-Return Mar 2014 1.30 Apr 2030
Tail Pulley Transition - Vee-Return Mar 2014 1.30 Apr 2030

 

Life Cycle Cost

Generally polyurethane ringed rollers are less expensive than rubber lagged rollers currently installed in common high wear locations, though are more expensive than the steel equivalents. Based on the above trial data and other experience the overall Life Cycle Cost is considerably dropped (approximately 30% of the LCC of steel rollers) due to the significant life increase. A variety of rings can be provided based on Client requirements and failure mode drivers.

Other Potential Benefits

  • Ringed rollers have a tendency to assist with belt cleaning due to the flex of the belt over the roller rings
  • Ringed rollers can assist in belt training as the largest areas of belt contact occur at the roller edges, guiding the belt into the centre
  • Ringed rollers assist with maintenance requirements by providing a visual wear indicator for replacement, as wear of the rings is clearly visible during inspections

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