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By Edmond O’Donovan

Selection of conveyor drives is an area of great confusion that frequently leads to poor system performance or overcapitalization. Many papers have dealt with the performance characteristics of different drive types, but users have often found that this only leads to further confusion. This paper presents the drive requirements from the "conveyor's" point of view. The drive requirements of different classes of conveyors are examined to illustrate why some drive types work well in certain situations but poorly in others. The appropriateness and shortcomings of different drives are examined in this context, along with the recurrent issue of load sharing.

Jan 1, 2000

By J. Stachulak, M. Scobie

"This paper addresses the occurrence and indicated causes of conveyor fires in North American and European underground mines. Some significant convey or fires which have been experienced in recent years in Canadian hardrock mines are then reviewed. The nature of existing conveyor monitoring technology is considered in the context of such fire hazards. Experiences with new monitoring technology recently installed at several conveyor sites at Inca Ltd. mines are then reviewed.IntroductionFires associated with conveyors have long been recognized as a serious hazard in underground coal mines. Recently, however, there have been some significant conveyor fires in Canadian underground hardrock mines. These offer important evidence as to the nature and causes of potential hardrock mine fifes. They also warrant attention with a view to improving over-all mine design, ventilation and emergency preparedness.In addition, a new era in mine communications and monitoring technology has been entered which should offer improved capability to protect against such fires. This paper was motivated by the need to understand the causes and mechanisms of conveyor fires in order to improve their safety. This should be possible through implementing more effective monitoring systems, as well as improving conveyor design. Underground mines are becoming more intensively mechanized, with less human surveillance of equipment and a greater dependency on remote monitoring systems."

Jan 1, 1992

By E. H. Mulligan

THE ERRINGTON B-I mine is located on the Errington orebody of Steep Rock Iron Mines, Limited, at Steep Rock Lake, Ontario. In 1946, this orebody entered the shipping lists of the Lake Superior iron ranges as an open-pit operation. During the period 1946 through 1953, the mine produced a total of 9,000,000 tons of iron ?ore. In 1950, as the mine approached the economic limits for open-pit operations, ground was broken for an underground development to exploit the deposit at depth. The mine is designed for an ultimate production of 1,500,000 tons per year by the block-caving system of mining. The initial shaft is 1,200 feet deep and will produce or-e from the 700 and the 900 levels. The 1,100 level will be used as a drainage level and as a haulageway for waste rock, which is hoisted to surface by skip. Ore from the two production levels moves by a system of ?ore passes to a crushing plant located below the 900 horizon and is hoisted from this point to surface by conveyor belt. At the present time, all material handling on the levels is by tramming, but as tram distances increase conveyor haulage will probably be installed. The initial stage of the Errington B-1 development is expected to produce 6,000,000 tons of ore over a period of four years. The second stage will require deepening of the shaft and development of lowe1? production levels. The conveyor hoisting plant will be extended to serve these new levels. We visualize the mining of this orebcdy down to 2,500 feet by these methods.

Jan 1, 1956

This paper discusses the use of tapered roller bearings in conveyor idlers. It shows that in medium and high capacity systems, tapered roller bearings can offer significant cost and performance advantages. In the next ten years, conventional conveyors will face increased competition from unconventional belt conveyors, pneumatic systems, pipeline "slurry" systems, unit trains and so on. The conveyor industry must meet these challenges by innova- tive use of technology. Conventional belt conveyors must continue to show the lowest cost per tonne-km or lose their position in the market. Tapered roller bearings can contribute to the achievement of this goal. The concurrent resources boom and liquid fuel crises may well see a decline in the use of heavy trucks for bulk material handling over moderate distances 10 to 50 km. There appears to be a trend in the conveyor industry to go to higher speeds with improved belting in conven- tional widths. The transmission of more material over a given period of time will place more demands on conveyor idler bearings. Australia has in general followed the European practice of using deep groove ball bearings in conveyor idlers.

Jan 1, 1978

By F. B. Olender

Idler engineering, operation, and maintenance cannot be covered in depth in a short paper. Therefore, this will be a general look into the subject matter in light or the present-day technology. Depending on the source or reference used, belts for handling bulk material underground came into being between 1900 and 1920, while strip mining appeared in the thirties. The conveyor belt speeds in that era were in the 300 rpm to 500 rpm range. Belt speeds or 600-700 rpm were in vogue in the thirties, and the early sixties saw speeds or 800-900 rpm. Today, speeds or 1000 rpm are not looked at with dismay; in fact, speeds or 2000 rpm are being discussed. Among the driving forces moving the bulk materials handling industry to these greater heights have been the mining operators and engineers. Their appetite to increase output, yield, and reduced per-ton costs has constantly challenged the bulk material handling industry to develop products capable or handling these increased capacities. One or the products affected by this movement is the idler. Apart from the conveyor belt itself, it is one or the most significant parts or a conveyor system because or the sheer numbers needed in an installation.

Jan 1, 1971

By Edmond J. O’Donovan

South Bulga is a new longwall operation located in the Hunter Valley coal-mining region in Southeastern Australia. The mine’s objective is to achieve productivity levels significantly higher than the current industry average. From the day longwall production began, South Bulga’s output was below both budget and industry expectations, primarily because of the poor performance of the conveyor system. In the past, conveyor systems have been seen as an adjunct to the mine plan, not as an integral part. At past production levels, this approach may have been acceptable. In today’s mining operations, the conveyor system must be treated as integral and vital to the mining operation. The conveyor system is analogous to the vascular or circulatory system of the human body. Of itself, the system does not do anything, but if it is not functioning satisfactorily, the mine cannot operate.

Jan 1, 1996

To reduce accidents associated with transporting, installing or maintaining mine conveyor belts by providing easy-to-use tools for use in specific tasks. Approach The Bureau of Mines, through a re-search contract, developed three devices for use on conveyor belt systems 1) for use in moving and positioning conveyor components. 2) to reduce spillage and clean-up around conveyors, and 3) to lessen the maintenance of the belt system. The Saucer Skid Moving conveyor components using runner nose 1-beam skids is a simple task when the direction of travel parallels the beams. However, when the unit is moved sideways or around corners for final positioning, the web of the beam scrapes the floor with a bulldozing effect. Many strain and sprain injuries hap-pen when mine workers drag the skids into position at this paint. To minimize such injuries, the Bureau of Mines developed a saucer skid five feet in diameter with rounded sides and a flat bottom. Its design incorporates eight reinforced ribs with holes so the component may be secured to the skid, and eight exterior eyelets to which towing chains may be attached. The skid can be easily moved in any direction because its rounded sides slide over the mine floor rather than drag across it.

Jan 1, 1984

By John K. Kellis, Fazley Azhar

Advancements in AC drive technology offer conveyor designers a viable drive alternative for conveyor systems which require accurate load sharing as well as multiple drive systems. Recently developed AC drives have the ability to accurately control the output torque of AC motor. These AC drives, compared to current DC drives, offer superior performance characteristics while enjoying the benefits of an AC motor. Conveyor applications and case studies incorporating this AC drive technology are presented for review.

Jan 1, 1998

The basic methods to remove material from underground mines are to: convey continuously, batch in trucks, or batch in a shaft hoisting system. A critical aspect in shaft hoisting is accurately batch loading the conveyance or skip. During the 20th century, the almost universally accepted method of loading was via a measuring flask. A measured quantity of material was filled into the flask as the conveyance traveled through the shaft and then, when the conveyance arrived at the loading position, it was ædumpedÆ into the skip for hoisting. Two skip loading conveyor systems have been developed in Australia: BHP BillitonÆs Cannington Hoisting System, installed in 1996, is believed to be the first conveyor loading system designed for two skips. Two parallel conveyors were installed with a two-way gate controlling feed onto each belt. Cannington was ideally suited to conveyor loading as the very high ore density and relatively low production rate required a relatively small volumetric storage capacity on the weighed belt. Newcrest MiningÆs Telfer Hoisting System, which is to be commissioned in 2005, consists of a single slewing conveyor loading each skip with 32 tonnes of ore. The development of this system eliminates the two-way transfer, improves the accessibility and minimises the excavation required. While every hoisting system must be considered on its merits, conveyor loading offers significant advantages to the Mining Industry in the 21st century.

Jan 1, 2005

By Mathew Cook

Technological developments in Distributed Fiber Optic Sensing and improvements in both hardware and software have allowed fiber optic sensing systems to be deployed in a variety of applications such as pipeline leak detection, perimeter security monitoring, and power cable real time thermal rating. Recently, there has been a larger adoption of monitoring of conveyor belts in so called Conveyor Health Monitiring Systems (CHMS) within the mining and bulk material handling industries to identify idler conditions on an ongoing basis. Several attempts have been made to institute sensing capabilities into conveyors with mixed success. However, recent breakthroughs in modeling, installation methodology, and technology, as well as increased understanding of application and industry requirements, have allowed the technology to be deployed at both experimental and commercial scales. This paper summarizes the application conditions and requirements, design considerations, methodologies used, the outcomes achieved, the logistical and field considerations, and the future possibilities of the use of this technology in CHMS using Distributed Fiber Optic Sensing.

Feb 22, 2026

By F. B. Speaker

MUCH of White Pine's success is due to the mechanization of mining operations and the development of an efficient beneficiation process to extract usable copper from the low-grade ore (averaging slightly more than 1 pct copper content). When the mine was first opened, all ore was trucked to a conveyor system installed in the slope leading out of the mine. But as new mining areas have been opened up at increasing distances from the slope, conveyors have replaced the trucks for much of the haulage. This conveyor program is expected to continue as mining progresses. Here is how the present underground system functions: Run-of-mine ore is dumped into two truck hoppers and withdrawn from the bottom of each hopper by a 60-in. apron feeder 22 ft long (see diagram). Collecting conveyors 54 in. wide and 44 ft long receive the material from the apron feeders and discharge to two main-line 54-in. conveyors, one 2000 ft and the other 2600 ft long. Operating at 312 fpm and handling 1200 tph, the main-line conveyors converge near the bottom of the tunnel leading out of the mine and discharge into two 72x168-in. Vibrex screens. Ore under 8 in. goes directly to the bin beneath. The oversize is fed to two 32x40-in. jaw crushers and after crushing joins the 8-in. material in the bin.

Jan 12, 1957

By David D. Gallagher, Edmond J. O’Donovan

It has been well accepted for many decades that hard starting of conveyors has associated problems. It is particularity damaging to the belt and splices. Recent measurements of hard starts on a long conveyor with a low modulus belt showed very unusual responses. These included violent accelerations and repeated "whip cracking" of the belt. Laboratory investigations of the very high strain rates experienced by the belt during the whip cracking, show mechanisms for belt damage that are not associated with normal usage. This paper outlines the measurement to show that for long, low modulus conveyors, constant torque controls are inappropriate and time ramp controls are really essential.

Jan 1, 1998

By D. Keech

The Conveyor Equipment Manufacturers Association (CEMA) specification B105.1 “Welded Steel Conveyor Pulleys” adequately defines standard pulleys for most aggregate material handling applications. However, many aggregate applications demand pulleys of higher capacity and reliability than that offered by CEMA pulleys. This paper examines the CEMA Pulley Standard and pulley specifications for aggregate applications requiring greater capacity and reliability than the CEMA Pulley Standard. Higher reliability increases the uptime and has a lower total cost of ownership.

Jan 1, 2003

By Rick Sarkisian, Greg Girardey, David Keech

The Conveyor Equipment Manufacturers Association (CEMA) specification B105.1 "Welded Steel Conveyor Pulleys" adequately defines pulley assembly standards for light material handling applications. However, most mining applications demand pulleys of higher reliability and load capacity than that offered by CEMA standard pulleys. Various sources have published specifications for "Engineered" conveyor pulleys. Typically, these specifications require T-section type pulleys applicable to operating belt tensions exceeding 439 N/mm (2,500 lb./in.). This paper examines the application of CEMA standard pulleys, T-section pulleys and also a mining duty pulley design. The mining duty pulley fills the void between CEMA standard pulleys and T-section pulleys and can eliminate the high cost and long lead times associated with T-section type pulleys.

Jan 1, 1998

By A. J. Surtees, M. P. Evans

This paper discusses the development and application of sophisticated monitoring equipment used to measure the operating parameters of conveyor systems. With the radical reduction in price of computer hard- ware and software during the last decade and an associated increase in memory capacity, the concept of continuous conveyor monitor is now a reality. With this tool, the various problems normally encountered in large conveyor installations can now be avoided at an early stage. • The four main areas of application are: • Design verification • Hand-over certification • Preventative maintenance and increase of system availability Failure analysis The paper introduces the techniques used and gives examples where the service has been used.

Jan 1, 1996

By Thomas J. Martin, James W. Martin, Paul F. Martin

The conveyor belt is the basic building block of a broad range of material handling applications in modern mining systems. The mining plans and site conditions dictate basic system requirements but this is only a part of total design evaluation. The total system in the typical mining situation can encompass all the activities from the excavators at the mining face to the processing plant, site loadout facilities and/or a power plant. The number of alternative configurations which must be evaluated including subsystems and components is limited only by analytical time and creativity. The constraints and issues which must be addressed continue to expand, driven by reliability, environmental impact and cost competitiveness. All of the system requirements must be translated into specifications for costing, final design and construction.

Jan 1, 1993

By M. Scobie, T. Atkinson

"This paper reviews the development of new designs in extensible and high angle conveyor systems. These aim to overcome the limitations of prior alternative concepts in design. The application of such systems in strip, terrace, open pit and mountain mining is reviewed. IntroductionTruck haulage costs have tended to escalate in recent years. This has been primarily due to operations generally moving to greater depths with associated increases in haul distances . Periods of high inflation rates have also been experienced for diesel fuel oil, tires and other petroleum based products. Recent international political events have tended to regenerate concerns over future oil supply and price stability. For such reasons, conveyor based transport is becoming increasingly attractive. Truck haulage maintains an inherent flexibility and improvements continue to be made in performance and capacity. Doubts must exist, however, over the extent to which further economies of scale may be made. Conversely, belt conveyor systems do not suffer this constraint and have the following advantages:• Electrical power is used and the specific energy consumption is at least half that required for truck haulage.• Operating costs and skilled labour requirements are lower.• Equipment has superior longevity and is ""inflation proof"" .• Access roads can be steeper and narrower in most mine environments, reducing construction and maintenance costs.• They are less prone to breakdown and bad weather delays .• In long haul, high capacity operations conveyors can save substantially on capital cost.• Environmental impact is improved with reduced noise level, dust and atmospheric pollution. Although conveyor systems are less flexible in operation than truck haulage and although a breakdown in any part of the system can immobilize the total system, mechanical availabilities of + 80% are constantly reported by large operators. There would appear in the past to have been some prejudice against conveyor systems in hard rock mines due to lack of experience. Apparent reservations would apply equally 10 underground coal mines, yet practically all of these mines (and some underground hard rock mines) find conveyor systems more economical than other transport systems."

Jan 1, 1991

By R. U. Jackson

FACED with rising costs, the mining industry is looking to new methods and equipment to supply the relief necessary for profitable operation. Conveyor transportation is rapidly taking a superior position to motor tramming in underground mines because of lower installation, maintenance, and operating costs. Haulage is always a critical problem in underground mining. The ease of operation and flexibility of a haulage system can have an important effect on ultimate mining cost. With the average tenor of ores on the downgrade, larger tonnages are required for the same metal recovery. This selection of a tramming system can be the key to a successful, paying plant. Because this shift is being made at an ever advancing rate, it may become necessary to tailor mining operations to the transportation system, rather than to select a haulage system fitting set mining methods. In choosing a haulage system, the relative costs of the various methods are of the greatest importance. Adapting the mine to one or the other type of tramming is not considered in the cost analysis, and very likely would make little difference, outside of location of drifts and raises. In the cost sheet, the problem presents recommendations for a conveyor installation and a comparison of equipment, installation, operation, maintenance, and power costs are made. Under the track haulage estimate, no allowance was made for dumping equipment at the shaft pocket or bin. If this equipment was added to the balance sheet, the additional

Jan 1, 1952

By J. D. Mooney

(San Francisco sleeting, September, 1915) THE accompanying chart has been drawn for the convenience of engineers as a means of quickly determining the correct number of plies of conveyor belts operating under specific conditions. The calculations are based on the average safe strength (factor of safety, 15) of the various standard rubber conveyor belts. The, calculations assume maximum loading conditions; that is, the belt is considered as carrying the greatest load that it will handle without spillage at ordinary belt speeds. This not only produces the most economical operating conditions, but also the maximum tension in the belt. The chart is a graphical representation of the formula: p = kgW (L + 1OH) Where, p = the correct number of plies k = a constant, depending on the type of drive g = the weight in pounds per cubic foot of material handled W = the width of the belt in inches L = the length of the belt in feet (approximately twice the center distance). H = the difference in elevation between the head and tail pulleys, in feet. For a simple drive, with a bare pulley, k = 1/250,000 For a simple drive, with a rubber-lagged pulley, k = 1/300,000 For a tandem dive, with bare pulleys, k= 1/375,000 For a tandem drive, with rubber-lagged pulleys, k = 1/455,000 The chart is drawn for a simple drive, with a bare pulley (k =1/250,000;

Jan 9, 1915

By M. C. Dow

INTRODUCTION BELT conveyors generally are conceded to be the most economical method yet devised for the transportation of large quantities of bulk materials within plants. Belts are coming into greater use for transportation over long distances and are replacing other forms of long-haul conveyance. It is not the intent of the writer to comment on the design of belt conveyors, but to offer some suggestions for improvement in the operation of conveying belts, based on many years experience with belts in several stonecrushing plants. It is the contention of this writer that opportunities for improvement not fully realized by most operators exist in many plants and that a study of the individual conveyors can result in lower unit belt costs. GENERAL RELIABILITY It is the fool-proof nature and general reliability of the belt conveyor that is responsible for its neglect. Even when abused, a belt will carry large tonnages and last a long time, often outlasting the personnel responsible for its care. Some operators look upon the purchase of a new belt as an expensive outlay every so many years, rather than a constant and steady cost amounting in belt wear alone to several dollars every operating day. This belt wear for all conveyors in one stone-crushing plant known by the writer costs 1 1/2 cents per ton or $12 to $15 per hour, based on the present cost of belt replacements. The fact that these replacement costs are double those of prewar quality emphasizes the necessity of improving the conditions that make belts wear out. Some of those conditions are the responsibility of the conveyor designer, and if a serious original error has been made, this handicap cannot be overcome by the operator. If the belt is too narrow, too steep, or too fast for good loading, the operator finds that he has an inherently expensive belt. The other factors that decrease the life of a belt are more or less under his control. The two factors of most importance are the loading conditions and the alignment. Most of the cover wear and carcass cutting occurs at the loading point and if the alignment is not good under all conditions, edge wear or damage may result, Fig I. LOADING THE BELT It is difficult to load a belt in an ideal manner; that is, to flow the material on the moving belt at a steady rate, without impact, without turbulence, and with a velocity equal to and in the same direction as the belt. An inclined belt is especially difficult to load and particularly when its speed is over 300 or 350 fpm. Inclined conveyors require longer skirt plates to prevent spillage until the load settles. It does not seem reasonable to expect an inclined conveyor to carry the same load as a horizontal belt of the same width and speed, because of the difficulty in loading

Jan 1, 1947