Tag Archives: bulk handling

BEUMER Group’s conveyor and ship loading solutions to be highlighted at MINExpo

BEUMER Group is planning to highlight just how conveying and loading systems enable safe, efficient and environmentally friendly handling of bulk materials at the upcoming MINExpo 2021 event in Las Vegas, USA.

The company’s overland conveyors and pipe conveyors enable mine operators to create individual routes for the transport of raw material with steep angles of inclination and narrow curve radii that are adapted to the respective task and topography, BEUMER says. When planning these systems, the system provider also relies on camera-equipped drones for planning, implementation and documentation. Using special software solutions, the engineers evaluate the aerial photographs photogrammetrically to generate digital terrain models.

The product range includes stackers and bridge reclaimers for storage yards, with or without blending bed systems. These reclaimers stack bulk material and guarantee a maximum blending effect, according to the company. Users can also efficiently homogenise large quantities of different bulk materials and bulk material qualities and, thus, ensure the uniformity of the raw materials used. For efficient loading, BEUMER Group also offers ship loaders with fixed booms and extendable telescopic belt conveyors. To supplement these, users can also procure bulk loading heads to use when loading bulk materials into silo vehicles quickly and without dust.

The company will present efficient system solutions with overland conveyors, pipe conveyors and ship loaders from September 13-15 at MINExpo.

Conveyor Components tackles belt alignment with latest control solution

Conveyor Components Company has added a Tilt Action (TA) belt alignment control solution to its offering for use on most belt conveying systems and wastewater filter presses.

The model TA is available in weatherproof or explosion-proof enclosures, with 120 VAC or 240 VAC input power rated microswitches, the company said.

This belt alignment control has dry, unpowered 20 amp SP/DT microswitches, or 15 amp DP/DT microswitches, to allow control of four separate output functions. The unit is bi-directional, able to operate in either direction and the red-coloured roller is highly visible from a distance.

The trip points are field-settable with a simple set screw adjustment on the cam, while the housing is cast aluminum, with optional epoxy coating available for corrosive environments.

PROK takes conveyor roller durability to a new level with HDPE solution

PROK has just released a new high-density polyethylene (HDPE) roller which, the company says, is lighter, more durable and avoids secondary conveyor damage in the event of a failure, reducing the unscheduled downtime that costs mining companies millions of dollars in lost productivity annually.

PROK Global Product and Engineering Manager, Ray Anderson, said the new roller was specifically designed for high speed and large tonnage applications where reliability was crucial.

“Conveyor rollers are a big cost and can cause huge risk to an operations output,” he said. “A mine or port facility with a large conveyor system will often need to replace several rollers in a day, and that requires a lot of maintenance manpower.

“If a traditional steel roller breaks it can damage the conveyor belt and the whole conveyor system can go offline, so the mining industry has been steadily moving towards lighter, more durable rollers made of advanced composite materials.

“Reliable rollers are crucial to maintaining production levels. If a conveyor stops due to roller failure, you start losing money.”

The global conveyor component manufacturer says it pioneered the use of lightweight HDPE material in conveyor rollers over 10 years ago searching for a solution that would not damage the conveyor belt in the event of failure, while reducing the risk of manual handling injuries when rollers were being installed or changed out.

Built on more than 18 months of research and development, its latest solution is state-of-the-art, taking low maintenance rollers to a whole new level, PROK said. Using a specially formulated reinforced polymer matrix, the lightweight, belt-friendly, wear-resistant roller has been created for heavy-duty applications.

Incorporating features to lower maintenance costs and a high-performance bearing housing to ensure there is no risk of end-cap walk over time, PROK HDPE delivers the reliability that can help mining companies increase production and improve safety, according to the company.

The HDPE rollers are made from a specifically engineered high-density polyethylene, which means they are suitable for corrosive environments. They also have a premium seal arrangement (with low friction properties to ensure low break away mass and run resistance during operation) and come in a range of sizes to suit a variety of mining operations and applications.

In what PROK claims to be a world first, the new HDPE roller also includes visual wear indicator technology to assist mining companies in improving their maintenance planning.

The original PROK yellow tube combines with a green inner layer to act as a visual wear indicator for maintenance teams so they can better plan their roller changeouts. This innovative feature will help customers to simplify idler maintenance and reduce costs, according to the company.

Metso Outotec to deliver overland conveyor system to South America mine

Metso Outotec has received an order for a heavy-duty overland mine conveyor system in South America set to run at speeds of up to 6 m/s and a delivery capacity of over 9,000 t/h, the mining OEM says.

The delivery consists of high reliability overland conveyors, including a 2 km single flight conveyor, it said.

The order value is around €10 million ($11.9 million) and it has been booked in the company’s Minerals division March quarter orders received.

Alexandre Martins, Business Manager, Crushing and Conveying Systems business line at Metso Outotec, said: “Metso Outotec’s full range of overland conveyor solutions provides economic and reliable material transportation for both open-pit and underground operations at the lowest total cost of ownership. Metso Outotec’s patented Energy Saving Idlers bring important power savings to long-distance conveyors, reduced belt tension, and extended rollers life, enabling a reduced maintenance cost over the equipment life and a more sustainable operation.”

The Metso Outotec conveyor offering covers complete end-to-end conveyor solutions, it says, including concept studies and definitions for all types of terrains and route types with horizontal and vertical curves.

In addition, the offering also includes post-installation services and maintenance, including a full range of accessories, belts and components for different types of applications.

Martin Engineering goes autonomous with N2 Twist Tensioner for conveyor belts

Martin Engineering has introduced an autonomous tensioning system that, it says, continuously monitors and delivers proper cleaner tension on conveyor belts.

By using Martin Engineering’s new smart technology platform to maintain proper blade-to-belt pressure, the N2® Twist™ Tensioner provides the best possible cleaning performance throughout the life of the blade, according to the company. The system also alerts operators on the Martin Smart Device Manager App when the blade needs changing or if there is an abnormal condition.

“The result is efficient cleaning, increased safety, reduced labour and a lower cost of operation,” the company said.

Andrew Timmerman, Product Development Engineer at Martin Engineering, said the company designed the unit for heavy-duty applications and tested it outdoors in punishing environments and applications.

“The N2 Twist Tensioner has proven itself to be a rugged and highly effective way to maximise both cleaning efficiency and blade life,” he added.

Located on the head pulley, primary belt cleaners commonly have a twist, ratchet or spring tensioner to ensure the cleaner blade stays in consistent contact with the conveyor belt for proper cleaning and material discharge, Martin Engineering says. Prior to the new design, belt tensioners had to be monitored and adjusted manually, in some applications on a daily basis, so they would maintain optimum pressure and carryback removal. Estimating when blades needed changing was often a guessing game that, if left too long, could lead to belt damage, according to the company.

The company continued: “Inadequate tensioning causes carryback to cling to the belt and spill along its path, piling up under the conveyor and emitting excessive dust. This requires extra labour for clean-up and can affect air quality. Over-tensioning leads to friction damage to the carrying side of the belt, premature blade wear and potential splice damage. Both scenarios create unsafe work conditions and raise the cost of operation significantly.”

The N2 Twist Tensioner automatically maintains precise cleaning pressure throughout the entire life of the blade, without maintenance, Martin Engineering says. The tensioner applies the proper amount of torque to deliver optimum cleaning pressure at the blade tip, supporting the Constant Angle Radial Pressure cleaner design that, it says, withstands the force of heavy bulk cargo but retains a consistently tight seal across the belt profile.

Martin Engineering’s smart technology platform monitors blade wear and informs operators when the blade needs changing from control systems that are housed in a durable weather-resistant NEMA 4 control box. Experts recommend changing blades before there is a chance of detachment or a “pull through” (inversion under the head pulley). In the event of a premature pull through, operators are alerted, and the tensioner’s internal self-relieving coupling rolls over. A blade detachment also triggers an alert allowing operators to quickly shut down the system and avoid expensive belt damage.

The electrical system runs both the tensioning system and the sensors, with the unit powered by a rechargeable 12 v battery life. It can also be specified to run on 110-220 VAC.

Martin Engineering concluded: “The N2 Twist Tensioner and Smart Device Manager App ease the burden on managers and workers so they can focus their attention on other critical details of the operation. Precise tensioning and improved belt cleaning reduce the volume of dust and spillage from carryback, improving workplace safety and decreasing the labour needed to maintain and clean around the discharge zone.”

MLT’s North America conveyor solutions business to be integrated into Flexco

Flexco and MLT Minet Lacing Technology have signed an agreement in which Flexco will be the exclusive source for MLT products in the US, Canada and Mexico.

As part of the agreement, MLT will continue to manufacture the products for North America as Flexco integrates MLT’s North America business into its organisation. MLT will continue to manufacture and distribute its products through its six subsidiaries and its distribution partners throughout the rest of the world.

Flexco is headquartered in Illinois US, and operates subsidiary locations in nine other countries, partnering with its distributor network to provide superior knowledge and products that make belt conveyor operations as productive as possible for its global customers.

MLT is headquartered in Saint-Chamond, France. With three factories located in France, six subsidiaries, and two R&D centres, MLT is distributed in more than 120 countries around the world. The company produces high-quality solutions that are quick and easy to install and reduce the downtime of conveyor belts with definitive splice and repair solutions, Flexco says.

Flexco President and Chief Operating Officer, Thomas S Wujek, said: “Flexco has long respected Minet Lacing Technology’s innovative and productivity-enhancing products and we are looking forward to growing our business with our North American customers through this agreement.”

Shawn Godfrey, Director of MLT USA, said: “We pride ourselves on providing our North American customers with the peace of mind of knowing that we are available to help them choose the right solution for their application, and that service and support will continue to grow with Flexco.”

MLT CEO Group – Operations and Innovations, Frédéric Guillemet, and MLT CEO Group – Business and Development, Patrick Vericel, said they were very happy with the strategic partnership with Flexco in North America.

“Our company is widely known for our innovation and technical developments, and we look forward to working with Flexco to increase the productivity and efficiency of the conveyor belts of customers in North America now and into the future,” they said in a joint statement.

Superior targets longer and wider material handling applications with new overland conveyors

Superior Industries is launching a new model of its Zipline® Overland Conveyors, expanding its range of modular products for longer and wider material handling applications.

Zipline conveyors target bulk producers looking for overland conveyors that require little or no pre-engineering for express deliveries and are designed for quick assembly in the field. With the addition of the new EXT Series, Zipline Conveyors are available in lengths up to 762 m and belt widths up to 1,220 mm.

Between the head and tail are a series of 12.2 m intermediate sections designed with 200 mm channel and 610 mm tall support stands. Standard Zipline Conveyor models are equipped with mechanical take-ups for shorter distances, but the new EXT Series includes a gravity take-up tower to accommodate longer-distance overland conveying, the company said.

All of the conveyor components – like the pulleys, idlers and scrapers – are also manufactured in-house.

“This unique advantage means higher quality, faster deliveries and all-inclusive support from Superior Industries,” the company said.

Martin Engineering goes virtual with conveyor training

With in-person training curtailed for the foreseeable future due to COVID-19 restrictions, Martin Engineering says it has developed an extensive array of tools to continue its tradition of educating those who maintain, manage and design conveyors for industrial operations.

The result is a wide range of globally-available options to help improve safety and efficiency, reduce maintenance expenditures and extend equipment life, ultimately contributing to greater profitability, it says.

“The pandemic has impacted our ability to teach traditional classes at customer sites,” PE Todd Swinderman, CEO Emeritus of Martin Engineering and an industry veteran with more than 40 years of hands-on experience, said. “But it doesn’t reduce the need for conveyor operators and facility managers to obtain the benefits and continuing education credits those sessions provide.”

In response to the restrictions that the virus has placed on face-to-face learning, Martin has created a series of interactive online modules based on the same non-commercial curriculum it has produced over the years. Designed to keep attendees engaged and organised into 90-120 minute segments, the virtual classes cover topics such as best practices for safety, fugitive material control and belt tracking. Upon completion, attendees are eligible to receive either Professional Development Unit (PDU) or Continuing Education Unit (CEU) credits.

“The Foundations™ online seminars deliver non-commercial, topic-specific problem-solving information that can be put to immediate use,” Swinderman said. “There’s no sales pitch, and even the most remote locations can take advantage,” he added.

Customer Development Manager, Jerad Heitzler, an instructor of Martin’s safety workshops since 2010, said: “Conveyors are one of the best productivity-enhancing tools available, but conveyor injuries cost employers millions of dollars annually. Because of the size of their material cargoes, the speed of their operation, and the amount of energy they consume and contain, conveyors have been shown to be a leading cause of industrial accidents, including serious injuries and fatalities. But injuries are preventable with the right training, preparation and safety precautions.”

According to Heitzler, the company’s preferred platform is Zoom, but its expert trainers also have experience with Google Meet, Microsoft Teams and Webex.

“Our platform has been built to increase attendee engagement as much as possible,” Heitzler added. “Many trainers don’t use the available platform features effectively, because they were thrust into online training as a result of the pandemic. But we’ve worked hard at using engagement features to increase learner participation, with options such as a raise hand button, chat, Q and A, screen sharing, white boards, private breakout rooms and polling.”

Heitzler said the Martin team has taught around 2,000 attendees using video conferencing since the onset of the virus.

“We’ve presented these modules to learners in coal handling plants, cement manufacturing, aggregate production and pulp and paper mills,” he said. “We’ve also provided training for industry consultants, service providers and engineering firms who design conveyors and plants.”

Swinderman estimates the firm has trained more than 50,000 miners, operators, maintenance staff and management personnel around the world.

There are two standard tracks: one for maintenance and operations personnel that stresses safe work practices and solutions to common conveyor problems, and one designed for technical and management personnel that emphasises the design and operation of conveyors for safety and productivity. In addition, Martin trainers and engineers can custom design programs not only for customers using conveyors but for those needing training on the application of industrial vibration, air cannons and silo cleaning.

“Both methods of training are highly interactive, effective and non-commercial, focusing on delivering timely information that can be put to immediate use,” Swinderman concluded.

Metso Outotec goes the distance with overland conveyor range

Metso Outotec says it has introduced a full range of overland conveyors for “economic and energy-efficient bulk material transportation”.

Designed for transporting bulk material in long distance mining applications, the overland conveyor solutions can be used at both open-pit and underground operations and, according to the company, offer the lowest total cost of ownership.

Lars Duemmel, Vice President, Bulk Material Handling Systems at Metso Outotec, said: “In mining and minerals processing applications, conveying is one of the most efficient and safest ways to transport bulk material. It is often referred as the backbone of the entire process.

“The robust design of our overland conveyors allows for capacities of up to 20,000 t/h, including over 5 km on a single flight for a seamless process. What is also important is that you can achieve power savings of up to 30% with the patented Energy Saving Idlers® (ESI).”

ESI, according to Metso Outotec, significantly reduces the overall rolling resistance on conveyor belts, leading to savings in the electrical power costs to operate the conveyor.

Duemmel added: “Thanks to our extensive process engineering capability and proven installations around the world, we are able to support our customers with complete end-to-end conveyor solutions.

“This includes concept studies and definitions for all types of terrains and route types with horizontal and vertical curves. Our expertise also covers post-installation services and maintenance, including a full range of accessories, belts and components featured in the recently launched Conveyor Solutions Handbook.”

Scrapetec keeps conveyor belts on track with newest component

Scrapetec has added to its range of conveyor components with the new PrimeTracker belt tracker, which, it says, eliminates problems associated with conveyor belt systems, including misalignment, abrasion and belt damage.

Thorsten Koth, Sales and Distribution for Scrapetec, explained: “For optimum performance of a conveyor system, it is critical that the belt always runs straight on the conveyor, without sideways movement. Our new PrimeTracker belt tracker has been designed to automatically guide a conveyor belt back into the correct straight-line position, to prevent costly downtime and component replacement.”

One advantage of the Scrapetec PrimeTracker is that it is always operates in the idling position, unless there is sideways movement of the belt, Koth said. This system corrects misalignment immediately by guiding the belt back into the correct position, with no damage or abrasion to the belt or tracker, he added.

“This is unlike conventional belt trackers that slide over the belt surface causing possible abrasion and belt damage – rather than adopting free rotation,” he said. “Conventional belt trackers, with tapered edges, never idle and are always in a braking mode.

“What’s also notable, is the cylindrical shape and pivot bush that allow this belt tracker to swing and tilt during operation and to always be in full contact with the belt. Added to this, the Scrapetec PrimeTracker has the same peripheral speed over the entire surface of the belt, where traditional crowned rollers have different speeds at the centre and edges of the system.”

Other advantages include easy installation, low maintenance requirements and protection of belt edges and structure of the conveyor belt, according to Scrapetec. A strong corrugated EPDM rubber hose protects this system from dust and sand, while the rubber pivot offers soft suspension of the tracker shaft, ensuring extended service life of the system, the company added. This system can be installed in front of every return pulley, above and below the belt.