Technibelt was commissioned to investigate high belt scraper component failure rates at a hard rock mine in NT. Major structural component failures were significant. However, unacceptably high consumable component failure rates (ranging from less than one shift to less than 4 weeks on critical conveyors) were of greatest concern. Through an extensive R&D program, Technibelt designed and implemented a series of cost-effective, innovative, engineered and tested solutions to optimise belt scraper performance. Since the upgrade, there have been no major structural component failures and consumable component life exceeds the shut interval on all conveyors.
Technibelt developed belt cleaning system performance specifications for a number of new coal handling and preparation plants in NSW and QLD. The average preset performance guaranteed carry-back level across all run-of-mine, reject and product conveyors was 10-12 kg/hr. The design and commissioning of Technibelt custom belt cleaning systems resulted in an average carry-back level of <1 kg/h with an average over the first 5 years of <5 kg/hr. Belt scraper adjustments and maintenance are based on actual performance (carry-back test data) not time in service. Belt cleaning system performance and scraper/conveyor component life continue to exceed operational, maintenance and life cycle cost expectations of our client.
Technibelt conducted benchmark performance monitoring (carry-back testing) of the existing belt scrapers at a hard rock mine in SA. After servicing by the existing belt scraper maintenance team (to ensure optimum performance), Technibelt recorded an average carry-back level of 420 kg/h across 13 conveyors (worst conveyor 875 kg/h). The benchmarking data and a review of the operational requirements of each individual conveyor was used to develop a performance specification (average preset performance guaranteed carry-back level of 11 kg/h). The design, supply, installation and commissioning of Technibelt custom belt cleaning systems resulted in an average carry-back level of <1 kg/h (worst conveyor 4 kg/h) with an average over the first year of 4 kg/hr (worst conveyor 8 kg/h). Belt scraper adjustments and maintenance were based on performance not time in service. Low carry-back levels also resulted in reduced spillage clean-up and increased roller and pulley lagging life.