Rollers reduce quarry noise for nearby residents

German gravel works reduces noise for nearby residential neighbours by replacing its bearings to Trellex plastic bearing rollers from Metso Minerals.

From the start of excavations in 2001 at the Hüdderath quarry, Boll Kiesbaggerei GmbH in Weeze, near the Dutch border, recognised the need to cultivate good relationships with its neighbours. The gravel-dredging operators always checked if the excavation work caused any noise problems. After 2 – 3 years of operation, the company identified a possible source of ongoing disturbance to neighbours when they found that the conveyor rollers were producing increasing noise.

It didn’t take long to locate the cause with the increasing wear and tear on the steel conveyor-belt plant being primarily responsible for the noise. Immediately, the steel bearing rollers were removed and replaced by plastic bearing rollers from Metso Minerals. Even in preliminary tests, the plastic bearing rollers proved to be the best low-noise solution.

The Weeze operation took the opportunity to look for a universal alternative to wear-and-tear intensive steel bearing rollers, as well as putting the background noise solution to the test. Boll Kiesbaggerei manager Ronny Janssen said, “We found a solution that, along with noise reduction, promised greater durability”.

They didn’t have to wait long for the results. By the end of 2005, the company had installed approximately 4,000 new plastic bearing rollers over an area of 1,200 m. The results of the test could be literally seen but not heard. The new belts glide softly along the long section containing the new rollers, without the interruption of unexpected knocks or a noticeable staccato occurring, particularly the section where floating belt transfers to the land belt.

In the turn station area steel bearing rollers with buffer rings are attached beneath the funnel, followed closely by the new plastic bearing rollers from Metso Minerals.

Although Ronny Janssen cannot comment on the durability of the new plastic rollers, he is already very happy with the staying power of the bearings.

“So far, I can’t see any minuses,” he said, adding,” With the steel bearing rollers, we would have had blockages a long time ago – especially in the digger area, where spills are a daily occurrence."

With steel bearing rollers it only needs a small piece of gravel caught between the bracket and the roller floor to block the bearing. Whilst conventional rollers can produce only small bearing diameters, the bearings of the plastic bearing rollers have a much larger diameter, which does not impair the turning of the outer coating and therefore its functionality, even when small pieces of gravel are laid down.

Furthermore, the bearings have threefold protection. Protective rings prevent the entry of water and dust and a special drainage groove ensures that the inside of the bearing roller stays dry even in the most unfavourable operating and weather conditions.

Ronny Janssen is already eager to see the outstanding durability of the new rollers put to the test. In any case, worn steel rollers are no longer successively replaced by new ones, but are recycled if necessary. Some wear-and-tear benefits do not have to be proved in advance. The roller casing, made from HDPE plastic (high density polyethylene), protects the conveyor belt, is shock-proof, acid-resistant, anti-alkaline and even rust-resistant.

As suppliers of the new Trellex plastic bearing rollers, Metso Minerals wants to offer its customer a concept for returning worn components.

”We are also planning something similar in the medium to long term for our PU screen coatings," says Thomas Peters, salesperson for wear protection and materials handling technology.

For further information please contact:

For further information, please visit:

https://edir.bulk-online.com/profile...o-minerals.htm

Photo 1:

Comparison of plastic bearing rollers and steel bearing rollers (Photo 2) at the turning station area

Attachments

trellex_1 (JPG)

■