Abstract: The subject of drive systems for conveyors always stimulates lively debate with various operators declaring that some type is good and other types are not. Unfortunately, different operators swear by different drive types and there are many successful drive types on the market. How can this be? The main reason for this is a poor understanding of why certain drives work in some applications and not in others. This course aims to give delegates a basic understanding of the various requirements for conveyor drives, an understanding of how different drive types work, and how these different drives can be effectively incorporated into a conveyor system.
Course Outline
1. Introduction
2. Requirements for a conveyor drive. (ie what so special about conveyors?)
Extreme operating range (no-load to fully loaded)
Time dependent response of driven machine.
Extended Starting Times
Load Sharing
Regeneration
3. Examples of the various challenges for conveyor drives.
4. Characteristics of a squirrel cage motor.
5. Basic Introduction to various drive options.
Direct On Line
Fixed/Delay Fill Fluid Couplings
Variable Fill Fluid Couplings
Hydroviscous Clutches
DC
Reduced Voltage Soft Starters
VFD
6. Working with what you have.
7. Presentations from Industry Experts
Wound Rotor
Fluid Couplings
Hydroviscous Clutches
Reduced Voltage Soft Start
VFD
8. Open Panel Discussion with Attendee Questions
Technical Sessions February 25-27, 2007
Case Studies of Large Belt Conveyance Projects (Part 1)
Monday 25 Feb 2007 2:00pm
Chairman: Mark Alspaugh, President, Overland Conveyor Co., Inc.
1. Case Study of the 11.9 mile long overland conveyor at ALCOA Rockdale
Author: Robert Corriveau, ThyssenKrupp Robins, Greenwood Village, Co USA
Abstract: This conveyor is 62,791 ft or 11.9 miles long. It has a design capacity of 1200 stph and runs at a design belt speed of 1400 fpm. It maneuvers through ten horizontal curves and utilizes three drive stations. There are five 750 HP drives installed. There is one drive installed at the tail, two at a booster drive area, and two at the head end. A long distance overland conveyor was the best choice when compared against the costs of trucking coal long distances. When designing such a long and fast conveyor that utilizes three drive stations, several challenges had to be overcome. This case study discusses those challenges.
2. Increasing Kaltim Prima Coal Overland Conveyor Speed to 8.5 mps
Author: Poltak Sinaga, PT Kaltim Prima Coal, Sengata, Kalimantan Timur, Indonesia
Abstract: PT Kaltim Prima Coal’s 13.1km overland conveyor was commissioned in 1991. It is of conventional 3 roller 350 troughed belt type. Cost and performance optimization during initial design ended up with 5.4m/s belt speed, 1000mm belt width to convey 1350tph, and 7mtpa of coal. Despite high initial figure, the belt speed was lifted to 6.5 mps in 1996 to accommodate mine throughput increase. In 2002, new low loss ST2100 1100mm wide belt replaced the old ST2250 due for change-out. An upgrade project was initiated at the end of 2003 to further increase the belt speed to 8.5 mps, hence to increase the OLC capacity to 30mtpa. Performance data, experience of site personnel, site observation and tests, benchmarking, and information from equipment manufacturers were major inputs to the design review. The project fast tracking was another challenge in addition to executing modifications on a production lifeline. The project was completed within fifteen months and the OLC was successfully commissioned at 8.5 mps belt speed in February 2005. The OLC has been to date conveying 4200tph satisfactorily.
3. Limestone Transportation by 17 Km Cross-Border Belt Conveyor for Lafarge Surma Cement Limited
Author: Pabak Mukhopadhyay- Larsen & Toubro, India,
Author: Kumar Vikram- Larsen & Toubro, India
Abstract: Abundance of low-cost fuel (Natural Gas) in Bangladesh and availability of prime quality limestone in adjoining areas of India made Lafarge envisage an integrated cement plant at a bordering district of Bangladesh. To feed the cement plant for its lime stone requirement the Long Belt Conveyor (LBC) was required. L&T created this engineering marvel on a turnkey basis with technology support of Aumund France.
4. Determinates for Feasibility Study of Materials Handling Projects
Author: Jan Salmond, Parsons Brinckerhoff, Brisbane Australia
Abstract: The optimal solution for transporting bulk solids is typically identified in a feasibility study. The drivers in a study, and what determines the outcome, vary according to the project needs, location, technology, parameters, commodity prices, community and environmental requirements. A multi-criteria analysis has proved an effective means of establishing study determinates and the use of these determinates in the decision making process. This paper reviews the drivers, and the employment of these drivers, that have determined the outcome of recent feasibility studies for materials handling projects, with a focus on projects where overland conveyor systems have proved the optimal bulk solids transport solution.
5. The Design of the 11.5 km Overland Conveyor for Isibonelo
Author: Prof.dr.ir. Gabriel Lodewijks, Delft Univeristy, Netherlands
Author: Phillip Staples, CKIT, South Africa
Abstract: This paper discusses the design of the 11.5 km overland conveyor for the Isibonelo project in the Republic of South Africa. This conveyor transports 1,600 MTPH of coal on a 1200 mm wide ST2500 belt. Special attention is given to the design choices made in general as well as the dynamics of the system and its performance in the horizontal and verical curves.
Design Considerations for Long Overland Conveyor
Tuesday 26 Feb 2007 9:00am
Chairman: Reese Kidman, Roberts & Schaefer Co
1. Evolutionary Belt Conveyor Design - Optimizing Costs
Author: Dr. Craig Wheeler, The University of Newcastle, NSW, Australia
Abstract: This paper will present findings of research that is currently being undertaken to reduce the annual equivalent cost of belt conveying systems. The work involves utilizing models to predict the motion resistance of belt conveyors that take into consideration the influence of key conveyor variables, such as idler roll diameter, spacing, etc. Given a specified conveyor configuration the capital and ongoing costs of the system can then be approximated based on the required belt, structure, drives, etc. The research provides an evolutionary computational means to analyze a large number of potential conveyor configurations and to compare each on an annual equivalent cost basis.
2. Dynamics of long belt conveyors with distributed drives
Author: Prof.dr.ir. Gabriel Lodewijks, Delft Univeristy, Netherlands
Abstract: Today most belt conveyors used for the transportation of bulk solid materials are driven in a centralized way with all drives in one location. The dynamics of these systems has been studied since the early seventies of the previous century and are well understood. Compared to the more conventional belt conveyor system with a centralized drive station positioned at the head or tail of the system, a decentralized driven layout with drive stations distributed along the whole length of the belt can offer a number of advantages. This paper discusses the dynamics of long belt conveyors with distributed drives. It highlights the importance of understanding the dynamics of belt conveyors and the tools that are used today for their design. It further discusses the fundamental differences between centralized and decentralized driven belt conveyors. It ends with a discussion of the design of decentralized driven belt conveyors with special attention to their control during starting, stopping, loading, and unloading of the belt.
3. The Merits of High Speed Conveying in Relation to Layout Capital and Operating Cost
Author: Philip Staples, Ckit Conveyor Engineers (Pty) Ltd., Johannesburg South Africa
Abstract: High speed conveying has been proposed in the materials handling industry for a number of years with the aim of reducing the “capital” cost of the installation. This paper sets out to explore the effect of high speed conveying at; the transfer point where material containment is critical, in relations to idler size and spacing, in relation to power utilization and subsequently in relation to the overall operating cost translated into a cost per ton and a cost per ton / kilometer. The writer will amongst other issues display a computer modeling tool developed specifically to demonstrate the effects of speed on capital and maintenance cost.
4. Conveyor Belt Rubber Indentation Research
Author: Thomas J Rudolphi, Ph.D., Iowa State University, Ames, IA USA
Abstract: Backing rubber characterization and prediction of indentation losses based on simple computational models can now provide good estimates of power requirements for a range of operating temperatures and belt speeds. A standardized prediction methodology using rubber test data and routine numerical software allows for prediction of indentation loss and conveyor design. Development of master curves for backing materials from test data, standardization of this process, and the usage of the material characterization in the indentation loss model is discussed. The paper discusses numerical models and the limitations and sensitivity of the methodology to the data and computational models and presents results of some typical backing materials with comparison to test and field measurements.
5. Belt Conveyor Idler Roll Behavior
Author: Allen V Reicks, Overland Conveyor Co Inc, USA
Abstract: This paper addresses the rotating performance of the individual idler roll concentrating on the bearing and seal design and performance. Rotating resistance and life issues are addressed in detail. In addition, idler rolls as a load support system and their interaction with the entire conveyor system will be discussed.
The State of the Conveyance Industry from the Perspective of Mining Executives
Tuesday 26 Feb 2007 2:00pm
Co-Chair: Mark Alspaugh and Edmond O'Donovan
Discussion Forum
Executives from major mining companies responsible for large capitol expansion projects and day to day operations express their views on the current state of the conveyance industry. What is done well and what is not. Hear how material handling problems effect an overall mining operation. What are the biggest problems facing operators. Is existing technology adaquate for todays demanding needs? What will the future require? What better way to understand where our industry needs to focus research than from the people building and running todays equipment and planning tomorrows. This open format will allow everyone the opportunity to question our distinguished panel representing a board cross section of mining.
Solving Real Problems using Numerical Analysis and Simulations
1. Simulation for Equipment Sizing - Longwall to Stockpile
Author: Edmond O’Donovan, BE, MS, PE, E. J. O’DONOVAN & Associates, Brisbane, AUSTRALIA
Abstract: When longwall equipment is being specified, a nominal capacity is generally given on which to base the design of the various face and out-bye systems and components. This capacity generally comes from a nominal annual capacity requirement based on realistic utilization rates. From illustrative examples of simple system simulation, this paper sets out to show that a single nominal capacity is not sufficient to size the different systems. The manner in which the Longwall is operated and the overall system configuration can have a significant impact on overall productivity. The importance of component availability on overall output is also addressed.
2. Simulation as a Tool to Determine Stockyard Handling Capacity
Author: Eric Monrad, Sandwell Engineering, Vancouver, BC (Agreement Returned)
Author: Dr Harry King, ,Sandwell Engineering, Vancouver, BC, Canada
Abstract: Discrete event simulation modeling provides a tool to quantify the throughput capacity of stockyards. Interactions between the main equipment types (trains, dumpers, conveyors, stackers, reclaimers, shiploaders) can be captured, including route blockages, breakdowns, and planned maintenance. This tool has been successfully used at world-class stockyard facilities to determine current capacity and to identify gains resulting from improvement projects. Recent projects have focused on iron-ore, coal, and soya facilities, but the technology is suitable to be used on any bulk material type.
3. Interfacing Belt Feeders and Hoppers to Achieve Reliable Operation
Author: John Carson , Jenike & Johanson, Inc., Tyngsboro MA USA (Agreement Returned)
Author: Francisco Cabrejos , Jenike & Johanson Chile S.A
Author: David Goodwill, Jenike & Johanson, Ltd
Abstract: Belt feeders are commonly used to meter the flow of bulk solids from bins and hoppers. If the interface between the hopper outlet and belt feeder is not designed correctly, flow from the bin may be severely compromised, resulting in problems of no-flow, segregation, flooding, etc. By knowing the flow characteristics of the bulk solid being handled and applying proven design techniques, such problems can be avoided. Relevant bulk solids flow characteristics will be identified, along with measurement techniques. Design procedures for correcting problems with existing feeders as well as proper design of new feeders will be presented, along with case histories of successful application of these procedures.
4. Predicting Material Behavior on Conveyors using DEM
Author: Dr Graham Mustoe, Colorado School of Mines, Golden, CO, USA
Author: Bin Ren, Colorado School of Mines, Golden, CO, USA
Abstract: Energy losses are important factors in a conveyor’s performance and design. A significant energy loss due to belt sag within a conveyor system occurs when shearing motion between the bulk material particles occurs as the material moves along the belt. This sag energy loss has been studied previously using analytical mechanical methods that employ several simplifying approximations such as: a) dry bulk material, b) assumed pressure distributions between the bulk material and belt, and c) inertial effects within the bulk material and belt, etc. The current work employs a discrete element modeling (DEM) approach eliminating the need for the simplifying assumptions required in previous analyses. The DEM method models: a) the bulk material as a discrete system of particles with a specified size distribution, and interaction laws for dry and wet materials, and b) the belt geometry shape with a detailed 3D CAD description. In this paper the effects of: a) idler spacing, b) belt speed, b) belt sag, and c) different bulk materials are studied.
Case Studies of Large Belt Conveyance Projects (Part 2)
Wednesday 27 Feb 2007 2:00pm
Chairman: Edwin Brady, Peabody Energy Inc
1. CADMAN Overland Conveyor
Author: W.R.(Bill) Sayer, Cadman, Inc. Redmond, WA USA (Agreement Returned)
Author: Peter Sehl, ThyssenKrupp Robins Inc. Greenwood Village, CO USA
Abstract: The new Cadman Overland Conveyor transports pit run from an upper mining area in North Bend, WA, downhill to a lower pit. The conveyor belt has a rated capacity of 1,000 stph, is 1.2 miles long and an elevation drop of 900 ft. The design includes provisions for transporting material uphill. The regenerative energy produced by the loaded conveyor is used to offset the power consumptions of the crusher and feed systems. The project team was faced with the challenge of building a conveyor that follows a complex route and maintains a “low–profile” design, which is minimally obtrusive to the environment.
2. Replacing the Long Distance Pipe Conveyor Belt at Western Arch Coal Skyline Mine
Author: Dr. Markus Keller, ContiTech Conyeyor Belt Group, Northeim, Germany
Abstract: Abstract: Located approx. 3500 m above sea level the Arch Western Coal Skyline Mine Pipe Conveyor in Utah has a centre distance of 3414 m and an elevation drop of 172 m. It transports coal at approx. 1200 tph downhill from the pit to the mine’s train loading facilities. In 2006, after 13 years of service, the replacement of the initially installed belt had become inevitable. The turnkey project to the customer covered both the design and supply of the pipe conveyor belt as well as the procedures for the actual carry-out of the belt installation and commissioning. With its 22 horizontal and 45 vertical curves the conveyor system follows the natural geographical contour in order to minimize the conveyors impact to the environment. Therefore the biggest constraints for the project were to ensure the new pipe conveyor belt being accepted by the existing structure as well as minimizing the inevitable downtime during belt installation and commissioning and therefore to avoid a potential loss of production.
3. Large-scale Stacking System at the Freeport McMoRan Safford Mine
Author: Michael O. Schmalzel, Phelps Dodge Safford, Inc., Safford, AZ, USA
Author: Andrew Osterloh, Fluor Canada Ltd., Vancouver, BC , Canada
Author: Ron Kelly, Terra Nova Technologies, Inc., Santee, CA USA
Author: Grant Graber, Terra Nova Technologies, Inc., Santee, CA USA
Abstract: Freeport-McMoRan Copper & Gold, Inc. will soon begin copper production from the Dos Pobres and San Juan deposits near Safford, Arizona. Ore reserves total 615 M tons grading 0.36% copper, predominantly as chrysocolla. Copper extraction will be by leaching with sulfuric acid. Fluor Canada provided EPCM services to design an ore handling and conventional SX/EW facility capable of producing a nominal 240 million pounds per year of cathode copper. The ore handling facility will process 114,000 tons per day of ore through three-stage, open-circuit crushing followed by agglomeration and product placement on the permanent leach pad. Stacking of ore on the leach pad will utilize Terra Nova Technologies' "Super Portable" mobile stacking system, comprising a fleet of (13) self-propelled, crawler-mounted, 72"-wide, 6,800 ton/hour mobile conveyor units, including (10) 250-ft-long portable conveyors, a 300-ft-long horizontal conveyor and a 220-ft-long radial stacker.
4. Thirty-Year Old Transfer Point Challenge
Author: Robert McEwen, Drummond Equipment Inc. Mississauga, Ontario Canada
Abstract: Conveyor equipment beyond its prime chronically suffers from lack of understanding in today’s plant environment regularly delivers more material than original designers ever expected. A case in point is a belt conveyor in a major hard rock mine/milling operation asking to bring the unit up to current standards while eliminating spillage and reducing airborne dust. The challenge was to keep the system going by revamping the system while keeping the same footprint and allowing for higher production rate. Thirty years of daily maintenance and dust collection costs have virtually disappeared by the end of this challenging upgrade.
Poster Session / Reception
Tuesday February 26, 2007 5:00pm
Display your 4 ft x 8 ft poster of an interesting new product or application case study. If you are interested in displaying a poster, contact Dick Bailey for information and cost.
Or come visit with old friends and new with good food and open bar sponsored by the poster session participants.
Registration
Registration is not open yet. Please watch this page or the http://smenet.org website for details.
Conference Executive Committee
Mark Alspaugh, Chariman, Overland Conveyor Co Inc
Michael Myers, Vice Chairman, Baldor Dodge Relaince
Conveyor Belt 7
SME Society for Mining, Metallurgy & Exploration
Bulk Material Handling by Conveyor Belt 7
...an International Symposium on Belt Conveyor Technology
2008 SME Annual Meeting & Exhibit
February 23-27, 2008
Salt Lake City, UT, USA
Schedule of Events
Pre Conference Workshop (Saturday-Sunday)
Technical Sessions
Case Studies of Large Belt Conveyance Projects (Part 1) (Monday Afternoon)
Design Considerations for Long Overland Conveyor (Tuesday Morning)
The State of the Conveyance Industry from the Perspective of Mining Executives (Tuesday Afternoon)
Solving Real Problems using Numerical Analysis and Simulations (Wednesday Morning)
Case Studies of Large Belt Conveyance Projects (Part 2) (Wednesday Afternoon)
Poster Session / Reception (Tuesday Evening)
Other Information
Registration
Conference Executive Program Committee
Pre Conference Short Course
Optimum Selection of Belt Conveyor Drives
February 23-24, 2007
Instructor: Edmond O'Donovan, E.J. O'Donovan & Assoc
Instructor: Steve Shadow, Conetic Resources Inc
Instructor: Todd Hollingsworth, Conveyor Engineering Inc
Abstract: The subject of drive systems for conveyors always stimulates lively debate with various operators declaring that some type is good and other types are not. Unfortunately, different operators swear by different drive types and there are many successful drive types on the market. How can this be? The main reason for this is a poor understanding of why certain drives work in some applications and not in others. This course aims to give delegates a basic understanding of the various requirements for conveyor drives, an understanding of how different drive types work, and how these different drives can be effectively incorporated into a conveyor system.
Course Outline
1. Introduction
2. Requirements for a conveyor drive. (ie what so special about conveyors?)
Extreme operating range (no-load to fully loaded)
Time dependent response of driven machine.
Extended Starting Times
Load Sharing
Regeneration
3. Examples of the various challenges for conveyor drives.
4. Characteristics of a squirrel cage motor.
5. Basic Introduction to various drive options.
Direct On Line
Fixed/Delay Fill Fluid Couplings
Variable Fill Fluid Couplings
Hydroviscous Clutches
DC
Reduced Voltage Soft Starters
VFD
6. Working with what you have.
7. Presentations from Industry Experts
Wound Rotor
Fluid Couplings
Hydroviscous Clutches
Reduced Voltage Soft Start
VFD
8. Open Panel Discussion with Attendee Questions
Technical Sessions February 25-27, 2007
Case Studies of Large Belt Conveyance Projects (Part 1)
Monday 25 Feb 2007 2:00pm
Chairman: Mark Alspaugh, President, Overland Conveyor Co., Inc.
1. Case Study of the 11.9 mile long overland conveyor at ALCOA Rockdale
Author: Robert Corriveau, ThyssenKrupp Robins, Greenwood Village, Co USA
Abstract: This conveyor is 62,791 ft or 11.9 miles long. It has a design capacity of 1200 stph and runs at a design belt speed of 1400 fpm. It maneuvers through ten horizontal curves and utilizes three drive stations. There are five 750 HP drives installed. There is one drive installed at the tail, two at a booster drive area, and two at the head end. A long distance overland conveyor was the best choice when compared against the costs of trucking coal long distances. When designing such a long and fast conveyor that utilizes three drive stations, several challenges had to be overcome. This case study discusses those challenges.
2. Increasing Kaltim Prima Coal Overland Conveyor Speed to 8.5 mps
Author: Poltak Sinaga, PT Kaltim Prima Coal, Sengata, Kalimantan Timur, Indonesia
Abstract: PT Kaltim Prima Coal’s 13.1km overland conveyor was commissioned in 1991. It is of conventional 3 roller 350 troughed belt type. Cost and performance optimization during initial design ended up with 5.4m/s belt speed, 1000mm belt width to convey 1350tph, and 7mtpa of coal. Despite high initial figure, the belt speed was lifted to 6.5 mps in 1996 to accommodate mine throughput increase. In 2002, new low loss ST2100 1100mm wide belt replaced the old ST2250 due for change-out. An upgrade project was initiated at the end of 2003 to further increase the belt speed to 8.5 mps, hence to increase the OLC capacity to 30mtpa. Performance data, experience of site personnel, site observation and tests, benchmarking, and information from equipment manufacturers were major inputs to the design review. The project fast tracking was another challenge in addition to executing modifications on a production lifeline. The project was completed within fifteen months and the OLC was successfully commissioned at 8.5 mps belt speed in February 2005. The OLC has been to date conveying 4200tph satisfactorily.
3. Limestone Transportation by 17 Km Cross-Border Belt Conveyor for Lafarge Surma Cement Limited
Author: Pabak Mukhopadhyay- Larsen & Toubro, India,
Author: Kumar Vikram- Larsen & Toubro, India
Abstract: Abundance of low-cost fuel (Natural Gas) in Bangladesh and availability of prime quality limestone in adjoining areas of India made Lafarge envisage an integrated cement plant at a bordering district of Bangladesh. To feed the cement plant for its lime stone requirement the Long Belt Conveyor (LBC) was required. L&T created this engineering marvel on a turnkey basis with technology support of Aumund France.
4. Determinates for Feasibility Study of Materials Handling Projects
Author: Jan Salmond, Parsons Brinckerhoff, Brisbane Australia
Abstract: The optimal solution for transporting bulk solids is typically identified in a feasibility study. The drivers in a study, and what determines the outcome, vary according to the project needs, location, technology, parameters, commodity prices, community and environmental requirements. A multi-criteria analysis has proved an effective means of establishing study determinates and the use of these determinates in the decision making process. This paper reviews the drivers, and the employment of these drivers, that have determined the outcome of recent feasibility studies for materials handling projects, with a focus on projects where overland conveyor systems have proved the optimal bulk solids transport solution.
5. The Design of the 11.5 km Overland Conveyor for Isibonelo
Author: Prof.dr.ir. Gabriel Lodewijks, Delft Univeristy, Netherlands
Author: Phillip Staples, CKIT, South Africa
Abstract: This paper discusses the design of the 11.5 km overland conveyor for the Isibonelo project in the Republic of South Africa. This conveyor transports 1,600 MTPH of coal on a 1200 mm wide ST2500 belt. Special attention is given to the design choices made in general as well as the dynamics of the system and its performance in the horizontal and verical curves.
Design Considerations for Long Overland Conveyor
Tuesday 26 Feb 2007 9:00am
Chairman: Reese Kidman, Roberts & Schaefer Co
1. Evolutionary Belt Conveyor Design - Optimizing Costs
Author: Dr. Craig Wheeler, The University of Newcastle, NSW, Australia
Abstract: This paper will present findings of research that is currently being undertaken to reduce the annual equivalent cost of belt conveying systems. The work involves utilizing models to predict the motion resistance of belt conveyors that take into consideration the influence of key conveyor variables, such as idler roll diameter, spacing, etc. Given a specified conveyor configuration the capital and ongoing costs of the system can then be approximated based on the required belt, structure, drives, etc. The research provides an evolutionary computational means to analyze a large number of potential conveyor configurations and to compare each on an annual equivalent cost basis.
2. Dynamics of long belt conveyors with distributed drives
Author: Prof.dr.ir. Gabriel Lodewijks, Delft Univeristy, Netherlands
Abstract: Today most belt conveyors used for the transportation of bulk solid materials are driven in a centralized way with all drives in one location. The dynamics of these systems has been studied since the early seventies of the previous century and are well understood. Compared to the more conventional belt conveyor system with a centralized drive station positioned at the head or tail of the system, a decentralized driven layout with drive stations distributed along the whole length of the belt can offer a number of advantages. This paper discusses the dynamics of long belt conveyors with distributed drives. It highlights the importance of understanding the dynamics of belt conveyors and the tools that are used today for their design. It further discusses the fundamental differences between centralized and decentralized driven belt conveyors. It ends with a discussion of the design of decentralized driven belt conveyors with special attention to their control during starting, stopping, loading, and unloading of the belt.
3. The Merits of High Speed Conveying in Relation to Layout Capital and Operating Cost
Author: Philip Staples, Ckit Conveyor Engineers (Pty) Ltd., Johannesburg South Africa
Abstract: High speed conveying has been proposed in the materials handling industry for a number of years with the aim of reducing the “capital” cost of the installation. This paper sets out to explore the effect of high speed conveying at; the transfer point where material containment is critical, in relations to idler size and spacing, in relation to power utilization and subsequently in relation to the overall operating cost translated into a cost per ton and a cost per ton / kilometer. The writer will amongst other issues display a computer modeling tool developed specifically to demonstrate the effects of speed on capital and maintenance cost.
4. Conveyor Belt Rubber Indentation Research
Author: Thomas J Rudolphi, Ph.D., Iowa State University, Ames, IA USA
Abstract: Backing rubber characterization and prediction of indentation losses based on simple computational models can now provide good estimates of power requirements for a range of operating temperatures and belt speeds. A standardized prediction methodology using rubber test data and routine numerical software allows for prediction of indentation loss and conveyor design. Development of master curves for backing materials from test data, standardization of this process, and the usage of the material characterization in the indentation loss model is discussed. The paper discusses numerical models and the limitations and sensitivity of the methodology to the data and computational models and presents results of some typical backing materials with comparison to test and field measurements.
5. Belt Conveyor Idler Roll Behavior
Author: Allen V Reicks, Overland Conveyor Co Inc, USA
Abstract: This paper addresses the rotating performance of the individual idler roll concentrating on the bearing and seal design and performance. Rotating resistance and life issues are addressed in detail. In addition, idler rolls as a load support system and their interaction with the entire conveyor system will be discussed.
The State of the Conveyance Industry from the Perspective of Mining Executives
Tuesday 26 Feb 2007 2:00pm
Co-Chair: Mark Alspaugh and Edmond O'Donovan
Discussion Forum
Executives from major mining companies responsible for large capitol expansion projects and day to day operations express their views on the current state of the conveyance industry. What is done well and what is not. Hear how material handling problems effect an overall mining operation. What are the biggest problems facing operators. Is existing technology adaquate for todays demanding needs? What will the future require? What better way to understand where our industry needs to focus research than from the people building and running todays equipment and planning tomorrows. This open format will allow everyone the opportunity to question our distinguished panel representing a board cross section of mining.
Solving Real Problems using Numerical Analysis and Simulations
Wednesday 27 Feb 2007 9:00am
Chairman: Todd Hollingsworth, Conveyor Engineering Inc
1. Simulation for Equipment Sizing - Longwall to Stockpile
Author: Edmond O’Donovan, BE, MS, PE, E. J. O’DONOVAN & Associates, Brisbane, AUSTRALIA
Abstract: When longwall equipment is being specified, a nominal capacity is generally given on which to base the design of the various face and out-bye systems and components. This capacity generally comes from a nominal annual capacity requirement based on realistic utilization rates. From illustrative examples of simple system simulation, this paper sets out to show that a single nominal capacity is not sufficient to size the different systems. The manner in which the Longwall is operated and the overall system configuration can have a significant impact on overall productivity. The importance of component availability on overall output is also addressed.
2. Simulation as a Tool to Determine Stockyard Handling Capacity
Author: Eric Monrad, Sandwell Engineering, Vancouver, BC (Agreement Returned)
Author: Dr Harry King, ,Sandwell Engineering, Vancouver, BC, Canada
Abstract: Discrete event simulation modeling provides a tool to quantify the throughput capacity of stockyards. Interactions between the main equipment types (trains, dumpers, conveyors, stackers, reclaimers, shiploaders) can be captured, including route blockages, breakdowns, and planned maintenance. This tool has been successfully used at world-class stockyard facilities to determine current capacity and to identify gains resulting from improvement projects. Recent projects have focused on iron-ore, coal, and soya facilities, but the technology is suitable to be used on any bulk material type.
3. Interfacing Belt Feeders and Hoppers to Achieve Reliable Operation
Author: John Carson , Jenike & Johanson, Inc., Tyngsboro MA USA (Agreement Returned)
Author: Francisco Cabrejos , Jenike & Johanson Chile S.A
Author: David Goodwill, Jenike & Johanson, Ltd
Abstract: Belt feeders are commonly used to meter the flow of bulk solids from bins and hoppers. If the interface between the hopper outlet and belt feeder is not designed correctly, flow from the bin may be severely compromised, resulting in problems of no-flow, segregation, flooding, etc. By knowing the flow characteristics of the bulk solid being handled and applying proven design techniques, such problems can be avoided. Relevant bulk solids flow characteristics will be identified, along with measurement techniques. Design procedures for correcting problems with existing feeders as well as proper design of new feeders will be presented, along with case histories of successful application of these procedures.
4. Predicting Material Behavior on Conveyors using DEM
Author: Dr Graham Mustoe, Colorado School of Mines, Golden, CO, USA
Author: Bin Ren, Colorado School of Mines, Golden, CO, USA
Abstract: Energy losses are important factors in a conveyor’s performance and design. A significant energy loss due to belt sag within a conveyor system occurs when shearing motion between the bulk material particles occurs as the material moves along the belt. This sag energy loss has been studied previously using analytical mechanical methods that employ several simplifying approximations such as: a) dry bulk material, b) assumed pressure distributions between the bulk material and belt, and c) inertial effects within the bulk material and belt, etc. The current work employs a discrete element modeling (DEM) approach eliminating the need for the simplifying assumptions required in previous analyses. The DEM method models: a) the bulk material as a discrete system of particles with a specified size distribution, and interaction laws for dry and wet materials, and b) the belt geometry shape with a detailed 3D CAD description. In this paper the effects of: a) idler spacing, b) belt speed, b) belt sag, and c) different bulk materials are studied.
Case Studies of Large Belt Conveyance Projects (Part 2)
Wednesday 27 Feb 2007 2:00pm
Chairman: Edwin Brady, Peabody Energy Inc
1. CADMAN Overland Conveyor
Author: W.R.(Bill) Sayer, Cadman, Inc. Redmond, WA USA (Agreement Returned)
Author: Peter Sehl, ThyssenKrupp Robins Inc. Greenwood Village, CO USA
Abstract: The new Cadman Overland Conveyor transports pit run from an upper mining area in North Bend, WA, downhill to a lower pit. The conveyor belt has a rated capacity of 1,000 stph, is 1.2 miles long and an elevation drop of 900 ft. The design includes provisions for transporting material uphill. The regenerative energy produced by the loaded conveyor is used to offset the power consumptions of the crusher and feed systems. The project team was faced with the challenge of building a conveyor that follows a complex route and maintains a “low–profile” design, which is minimally obtrusive to the environment.
2. Replacing the Long Distance Pipe Conveyor Belt at Western Arch Coal Skyline Mine
Author: Dr. Markus Keller, ContiTech Conyeyor Belt Group, Northeim, Germany
Abstract: Abstract: Located approx. 3500 m above sea level the Arch Western Coal Skyline Mine Pipe Conveyor in Utah has a centre distance of 3414 m and an elevation drop of 172 m. It transports coal at approx. 1200 tph downhill from the pit to the mine’s train loading facilities. In 2006, after 13 years of service, the replacement of the initially installed belt had become inevitable. The turnkey project to the customer covered both the design and supply of the pipe conveyor belt as well as the procedures for the actual carry-out of the belt installation and commissioning. With its 22 horizontal and 45 vertical curves the conveyor system follows the natural geographical contour in order to minimize the conveyors impact to the environment. Therefore the biggest constraints for the project were to ensure the new pipe conveyor belt being accepted by the existing structure as well as minimizing the inevitable downtime during belt installation and commissioning and therefore to avoid a potential loss of production.
3. Large-scale Stacking System at the Freeport McMoRan Safford Mine
Author: Michael O. Schmalzel, Phelps Dodge Safford, Inc., Safford, AZ, USA
Author: Andrew Osterloh, Fluor Canada Ltd., Vancouver, BC , Canada
Author: Ron Kelly, Terra Nova Technologies, Inc., Santee, CA USA
Author: Grant Graber, Terra Nova Technologies, Inc., Santee, CA USA
Abstract: Freeport-McMoRan Copper & Gold, Inc. will soon begin copper production from the Dos Pobres and San Juan deposits near Safford, Arizona. Ore reserves total 615 M tons grading 0.36% copper, predominantly as chrysocolla. Copper extraction will be by leaching with sulfuric acid. Fluor Canada provided EPCM services to design an ore handling and conventional SX/EW facility capable of producing a nominal 240 million pounds per year of cathode copper. The ore handling facility will process 114,000 tons per day of ore through three-stage, open-circuit crushing followed by agglomeration and product placement on the permanent leach pad. Stacking of ore on the leach pad will utilize Terra Nova Technologies' "Super Portable" mobile stacking system, comprising a fleet of (13) self-propelled, crawler-mounted, 72"-wide, 6,800 ton/hour mobile conveyor units, including (10) 250-ft-long portable conveyors, a 300-ft-long horizontal conveyor and a 220-ft-long radial stacker.
4. Thirty-Year Old Transfer Point Challenge
Author: Robert McEwen, Drummond Equipment Inc. Mississauga, Ontario Canada
Abstract: Conveyor equipment beyond its prime chronically suffers from lack of understanding in today’s plant environment regularly delivers more material than original designers ever expected. A case in point is a belt conveyor in a major hard rock mine/milling operation asking to bring the unit up to current standards while eliminating spillage and reducing airborne dust. The challenge was to keep the system going by revamping the system while keeping the same footprint and allowing for higher production rate. Thirty years of daily maintenance and dust collection costs have virtually disappeared by the end of this challenging upgrade.
Poster Session / Reception
Tuesday February 26, 2007 5:00pm
Display your 4 ft x 8 ft poster of an interesting new product or application case study. If you are interested in displaying a poster, contact Dick Bailey for information and cost.
Or come visit with old friends and new with good food and open bar sponsored by the poster session participants.
Registration
Registration is not open yet. Please watch this page or the http://smenet.org website for details.
Conference Executive Committee
Mark Alspaugh, Chariman, Overland Conveyor Co Inc
Michael Myers, Vice Chairman, Baldor Dodge Relaince
Richard Bailey, Conetic Resources
Edmond O'Donovan, E.J. O'Donovan & Associates
Walter Kueng, Takraf
Todd Hollingsworth, Conveyor Engineering Inc
Reese Kidman, Roberts & Schaefer
Jason Pope, Sandwell
Fernando Jauregui, Freeport
Ingolf Neubecker, ThyssenKrupp Robins
Marcus Keller, ContiTech
Edwin Brady, Peabody Coal
The complete program can be found at:
http://overlandconveyor.com/2008sme/bmh
For more information or questions about this symposium, contact Mark Alspaugh at:
https://edir.bulk-online.com/profile...d-conveyor.htm
Attachments
alspaugh (JPG)
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