End-to-end material transportation performance – From pit to plant

This article was first published on Mining.com.

In a typical concentrator plant, high value assets found in the crushing or grinding circuits are often the focus for sites process and maintenance experts’ time. Equipment in the recovery or dewatering stages of the plant such as float cells or filters also garner their share of attention as improvements in these areas can have a major impact on a site’s profitability. However, one critical but often overlooked part of the mineral processing setup involves the equipment that moves the ore through the system from one stage of the process to the next, what we refer to as material transportation. 

A mine site and plant can be compared to a small, bustling city. Trucks, chutes, feeders and conveyor belts are the connecting transportation links between the pivotal pit stops of the flowsheet. If there are any interruptions in that flow, gridlock can result, bringing the entire process to a standstill, with major implications for production deliverables, a site’s bottom line and customer satisfaction. Four of the common material transportation areas where hidden production or sustainability improvement opportunities may lie are: 

• The trucks transporting ore from the rock face to the plant 

• The chutes connecting various assets in the plant 

• The conveyor belt loading zones and their sealing systems 

• Hauling more with less 

Metso truck bed rubber lining 

At many mine sites, trucks with metal-lined truck beds are often still the primary way of transporting ore to the concentrator plant. Truck beds need to stand up to the heavy abuse of abrasive material continually dumped into them with each visit to the mine face. Metal-lined truck beds can be heavy, which can limit the payload the truck can transport as well as result in high fuel consumption. One hidden opportunity at this stage is to consider rubber-lined truck beds. 

Metso truck bed rubber lining lasts up to 300% longer than traditional truck bed lining. It protects the chassis of the truck and the bed from wear and vibrations from the loading impact, prolonging the truck bed’s life and drastically reducing the need for maintenance. The modular design of the lining means that only worn parts need to be replaced. The Metso-designed truck bed rubber-lining reduces vibration and perceived noise. Less vibration and perceived noise provide a safer and more comfortable working environment for your drivers. Increased safety, modularity and lower fuel costs move you closer to your sustainability goals. 

WearSense™ wear monitoring systems – Linking equipment with chutes 

Continuing in our busy city, we make our way to the chutes where material is either fed or discharged into a process. Chutes collect, convey, and prepare the material flow for the next processing phase. They are used with crushers, feeders, conveyors, stackers, and grinding mills. If any of the chutes require an unplanned service stop, the equipment it serves will also be affected, and production can come to an abrupt stop. Sites end up trying to find a balance between waiting too long to change a chute liner and risking an unplanned stop or changing a chute liner too early and not using the full life of a wear part, leading to unused liner being wasted and sent too early to landfill.

But wouldn’t it be nice to be able to predict when inspections, maintenance or even a chute reline should be performed? Here lies a second hidden opportunity. WearSense™ wear monitoring systems optimize the interval time between chute liner replacements, resulting in fewer change outs, less downtime, and reduced waste. This wireless online wear monitoring system can be fitted to any metallic or ceramic liner independent of the attachment system in use. It monitors wear in real-time and tells you when to change liners – not too early, and not too late. 

Keeping the lanes flowing 

Conveyors are often the main highways, the on and off ramps and side streets in our productive little city. In any mining or aggregate operation, the conveyor belts, frames and rollers are subject to relentless forces and impacts, day after day. The loading zone is often a specific weak point, where the belt must endure the 24/7 pounding of the rocks flowing directly onto the belt. Here is another often overlooked improvement opportunity. What if there was a way to help absorb the impacts at the critical loading area of the belt? Conveyor loading systems consist of a cradle, glide bars, and impact bars placed at transfer or loading points, often between two conveyors. They protect your valuable equipment and belts from impact damage when the material is being transferred. The addition of a loading system can significantly extend the life of belts, especially when dealing with abrasive feed. 

Another challenge with conveyors is that material often spills off the belt, creating buildup and safety issues for staff. Designed to safely seal the area where the chute meets the conveyor, conveyor sealing systems prevent dust or material spillage. Made using special material, which is softer than the conveyor belt, the conveyor sealing system helps to safeguard your belt. It helps to avoid grooves forming in the belt over an extended period of operation, as well as protecting the belt material from being worn down prematurely. Conveyor sealing systems also prevent product waste and shield your equipment from damage. And most importantly, they prevent dust from escaping into the atmosphere – protecting the health of your operators. A multi-purpose solution with many sustainability advantages.

WAMskirt sealing system 

Just as many busy highways have guardrails, a WAMskirt sealing system can bring additional advantages. This system is mounted externally, eliminating the need for workers in confined spaces and therefore significantly improving safety. A tapered face on the lower liner trains material away from the skirting and back into the center of the belt, improving overall performance. Fixed and removable options are available, and modules can be customized or retrofitted to meet your needs. 

WAMskirt provides two-stage control of spillages and dust, with proven durability in tough mining environments. As a first line of defense, fully adjustable metallic primary wear liners direct the flow of material and prevent spillages of larger particles. Then, the rubber or urethane secondary dust seal captures dust and smaller particles. There is also a removable WAMskirt option that features modules that allow every second liner to be removed, freeing up space to maintain the fixed liners. All removable components weigh less than 20 kg, making handling safe and easy. 

End-to-end solutions 

So don’t wait until the sirens sound in the streets of your city. Contact your Metso representative for end-to-end solutions that can help control your plants “highways and byways” like a professional urban planner. Avoid gridlock and downtime, keep your operation running smoothly and enjoy the results of on-time delivery to your customers.