Feeding the facts: Hybrid feeder benefits, applications and how they fit in mining

What makes a hybrid feeder different than a traditional apron or belt feeder?

Metso Outotec's Crossover™ feeder is a hybrid feeder that includes features of the reputable ”tractor chain” apron feeder and a reliable belt feeder. The Crossover™ feeder is a unique design of a belt-over-apron concept with an outboard chain and modular construction frame resulting a lower installation height.

What types of applications are hybrid feeders best suited for?

The Crossover™ feeder is suitable for both light and heavy-duty applications. Some examples include:

• Layouts that require handling material of minus 300mm and a sealed conveyor design to eliminate the need of a dribble belt to collect the fines under feeder, are popular installations
• Configurations that require a horizontal transitioning to incline installation
• Applications of feeding secondary type crushers, HPGR’s, mills, screens are also a good choice for the Crossover™ feeder.

These can be either greenfield or brownfield operations.

Installations of direct dumping from haul trucks, rail car dumpers, handling of sharp metal or hot material, should be avoided. This is where traditional apron feeders fit the best.

Will I need a dribble fines collecting belt conveyor under my Crossover™ feeder?

No, a dribble fines conveyor is not required when using a Crossover™ feeder. Since the Crossover™ already incorporates a belt-over-apron concept, that prevents finer material from leaking between the pans and carryback of fine material to the dribble belt conveyor.

Eliminating the dribble conveyor also reduces the overall height by up to 50% compared to a traditional apron feeder and dribble belt configuration.

What are the key benefits of the Crossover™ Feeder?

There are many benefits using the Crossover™ hybrid feeder. But do not only consider CAPEX savings from the equipment, but from the overall operation view as well.

Some of the main benefits include:

• Reduction in height by up to 50%, leading to overall lower CAPEX for the project (Less height for civil works and infrastructure of stockpile reclaim tunnel and/or building)
• Eliminating the need for a dribble belt conveyor to be installed
• Containing fine material that may otherwise leak from the overlapping pans (Like with a traditional apron feeder)

Other benefits may include:

• Reducing the vertical discharge drop height and reducing degradation of the ore, wear of components and dust emissions
• Cost savings from no parts or maintenance required for the dribble belt
• Eliminating the need for second drive system of the dribble belt
• Power savings from operating the dribble belt

Remember, a meter in height savings can bring significant cost savings!

Can a Crossover™ feeder replace your existing feeders?

In addition to new greenfield installations, the Crossover™ feeder can easily be retrofitted to replace existing feeders of various types. Such feeders may be old apron feeders, possibly with dribble belts, belt feeders, vibrating pan feeders, push type or drag chain style feeders. Due to the fact that the Crossover™ feeder has a low, compacted installation height, makes it a perfect solution to replace existing feeders that may not be performing up to customer expectations, is no longer cost effective, or spare parts may be obsolete or not available.

Another consideration for replacing an existing feeder is when the current feeder is increasing general OPEX due to mechanical malfunction, maintenance, or general housekeeping.

If you are facing any of these challenges or would like help evaluating if you are unknowingly facing those challenges, Metso Outotec experts are happy to help you.