Efficient in-plant conveying of materials – with safety in mind
Safe, cost-effective transport with our In-Plant Conveyors
Our In-Plant Conveyors offer safe mechanical conveying and are built to efficiently handle sticky and/or highly abrasive materials. We provide a solution that minimises blockages and liner wear, while extending the life of the belt and other major components.
Working together with real-world operations, we have designed a solution that addresses the challenges that often come with moving large volumes of highly abrasive material around the clock. Maintenance personnel have told us that chutes and skirtboards, in particular, cause the majority of their In-Plant Conveyor problems, downtime and operating headaches.
Input we have received from plants around the world has also influenced the design of our In-Plant Conveyor’s discharge section, most importantly, access to it. Two small inspection hatches and a major double working door at the end of the conveyor allow easy access for operation monitoring and maintenance procedures.
Safety comes first
A key objective when designing our in-plant conveying solutions was avoiding accidents. This means that all parts involved in the maintenance work – while the belt is still in motion – have been moved outside the safety guards. This includes an innovative patented system for idler frames, which allows operators to adjust idler frames for belt tracking from outside of the cover with just a wrench and a hammer.
The cover also contains three small holes that allow the operator to see inside the cover without opening it, to see if the belt is tracking correctly. Another maintenance advantage includes placement of the lubrication points outside of the safety guard.
A “dynamic rock box” is adjustable from outside the safety guard. This cutting-edge rock box design ensures the bulk material lands in the centre of the belt, and greatly reduces dust emissions in the inlet.
Simplified design for easy mounting
Our In-Plant Conveyors are quick and easy to assemble onsite, mainly because they contain fewer parts – up to 70% fewer than our previous design – and because they are preassembled in our workshop. For example, most nuts are welded to the construction, providing logistical, installation and maintenance benefits. Additionally, the number of different bolt sizes have been reduced from our previous model, which helps to significantly reduce installation time.
Components needed for a stringer section are reduced, and each component can be carried by hand to the installation point, or are preassembled. In addition, the idler frame and cover frame are fully integrated as one unit, lowering total weight and reducing the number of parts.
Modelling technology leads to innovation
In earlier models of our In-Plant Conveyors, we used a mathematical formula for material trajectory that was not as accurate as we would like. We wanted our conveyors to cater for actual in-plant conveying conditions as much as possible. So, we set about conducting some practical experiments at our Denmark-based research facility, testing sample materials with differing properties at different speeds.
We also used a technique called discrete element modelling (DEM) to predict how solid particles move and interact in space. Mathematical equations considered the shape, position, cohesiveness, velocity and force of each particle, and calculated how they flowed as they passed through a predefined space, such as chutework.
The formula for material trajectory was then updated to incorporate results from the practical experiments and from the DEM. This update helps to minimise common mechanical conveying challenges, such as blockages caused by sticky material, excessive dust and liner and belt wear.
Operator- and maintenance-friendly in-plant conveyor solutions
- Improved safety
As part of our design, we have removed all parts associated with maintenance work that is required while the mechanical conveying belt remains in operation to points outside the lightweight safety guards, including lubrication points. Operators can observe the conveyor in action without opening the In-Plant Conveyor’s cover, and can make most adjustments outside the safety guard to ensure bulk material lands in the centre of the belt.
We introduced the lightweight safety guards in response to a challenge we have often seen with In Plant Conveyors. Big and heavy safety guards typically end up being removed and leaned against the walkway rails, as they are too heavy to be put back in place by just one person. By having lightweight safety guards, this dangerous practice is avoided.
- Lower cost
- Our simplified design for trouble-free mounting facilitates rapid transport to your site and easy onsite installation – lowering your costs.
- Easy maintenance
- All parts requiring maintenance, including lubrication points are located outside of the safety guard surrounding the mechanical conveying belt. This ensures the parts are easily accessible for maintenance while the belt is still in motion.
- Our years of experience in designing and working with operators of In-Plant Conveyors have resulted in the development of a reliable mechanical conveying solution for day-in-day-out material transport.
- Handles sticky and/or abrasive materials
- Wear plates in the inlet box are fixed with a simple system, and can easily be replaced to handle abrasive and sticky bulk material. For abrasive materials, wear parts can be hard-faced with durable Hardox® or our newly developed FerroCer®. For sticky materials, low-friction liners are used to prevent material build-up.
In-Plant Conveyors with critical design considerations put to practice
Light, yet strong covers for easier handling
A unique feature of our In-Plant Conveyor is the cover. Considerable effort was put into creating an equally strong, more flexible and lighter cover to replace the corrugated iron design of our previous model. The new cover is easier to open and handle, as the individual covers do not overlap – instead, it easily slides open like a breadbox.
Adjustable rock box optimises operation
The dynamic rock box is standard in all inlets handling free-flowing materials. Situated outside the safety guard for straightforward access, the dynamic rock box ensures a dust-free and centred load to the consecutive conveyor. It also reduces wear from abrasive materials in the inlet box.
Well-designed discharge section
The discharge casing has hollow shaft gears, which hang on the pulley shaft and are supported directly by the main frame. This means our In-Plant Conveyor does not need civil construction, and offers better access around the discharge. At the same time, it provides full access for the primary and secondary scrapers.
Large double-working doors and inspection windows mean operators can safely gain an overview of the In-Plant Conveyor’s status during operation and have full access for maintenance when stopped. Other special features of the discharge section include space for a spillage conveyor and a specially designed baffle plate.