Rough, isolated terrain? No problem with our Overland Conveyors
Long-distance, high-tonnage and cross-country: Overland Conveying
Call on us to meet your overland conveying challenges. As leaders in the technology of designing Overland Conveyors with horizontal and vertical curves, we have provided systems to efficiently handle material transport for the most diverse and demanding applications in some of the severest environments around the globe.
Minimise site prep earthwork
The ability to design Overland Conveyors with horizontal and vertical curves means that our cross-country conveyors follow the existing terrain. This greatly reduces the costly earthwork that might otherwise be required to build a long-distance conveyor system. Curves also can eliminate the need for expensive and maintenance-intensive transfers by reducing the necessary number of conveyor segments. They ultimately allow the conveyor to adjust to the topography, rather than making the terrain fit the conveyor.
Minimise installation fieldwork
Design considerations for erection, along with shop pre-assembly, significantly reduce installation fieldwork, and also can reduce the construction schedule. Our conveyor engineers and designers have decades of experience in the field that to help reduce conveyor erection costs.
By using a combination of head, tail intermediate and booster drives that run only during predetermined demand conditions, our Overland Conveyors minimise energy consumption. This results in substantial energy savings and considerable operating cost reduction over the life of the project.
Steep downhill power regeneration
We have designed downhill conveyors that generate up to 8,000 kW of power. This amount of energy can significantly reduce the power consumption of a project. Steep downhill conveyors can be difficult to build because of the sloping work area. Our design technology allows us to achieve what would have been impossible just a few years ago.
We currently have more than 165 Overland Conveyors of greater than 1 km (0.6 mi) in length in operation (the longest of which is 20.3 km (12.6 mi) single flight!). You can turn to us with confidence in designing an Overland Conveyor system that will readily handle your material transport needs.
Reducing your costs, maximising your efficiency
- Minimise installation site prep and field work
Our Overland Conveyors utilise horizontal and vertical curves, allowing them to adjust to the topography and follow the existing terrain. This greatly reduces the initial earthwork that might otherwise be required to build a cross-country conveyor system.
We include considerations for conveyor system erection and employ pre-assembly in the shop wherever possible to significantly reduce installation fieldwork. This ability greatly reduces the construction schedule.
- Reduce power requirements
Minimise your energy consumption with our Overland Conveyors. We can design our systems to use a combination of head, tail intermediate and booster drives that will run only during predetermined demand conditions. This results in substantial energy savings and operating cost reduction for your mine.
In a project in Peru, isolated operating conditions required 9,000 kW installed power, but the normal operating power was only 1,000 kW. Running all 9,000 kW motors continuously would have been uneconomical, since motor efficiency is reduced when not operating at full load. Our solution as described above delivered energy savings and reduced operating costs.
- Reduce transfer points
- Our ability to design Overland Conveyors with horizontal and vertical curves can eliminate the need for expensive and maintenance-intensive transfers by reducing the necessary number of conveyor segments.
- Reduce operating costs
Advanced Overland Conveyor designs for challenging applications
It all starts with the design. And our engineers are leading the industry by utilising the most up-to-date licensed and proprietary software. In this way, we meet the challenges presented by the most diverse and demanding applications in some of the most severe environments around the world.
Dynamic analysis software allows our engineers to evaluate and anticipate a multitude of operating conditions and provide Overland Conveyors to meet your requirements. Discrete element modelling (DEM) helps our designers predict how material will flow through chute work and determine how the material will affect the life of the wear liners and the belt.
Design considerations for controlled starting and stopping
These drive components and cutting-edge technologies can provide solutions for complex drive challenges.
- Variable frequency drives
- Wound rotor induction motors
- Fluid couplings
- Dodge controlled-start transmission
- Power and control systems
- Gearless drive solution
Variable frequency drives (VFDs)
In an Overland Conveyor application, VFDs can provide a number of benefits, including smoother operation, acceleration control, different operating speeds, compensation for variables and torque control.
Wound rotor induction motors (WRIDs)
WRIMs offer controlled starts and higher efficiencies for conveyor running at constant speeds.
Fluid coupling can be a low-cost method of providing a controlled soft start in many applications.
Dodge controlled-start transmission (CST)
The Dodge CST is a planetary gear reducer with an integral wet clutch that is well-suited for starting, accelerating and stopping Overland Conveyors in certain applications. One of its unique features is the ability to provide unlimited starts per hour, torque limiting and inspection speeds.
Power and control systems
The electrical system is often an integral part of an overland conveyor design. We can provide a complete electrical power and control system for your project.
Gearless drive solution
Overland Conveyors are increasingly becoming the preferred mode of transporting ore from the mine to the processing plant. The growing prevalence of remote mining locations drives the demand for longer overland conveyors with higher capacity, resulting in higher power requirements and the need for low-maintenance solutions. A gearless drive, which eliminates the need for gearboxes, offers just such a solution to our customers.