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Common Conveyor Belt Issues in Mining and How to Fix Them

Sep 30, 2024

Essential Tips for Effective Mining Conveyor Belt Maintenance

Conveyor belts play a crucial role in the mining industry, transporting bulk materials over long distances, often under harsh conditions. However, like any equipment, conveyor belts are prone to various issues that can lead to downtime, reduced productivity, and costly repairs. Understanding the most Conveyor Belt Issues and how to fix them is essential for maintaining efficiency in mining operations.

1. Belt Mistracking

Belt mistracking occurs when the conveyor belt moves to one side of the conveyor structure instead of running straight down the center. This problem can cause serious damage to the belt and the conveyor system.

Causes of Belt Mistracking:

  • Misaligned pulleys or rollers
  • Worn-out conveyor components
  • Material buildup on rollers
  • Uneven belt tension

How to Fix It:

  • Regularly inspect and realign pulleys and rollers.
  • Clean any material buildup to prevent obstructions.
  • Use self-aligning idlers to help the belt stay on track.
  • Ensure the belt tension is evenly distributed across the system.

2. Belt Slippage

Belt slippage occurs when the conveyor belt does not maintain enough grip on the pulley, leading to inefficient material movement. This issue is often seen when the belt is carrying a heavy load or when the pulley is worn out.

Causes of Belt Slippage:

  • Inadequate tension on the belt
  • Worn or dirty pulleys
  • Excessive load on the belt
  • Incorrect belt selection for the application

How to Fix It?

  • Adjust the tension of the belt to prevent slippage.
  • Regularly clean and maintain the pulleys to ensure they are in good condition.
  • Reduce the load on the belt to within its recommended capacity.
  • Use a pulley lagging system to increase grip on the belt.

3. Material Carryback

Material carryback occurs when small amounts of material stick to the belt and fall off at various points along the return path. Over time, this buildup can damage conveyor components and lead to material spillage, which is both wasteful and potentially hazardous.

Causes of Material Carryback:

  • Ineffective or worn-out belt cleaners
  • Sticky materials with high moisture content
  • Poorly designed or installed cleaning systems

How to Fix It?

  • Install primary and secondary belt cleaners to remove material effectively.
  • Regularly inspect and replace worn-out or ineffective cleaning systems.
  • Use belt scrapers and plows to prevent material accumulation on the belt.
  • Consider using materials with lower moisture content when possible.

4. Belt Tears and Rips

Tears and rips in the conveyor belt can be catastrophic, leading to significant downtime and costly repairs. These issues are often caused by sharp objects, heavy impacts, or excessive belt wear due to improper loading or operation.

Causes of Belt Tears and Rips:

  • Foreign objects or debris on the conveyor
  • Poor material handling practices
  • Improper loading of materials
  • Worn-out or damaged conveyor belts

How to Fix It?

  • Install belt plows and impact beds to reduce the risk of tears from sharp objects.
  • Regularly inspect the belt for signs of wear and tear, and replace damaged sections promptly.
  • Improve material handling and loading procedures to prevent unnecessary stress on the belt.
  • Use rip-detection systems to detect small tears before they become major issues.

5. Blocked Chutes and Transfer Points

Blocked chutes and transfer points can cause material to back up, leading to system overloads and equipment failure. When materials are not flowing correctly through chutes or transfer points, it can affect the entire conveyor system’s performance.

Causes of Blocked Chutes and Transfer Points:

  • Material buildup due to poor flow design
  • Moisture causing materials to stick together
  • Improper sizing of chutes and transfer points

How to Fix It?

  • Regularly clean chutes and transfer points to prevent buildup.
  • Improve chute design to enhance material flow and reduce the risk of blockage.
  • Install vibration systems to help dislodge sticky materials.
  • Use flow aids like air cannons or lining materials to keep material moving smoothly.

6. Belt Misalignment at Transfer Points

Misalignment at transfer points can lead to belt mistracking, material spillage, and excessive wear on conveyor components. This often happens when the conveyor belt is not centered as it moves through the transfer point.

Causes of Belt Misalignment:

  • Poorly aligned transfer chutes
  • Uneven loading of materials
  • Worn or damaged transfer points

How to Fix It?

  • Realign transfer chutes and ensure they are directing materials onto the center of the belt.
  • Adjust loading procedures to distribute materials evenly across the belt.
  • Replace or repair damaged transfer points and chute linings.

7. Conveyor Belt Wear and Tear

Over time, conveyor belts can experience wear and tear, especially in mining environments where abrasive materials are constantly being transported. This can result in cracks, holes, and overall degradation of the belt.

Causes of Conveyor Belt Wear:

  • Abrasive materials like rocks and ores
  • Poor maintenance practices
  • Constant exposure to extreme conditions

How to Fix It?

  • Use higher-grade, wear-resistant belts for abrasive materials.
  • Implement a regular maintenance and inspection schedule to catch early signs of wear.
  • Replace the belt or damaged sections when necessary to avoid further damage.

8. Overloaded Belts

Overloading a conveyor belt can cause severe strain on the entire system, leading to premature wear and potential failure. This issue can be particularly challenging in mining operations, where the temptation to move large volumes of materials quickly is common.

Causes of Overloaded Belts:

  • Attempting to move more material than the system is designed for
  • Improperly sized conveyor belts
  • Faulty load calculation
  • Conveyor Belt Cleaning

How to Fix It?

  • Ensure that the belt is being used within its capacity limits.
  • Recalculate the load to ensure that it matches the belt’s design specifications.
  • Install load sensors to monitor and prevent overloading.

9. Pulley Lagging Failure

Pulley lagging failure occurs when the layer of material covering the pulley wears out, reducing the friction needed for the conveyor belt to move effectively. This issue can lead to belt slippage and reduced productivity.

Causes of Pulley Lagging Failure:

  • Excessive wear due to harsh environmental conditions
  • Lack of maintenance
  • Improper lagging installation

How to Fix It?

  • Regularly inspect and replace the pulley lagging material.
  • Implement a preventive maintenance plan to catch early signs of wear.
  • Ensure proper installation of lagging to avoid premature failure.

Conclusion

Conveyor belts are an essential part of mining operations, but they are prone to several common issues. Addressing these problems promptly and effectively can minimize downtime, improve productivity, and reduce operational costs. TSGlobal, based in Sydney, Australia, offers comprehensive solutions for conveyor belt maintenance and repair, ensuring that your mining operations run smoothly and efficiently.

FAQs

1. What is belt mistracking? Belt mistracking occurs when a conveyor belt moves off-center, often causing damage to both the belt and surrounding equipment. It can be corrected by aligning pulleys, adjusting belt tension, or using self-aligning idlers.

2. How can I prevent material carryback on my conveyor belt? Material carryback can be minimized by installing effective belt cleaners, regularly cleaning and maintaining them, and using belt scrapers or plows to remove excess material.

3. What causes belt slippage, and how can it be fixed? Belt slippage is typically caused by inadequate tension, worn pulleys, or excessive load. It can be resolved by tightening the belt, cleaning or replacing pulleys, or reducing the load.

4. How do I prevent belt tears and rips in a mining operation? You can prevent belt tears by installing belt plows, regularly inspecting the belt for wear, improving material handling practices, and using rip-detection systems.

5. What are the benefits of regular conveyor belt maintenance? Regular maintenance helps identify early signs of wear and tear, prevents unexpected breakdowns, and extends the lifespan of the conveyor system, ultimately saving time and reducing costs.