An Effective Belt Conveyor for Underground Ore Transportation Systems

Abstract

Raw material transportation generates a substantial share of costs in the mining industry. Mining companies are therefore determined to improve the effectiveness of their transportation system, focusing on solutions that increase both its energy efficiency and reliability while keeping maintenance costs low. In the underground copper ore operations in Poland’s KGHM mines vast and complex belt conveyor systems have been used for horizontal haulage of the run-of-mine ore from mining departments to shafts. Basing upon a long-time experience in the field of analysing, testing, designing and computing of belt conveyor equipment with regard to specific operational conditions, the improvements to the standard design of an underground belt conveyor for ore transportation have been proposed. As the key elements of a belt conveyor, the energy-efficient conveyor belt and optimised carrying idlers have been developed for the new generation of underground conveyors. The proposed solutions were tested individually on the specially constructed test stands in the laboratory and in the experimental belt conveyor that was built up with the use of prototype parts and commissioned for the regular ore haulage in a mining department in the KGHM underground mine “Lubin”. Its work was monitored and the recorded operational parameters (loadings, stresses and strains, energy dissipation, belt tracking) were compared with those previously collected on a reference (standard) conveyor. These in-situ measurements have proved that the proposed solutions will return with significant energy savings and lower maintenance costs. Calculations made on the basis of measurement results in the specialized belt conveyor designing software allow to estimate the possible savings if the modernized conveyors supersede the standard ones in a large belt conveying system.