Condition-Based Conveyor Belt Replacement Strategy in Lignite Mines with Random Belt Deterioration

Abstract

In Polish lignite surface mines, condition-based belt replacement strategies are applied in order to assure profitable refurbishment of worn out belts performed by external firms specializing in belt maintenance. In two of three lignite mines, staff asses belt condition subjectively during visual inspections. Only one mine applies specialized diagnostic device (HRDS) allowing objective magnetic evaluation of belt core condition in order to choose the most profitable moment for the dismantling of worn out belt segments from conveyors and sending them to the maintenance firm which provides their refurbishment. This article describes the advantages of a new diagnostic device called DiagBelt. It was developed at the Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology. Economic gains from its application are calculated for the lignite mine and for the belt maintenance firm, taking into account random life (durability) of new and reconditioned belts (after the 1st and the 2nd refurbishment). Recursive calculations for following years allow the estimation of the length and costs of replaced, reconditioned and purchased belts on an annual basis, while the use of the Monte Carlo method allows the estimation of their variability caused by random deterioration of belts. Savings are obtained due to better selection of moments (times) for the replacement of belt segments and die to the possibility to qualify worn out belts for refurbishment without the need to remove their covers. In effect, increased belt durability and lowered share of waste belts (which were not qualified for reconditioning) create savings which can quickly cover expenditures on new diagnostic tools and regular belt inspections in the mine.