Development of design criteria for reducing wear in iron ore transfer chutes

Abstract

In high throughput Australian iron ore handling operations, premature failure of conveyor belts and transfer chutes due to wear is of great significance to the success of operations. Here, a down time in the order of a few hours may result in millions of tonnes of annual export losses. Optimisation of existing or brownfield high capacity and utilisation mine, plant and port facilities with minimial capital spend has not always reduced maintenance costs. Gauging the success of such endevours allows for the establishment of design standards that are becoming accepted by the iron ore industry. The aim of these standards is to improve functionality and maximise the service life of installed equipment without compromising flow performance.This paper outlines key criteria for design standards, with a focus on minimising conveyor transfer and belt wear, that can be integrated into an existing frawework of engineering management in iron ore operations. Research and industry experience are blended with a theoretical (continuum mechancis based) and numerical (Discrete Element Method based) modelling assessment. A qualitative modelling case study is presented investigating the sensitivities associated with transfer chute design geometry and the resulting chute and belt wear life. An outline of the elements for consideration towards design criteria specification in iron ore transfers is presented. Such specifications must result in adequacy of the designed transfer to meet both technical and functional requirements across the range of operational conditions and variation of the characteristics of the ores handled.