Engineered Design
The application of transfer chutes is central to any operation in the bulk handling industry. The mining sector, in particular, presents a number of challenges due to the nature and volume of the material being transferred from one point to another.
Optimising Transfer Point Design:
Challenges and Solutions
Regardless of the direction or type of transfer, there are some design requirements that require specific attention. These include reducing dust, the elimination of blockages, reducing wear on chute liners and providing the correct discharge velocity, as well as minimising material degradation and conveyor belt wear.
Weba Chute Systems maintains that there is a need to challenge conventional thinking around chute systems and transfer points. The current trend seems to be that the company is called in to supply appropriate solutions to recently installed chute systems that are not fully operational. This is a huge concern and needs to be addressed as a top priority.
We urge engineers to consult with Weba Chute Systems during this vital phase. The experience and expertise we have gained, during thousands of installations, is available to assist engineers both in the design of new transfer points and the redesign of existing systems that are becoming too expensive to operate.
Challenges in Conventional Chute Design
- One of the most common problems associated with conventional chute design is where the product drops, from any height, directly onto the belt. This basic design fault causes the most catastrophic damage and cost, as the impact of product falling directly onto the belt causes excessive wear and, in the worst case scenario, can even result in tearing of the belt.
Impact and Spillage Issues
- In addition to the impact experienced, excessive spillage also occurs resulting in an increase in maintenance requirements. This has a direct bearing on both productivity and costs, due to unnecessary downtime and component replacement. The common practice of installing skirting and a skirting box as a remedy to control spillage incurs an additional capital outlay and is not guaranteed to alleviate the problems associated with incorrect belt loading.
Maintenance and Safety Concerns
- Excessive spillage also causes material build-up on idlers and can then cause major problems on a conveyor system if left unattended. In addition, a chute that has been engineered to allow a direct drop poses a safety issue when liners need to be replaced. The maintenance crew will need ladders and harnesses to access the inside of the chute, which is not considered best practice in the stringently regulated mining sector.
Proper Chute Liner Installation
- Another factor that requires close attention is the manner in which chute liners are installed. Typically, chute liners are bolted or welded in place and the direct impact of material against these liners causes excessive wear. Additionally, liners can detach from the inner wall of the chute and fall through the chute, causing excessive belt damage, blockages further down the line and could even cause damage to the crusher.
Importance of Efficient Conveyor Systems
- Conveyor belting is one of the most costly items in any bulk materials handling operation. Any operation achieving a lifecycle of less than three years life on conveyor belting needs to seriously review its transfer points, belt alignment, idler maintenance, pulley maintenance and cleaners. Weba Chute Systems’ experienced team of engineers is available to undertake a full analysis of existing and new chute installations and design a solution that is geared around cost-effectiveness and operational efficiency.
Comprehensive Analysis and Design Solutions
- We pride ourselves on comprehensive analysis of your needs to thoroughly scope all projects, so we can cost appropriately and realistically. Our process leaves no stone unturned and differentiates us from our competitors. Our design team adopts a simple philosophy, to give a total solution for problems traditionally associated with transfer points. Certain materials are much more challenging to transfer than others and we have the experience and know-how to find cost-effective and bespoke solutions.
