Conveyor belts are of utmost value in the mining industry. They help transport the ores, coal, and other materials from extraction to processing units. These belts must be durable and strong to withstand abrasive materials. That brings a question about how to choose the right mining conveyor belt that is strong and rugged.
Remember, using a weak conveyor belt reduces the efficiency of the mining operation. It also affects the safety of workers in the underground mining operations. Therefore, it is crucial to choose mining conveyor belts that are very rugged and abrasion-resistant. In this article, I’ll guide you in selecting the right conveyor belts for high-end mining operations. So, let’s begin!
What is the Best Conveyor Belt for Mining?
There is no single conveyor belt considered the best for all mining needs. For heavy-duty mining operations, highly rugged conveyor belts are considered suitable. For mild operations, less durable, less expensive conveyor belts are suitable. A conveyor belt that can withstand abrasive materials is considered high-quality.
Additionally, it should not stretch when exposed to impact or heavy loads. Additionally, mining belts must be durable enough to transport coal, ore, and heavy rocks. They should be long enough to carry coal over long distances, whether underground or on the surface. According to my experience, here is the list of the two best conveyor belts for mining needs:
- EP-Fördergurte
- Steel-cord Conveyor Belts
I consider EP conveyor belts the best option for low to medium-pressure mining operations. Why? The EP conveyor belts are durable but not ideal. Its carcass is made of polyester and nylon materials. These materials give the mining conveyor belt the strength to withstand the harsh materials during mining.
However, these EP conveyor belts are not ideal for extreme mining operations. In such conditions, I favor Stahlseil-Förderbänder for these mining operations. The reason is that their carcasses consist of strong steel cords or wires. These steel cords make these conveyor belts more durable and perform better in mining operations.
It is crucial to choose a belt whose external layer is made of flame-retardant rubber. Remember, both EP and steel-cord conveyor belts have an external rubber layer. This rubber must be heat and flame-resistant. In this way, your conveyor belt will remain safe, even when handling the harshest materials. Flame-retardant conveyor belts are a bit more expensive, but they are worth the cost.
Wie wählt man das richtige Förderband für den Bergbau aus?
Mining conveyor belts are not the simplest. Their selection is a bit more tedious and challenging. Why? The reason is that small mistakes can make these belts unfit for heavy-duty mining operations. In the section below, I will discuss the key factors to consider when choosing mining conveyor belts.
1- Type of Material You Need to Transport
First, analyze your specific mining needs. Are you going to transport heavier and abrasive materials? Those can be either harsh ores or rocks. If so, you’ll need a mining conveyor belt with a very thick cover. Such conveyor belts will perform better when transporting abrasive (harsh) materials.
On the other hand, if you transport lightweight coats or ores, you don’t need heavy-duty mining belts. In such a case, a conveyor belt of a thinner layer will be more than enough. Some mining operations require transporting heavy-duty rocks from extraction to process units. In such a case, you must use steel-cord belts with thicker, stronger rubber layers.
Mistake to Avoid: Inexpensive mining conveyor belts are available with low-quality rubber on the outer layer. I advise you not to buy such conveyor belts for mining operations. Why? The reason is that these belts cannot withstand abrasive materials and degrade. You should choose a mining conveyor belt with stronger external rubber (heat and flame-resistant).
2- Conveyor Length or Size
The length or size of the conveyor belt is an important parameter to consider. In underground mining operations, the distance between the extraction point and the processing unit is high. In such a case, you’ll have a conveyor belt that’s longer. If the belt moves a greater distance, it means it will face more friction with the pulley and the rollers. Right?
More friction will cause wear out of the conveyor belts. For such conditions, the conveyor belts you choose must be strong. It should be able to withstand the friction from the belt rubbing against the pulley and rollers. Remember, the thickness of the external layer plays a key role in such conditions. On the other hand, some mining operations require shorter conveyor belts.
In such cases, you can choose a cheaper conveyor belt with decent strength. I recommend steel cord conveyor belts if your mining operation requires a longer belt. For small- to medium-sized mining operations, EP conveyor belts are a decent option. They are flexible, easy to install, and offer decent performance for shorter-distance operations.
3- Underground vs Open-Pit Mines
There are generally two types of mining operations. Those include underground mining and open-pit mining (above the surface). Both of these mining operations have different requirements for the conveyor belts. In underground mining, you should choose a conveyor belt with flame resistance. Why?
They can catch fire from consistent rubbing against the pulley under high-temperature conditions. For open-pit mining, I recommend choosing conveyor belts that are heat and moisture-resistant. Remember, in open-pit mining, the conveyor belts remain exposed to sunlight, UV rays, moisture, and rain. So, they must be strong enough to resist these environmental elements.
4- Vulcanized vs Mechanical Splicing
The ends of conveyor belts are joined together. This joining of two ends forms a loop of conveyor belt that runs on the pulley. The joining of two ends of the belt is called splicing. There are two types of splicing, which are as follows:
- Vulcanized Splicing
- Mechanical Splicing
Vulcanized splicing involves the joining of the ends of the belt using heat and pressure. On the other hand, mechanical splicing uses clips to join the belt ends. For mining operations, I recommend conveyor belts with vulcanized splicing. Why? That’s because vulcanized splicing creates a strong bond between the belt ends. Such belts remain durable and strong even under harsh conditions.
5- Elongation, and Pulley Diameter
Knowing the belt’s elongation and the pulley diameter is very important. Are you confused about what elongation and diameter of a pulley mean? Elongation indicates how much a belt stretches over time. Belts with higher elongation can stretch too much due to consistent use and heavy loads. As a result, this belt can slip off or become too loose.
I recommend choosing the mining conveyor belt with low elongation. The reason is that such belts don’t stretch too much. As a result, they don’t slip off the pulley and remain in place. The diameter of a pulley means how thick the pulley is. Remember, if the pulley diameter is higher, you should not choose a belt with higher thickness. The reason is that such belts can get damaged during bending on the pulley.
6- Temperature Range of Operation
Not all the mining operations or sites have the same temperature. At some point in the extraction, the temperature is generally too high. On the other hand, this temperature can be low in some areas (regions). Therefore, you should carefully analyze the expected temperature at the mining site.
If the temperature is expected to be high, choose a belt with heat resistance. Such belts have an external heat-resistant rubber layer. On the other hand, low-temperature conditions can always affect the belt if it is not durable. How? The belt can contract at low temperatures. This will cause the belt to break as it moves on the pulley.
7- Cost of Ownership & Maintenance
One of the biggest mistakes people make when choosing a mining conveyor belt is failing to consider the initial cost. Remember, conveyor belts with low initial cost can be low quality and cheap. Therefore, I recommend you check the following things when buying mining conveyor belts:
- Initial Cost
- Operational Cost
- Maintenance Cost
The conveyor belt with a higher initial cost can be OK if its operating and maintenance costs are low. The operation cost indicates how much electricity conveyor belts consume during their operation. If it consumes too much energy, it will make mining operations less profitable. Additionally, if the conveyor belts break down too often, that’s another red flag.
You will have to spend money on its maintenance and repair. I recommend choosing a high-quality belt with low operation and maintenance costs. Considering only the initial cost while buying a mining conveyor belt is never a good idea. Imagine you buy a belt at a low initial cost but with higher operation and maintenance costs. That would be a horrible mining experience to say the least.
Schlussfolgerung
Mining conveyor belts are costly. Small mistakes during selection can lead to the wrong belt being selected, affecting your mining operation. If you ask my opinion, I would recommend a conveyor belt with the following characteristics:
- Abrasion resistance
- Heat and cold resistance
- Low elongation and better durability
- Low operational and maintenance costs
The belt with these characteristics is considered suitable for all types of mining operations. Still want my opinion on which belt you should choose? I think steel cord conveyor belts are ideal for extreme mining operations. Their excellent durability and strength come from their steel cords or wires. These belts can last for years to come and perform reliably in mining operations.