ASGCO Manufacturing, the worldwide leader in providing the most effective products for bulk material handling, is now offering expanded conveyor training school services for the (ACT™) program.
The (ACT™) conveyor training school offers both in-house and on-site-location training to ensure the best instruction to solve your bulk handling concerns.
4 Major Benefits Of Conveyor Training School:
- Gain efficiency
- Keep conveyor systems running longer and producing more
- Have the latest splicing, installation, service and maintenance technology
- Reduce your bulk material handling maintenance costs
ASGCO® Products Solve Fugitive Material Containment Problems at a Northwestern Coal Fired Power Plant
Northwestern Coal Fired Power Plant
ASGCO® Tru-Trainer® series of conveyor belt tracking idlers, Impact Cradle Beds”‘, X-Wear”‘ (AR) Internal Skirtboard Liners & Clamp-Mount”‘ Conveyor Skirtboard Sealing System with Tri-Seal”‘
To contain the fugitive material by reducing airborne dust, controlling spillage and reducing or eliminating housekeeping issues.
This northwestern coal fired power plant was experiencing tremendous amounts of coal escaping through the load zone area. There were several issues that needed attention. The belt was mis-tracking in the impact area of the load zone and it was not fully supported due to impact rollers being used. Both situations resulted in excess spillage and airborne dust. Read more
Conveyor efficiency, safety and productivity are critical components to any mining operations or bulk shipping terminal. Therefore conveyor belt mis-tracking or mis-alignment can be a major concern.
The problem, as shown in the pictures of the right, conventional training idlers are not effective. Some of the problems are; the side-guide rollers and exposed center pivot will seize, which can creates sever belt edge damage, the trainer in most cases is tied off in one direction therefore not allowing the trainer to actuate when need and lastly conventional tracking idlers will not work on reversing conveyor systems. On one particular reversing conveyor system the customer had a conveyor belt mis-alignment switch sending and alarm nearly every day.
After a complete survey of the conveying systems and the biggest problems were identified, it was recommended to the customer that they install ASGCO Tru-Trainer® series of conveyor belt tracking idlers approximately 20’-30’ (7m-10m) prior to any conveyor pulley. After the installation of the Tru-Trainers the customer has not had a single belt mis-alignment alarm on any conveyor that now has a Tru-Trainer; including the reversing conveyors.
The Tru-Trainer series of Conveyor Belt Tracking idlers employs a patented, unique highly effective tracking action, which in non-damaging to the conveyor belt and reacts immediately if the belt begins to steer off center. Because it does not rely on contact with the belt edge in order to guide the belt, belt edge damage which frequently occurs with conventional tracking systems, is avoided.
This copper mill facility was processing crushed ore the consistency of sand. They were using conventional guide roller trackers that kept failing. Due to the design of the guide rollers they continually came in contact with the belt’s edge which made them slow to react and caused premature “side wear” on the belt. The operators were prone to “tying the guide rolls off” which eliminated “the ability for it to train/align the belt.” Also, “build-up” of carry-back on the external pivot caused freeze-up (stop working) making it vulnerable to the elements of the harsh environment.
Install ASGCO 36” Troughing Tru-Trainer® prior to where the problem of miss alignment occurred on the “load-carrying side of the belt.” Conventional training devises utilize “guide rolls” that cause premature belt wear and are slow to react to belt miss tracking. At no time does the ASGCO Troughing Tru-Trainer wing’s contact the belt’s edge.
ASGCO Tru-Trainer Troughing Idler’s unique center roller does all the belt’s steering. It’s quicker to react than conventional trainers with guide rolls. The internal sealed pivot was protected from the harsh elements and fugitive build-up in the copper mill, which caused the other conventional guide roller pivots to “freeze up” and not perform. ASGCO’s Tru-Trainer Troughing Idler’s superior belt tracking performance is saving them money due to less spillage, less downtime and less belt wear.
This coal mine facility faced many challenges, as all bulk handling facilities do. Overcoming obstacles in improving the safety of their conveyor system was a top priority. These type of conveyor systems have tendency to mis-track causing the belt to cut into the hanging metal brackets holding the return roller in place. If and when the bracket gives way, the large return roller will be sent tumbling downward, creating a dangerous safety hazard.
After a thorough inspection of the conveyor it was pointed out that in addition to resolving the belt mis-tracking issue, there needed to be further changes made to ensure safety in the workplace and to comply with OSHA and MSHA requirements. It was recommended that they install ASGCO Safe-Guard Return Idler Cages to protect the return rollers and objects from falling, preventing injuries to workers and equipment.
ASGCO Safe-Guard Return Idler Cages were installed in the work areas and along the roadways to catch the return rollers if they fell. This brought the conveyors into compliance with MSHA title 30 regulations and helped the mine to reach its safety compliance goal! The customer was very pleased with the success.
In today’s manufacturing environments where the cost of downtime is measured in thousands of dollars per hour, polyurethane’s incredible durability actually increases your company’s profitability.
The diverse properties of castable polyurethane make it the leading choice of engineers looking for long lasting materials for their high load, high stress environments. Polyurethane routinely outperforms plastic, rubber and steel in its overall ability to resist harsh environmental factors such as abrasion, heat, solvents, oil and acid. In addition, polyurethane‘s noise abatement ability makes it the preferred material in chain-drive designs, conveyor belt systems and assembly line environments.
Advantages of a Custom Molded Urethane Part:
- Prints are not required. We can reverse engineer an existing part.
- Considerably tougher than plastic.
- One step molding process is more cost effective than machining blocks of plastic.
- Can produce custom molded parts to replace brass parts which require expensive machining. The parts can be slick with low friction if needed.
- Tooling for compression-molded parts is very inexpensive in comparison to other forms of molding such as injection and transfer.
- Delivery for a custom molded urethane part is very quick.
- Able to mold intricate shapes with or without metal inserts.
- We can quote from 1 custom molded part to over 1000 custom molded parts.
- We can bond custom molded urethane parts to other substrates such as phenolic, steel, aluminum and plastic
ASGCO manufactures urethane cast products as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Urethane Classifier Shoes
ASGCO Urethane Classifier Shoes feature our special wear-resistant urethane material at the outer edge of the shoe (the area that sees the most abrasion) to extend the wear life of the shoe. Longer shoe life means you experience less maintenance downtime and lower operating costs, resulting in higher productivity and profits.
Urethane Lagged Pulleys & Rollers
ASGCO manufactures Urethane Cast Rollers and Pulleys as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Urethane Hydrocyclone Liners
At ASGCO we manufacture Hydrocyclone Urethane Liners as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Pipeline Products and Pigs
ASGCO manufactures quality Pipeline Products and Pigs, particularly for the pipeline and offshore oil and gas industry, as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Urethane Sheets and Linings
Our ASGCO-thane® Polyurethane Liners are custom manufactured to solve wear issues related to bulk transport of many types of materials. Urethane’s exceptional abrasion resistance makes it an ideal solution for protecting metal hoppers and chutes from abrasive compounds, as well as great for sticky materials.
ASGCO’s Impact Bed Cradles prevent large rocks, tramp metal, roof bolts and bucket teeth from stopping your operation!
ASGCO’s Impact Bed Cradles (patent pending) are designed to provide protection to your conveyor belt from impact damage. Our modular style impact beds provide protection for the conveyor belt, as well as a tool to help control spillage in the conveyor-loading zone. Our unique, semi-U-shaped design supports the conveyor belt across the entire width – eliminating any unsupported areas between the rollers or bars found on traditional impact idlers or traditional impact beds where typical damage can occur in the idler junction points. The Impact Bed Cradles consist of a heavy-duty frame with removable (Slide-in or Slide-out) sides with center sections for ease of installation and maintenance.
- Impact Bed Cradles - no pinch point or idler junction area utilizing our 17.5° bars for 35° idler systems; 10° degree bars for 20° idler systems and 22.5° degree bars for 45° idler systems.
- Absorbs Impact - with heavy-duty steel designed framework and our impact bars that are manufactured with absorbent, 40-durometer rubber that can really take the shock of large material.
- Modular Design - cradles can be manufactured in 2′ (600mm), 3’ (900mm), 4′ (1200mm) or 5′ (1500mm) long, depending upon the size of your material impact area.
Available in either Standard duty (1,000 ft/lbs of impact) or Mine duty (2,000 ft/lbs of impact).
By Aaaron Gibbs
Article Published in Bulk Solids Handling – Issue 2, 2012
Modernization of conveyor systems in today’s coal mines and coal-fired power plants is an essential goal for the management, employees and share holders of the company. It helps ensure that the mine or plant is running to its’ optimum potential, maximizing its’ tons per hour or most amount of BTU’s produced by the mine. Doing this with as little impact to the environment as possible. Power plants being built today emit 90 percent less pollutants (SO2, NOx, Particulates, mercury) than the plants they replaced from the 1970′s, according to the National Energy Technology Laboratory.
Asset optimization / modernization has never been more critical in the everyday things we do at home and at work. Coal is abundant, clean and the most efficient energy source available. Conveyors are the lifeline to any coal-fired power plant’s productivity. No coal = No low cost, clean, abundant, affordable energy. Proper consistent training, periodic inspections of the conveying systems and reliable turn-key installation and on-going maintenance will ensure an incident and injury free workplace while maintaining a productive reliable workforce. All of which are essential to any material handling system and the employees who maintain and are responsible for them.
“Coal is the most affordable source of power fuel per million BTU, historically averaging less than one-quarter the price of petroleum and natural gas,” according the National Mining Association.
Problem: A coal preparation plant that handles over 13,000,000 tons of coal per year, had several issues with spillage in the various conveyor load zones throughout the plant. The spillage was created from the belt not being properly supported (too much sag between idlers) where the coal was being loaded. Read more
A large longitudinal rip / grooving was noticed in the center section of a long overland steel cable conveyor belt. This was caused by a faulty bearing on a belt turnover pulley that then allowed the top cover to be grooved by the conveyor structure and other mechanical components. Read more