ASGCO Providing Solutions to Sulphur Processing Plant’s Transfer Conveyor’s Belt Tracking Challenges
A sulphur processing plant was having difficulty tracking their 24” transfer belt due to conveyor miss alignment and unleveled conveyor structure. These issues were causing short belt life, structural damages and loading challenges ultimately creating down time and costing precious operating moneys.
ASGCO created a sound solution to the customer’s tracking challenges by advising the need of leveling the conveyor’s structure and properly aligning the tail pulley. After structural corrections and pulley adjustments were made, we installed the ASGCO 24” Tru-Trainer “top-side pushing down”, (8’) prior to the tail pulley. This distance and mounting configuration allowed for the Tru-Trainer to mechanically train the belt from the “clean-side”(i.e. no material accumulation on the trainer’s lagging) and, gave the Tru-Trainer ample belt length to track prior to the transition of the pulley. The end performance: The ASGCO Tru-Trainer is now centering the transfer belt prior to the loading of material and keeping the belt from wandering thus eliminating costly conveyor structural damage.
Industry: Sulphur Palletizer and Sulphur Storage Processing
Application: Transfer Conveyor
Product: Sulphur Pallets
Objective: Conveyor Belt Tracking
Conveyor: 75 ft. long; 10% incline; 24-inch wide belt; 25-degree troughing idlers; conveyor runs intermittently
For more information: http://www.asgco.com/conveyor-products/conveyor-idlers
Improving Conveyor Belt Tracking and Reducing Airborne Dust on a Re-design of a PRB Coal-Fired Power Plant Conveyor Transfer System
By Phil Wowak and Aaron Gibbs
Article Published in World Coal – June 2012
One of the big challenges to the safe conveying of coal, especially sub-bituminous coal such as that from the Powder River Basin (PRB), is dealing with the fuel’s high concentration of fine dust. The presence of this dust, combined with PRB coal’s high moisture content (20- 30% ), raises the risk of spontaneous combustion. Properly designed, maintained and operated conveyer belt systems play a major role in the safe handling of PRB coal.
Particular attention must be paid to cleaning because the buildup of dust on and along conveyors and transfer points poses safety problems. However, even fanatical cleaning is no substitute for a well-designed and operated coal conveying system. There are three major areas of concern to minimize dusting and spillage on a typical conveyor:
• Load zone transfer points.
• Discharge point belt cleaners.
• Belt tracking.
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.
The ASGCO® Dry Wipe Conveyor Belt Cleaner is designed to be the final cleaner in a cleaning system on the conveyor belt. When there is still water remaining on the belt after the primary and secondary cleaners have done their job, this can cause a mess along the belt line. The squeegee effect of the Dry Wipe Cleaning system can wipe the belt dry.
Redesign of a PRB Coal-Fired Power Plant Conveyor Transfer System Improves Conveyor Belt Tracking and Reduces Airborne Dust
This coal fired power plant burning PRB coal had a serious dusting problem at a primary underground transfer point. The 72” conveyors were handling a varying load from 0 to 3600 ton per hour at 650 feet per minute. The existing chute design caused extensive dusting, internal liner wear as well as material spillage and receiving conveyor belt mis-tracking due to off center loading with varying loads as well as belt cover wear.
The existing transfer chute was modeled and re-designed using ASGCO’s 3-DEM material modeling software, to allow the coal flow to smoothly transfer from the supply conveyor to the center of the receiving conveyor. This new design eliminated the off center loading conditions due to the varing coal load which cause belt mis- tracking and material spillage. The new design loads the coal onto the receiving belt directly in the center and flows in the direction of belt travel. Airborne dust and spillage is virtually eliminated with this new design. Clampmount skirting, dust curtains and Slide-N-Roll support beds further aid in the elimination of any fugitive dust and carryback and helped make this project a great success.
The newly installed transfer chute with a hood and centering spoon now operates with improved coal flow without buildup, spillage or any significant amount of airborne dust. The receiving belt now tracks centered on the conveyor system regardless of the varying load condition. This successful project once again proved that ASGCO can provide a “Complete Conveyor Solution”.
Industry: PRB Coal Fired Power Plant
Application: Underground 72”Conveyor Transfer Chute and Load Zone
Material: PRB / Sub-Bituminous Coal 3″ minus
Product: 3-DEM Chute Analysis, Redesign, Fabrication and Installation
Objective: Improve material flow, reduce airborne dust, eliminate off center loading and cover wear on the receiving belt
Conveyor #1 (Feed Conveyor)
Width / 72 inch
Speed / 650 FPM
Incline / 0 deg
TPH / Variable 0 to 3500
Conveyor #2 (Receiving Conveyor)
Width / 72 inch
Speed / 640 FPM
Incline / 14.1 deg
TPH / Variable 0 to 3500
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
Objective: To protect workers from all areas of conveyor systems that create a safety hazard, yet allow for easy removal of conveyor guarding, and replacement, when maintenance on the conveyor system is required. Read more
At this copper mining operation, the return idlers that track the belt on the conveyor system were very hard to access. The only way to change the idlers on this 36” wide conveyor belt, was to clear out all of the material on the ground and rent a 135’ man lift to access the conveyor belt tracking return idlers. Read more
The tripper component of the coal handling conveyor system was a major issue for several reasons, with the current OSHA NEP combustible dust requirements, to address any airborne dust issues, being the top priority. Read more