Conveyor systems are integral to a mine’s operational infrastructure, as they enable the safe and efficient movement of rock ore and other materials with low environmental impact.
Being at the core of mining’s operational processes, conveyors and their components need to be regularly inspected and properly maintained to ensure profitability and avoid unplanned downtime or shutdowns due to critical failures.
Belt conveyors are the most common type used across the industry, designed for low-cost transportation of materials up and down inclines, around obstacles, and over long distances such as overland conveyors that connect mining pits with processing plants.
Other types include shuttle conveyors that move back and forth on a track with multiple drop-off points, and trunk conveyors which are designed to transport mined materials from the underground face to a processing site or lift shaft.
The incorporation of new technologies into conveyor systems has not only improved safety outcomes and aligned with decarbonisation initiatives but fostered the adoption of preventive maintenance techniques and has resulted in innovations that extend component life.
Remote inspection is becoming increasingly viable for extraction industries as better monitoring, scanning, and data acquisition tools become available.
These tools work together to collect near- or real-time data of potential system problems through sensors placed on a conveyor system’s rollers or pulleys, enabling operators to anticipate maintenance, avoid unplanned downtime, and improve belt reliability.
Types of data that can be obtained include track speed, misalignment, damage, thickness and wear, slippage, and temperature of the conveyor belts.
Wireless and remote-sensing solutions make it possible for service technicians to monitor conveyor systems in real time and employ predictive maintenance, which uses sensors supported by software to directly monitor equipment performance and accurately anticipate failure conditions.
Unlike preventive maintenance, which is determined by an average or expected lifespan, predictive maintenance is based on the actual current condition of the equipment.
Sensor-based inspection methods enable data-assisted remote monitoring of a conveyor system’s condition, detecting potential damage at an early stage before it affects production.
They can also be utilised in conjunction with cloud computing and the Internet of Things to obtain instant alerts and reports from conveyor assets anywhere in the world.
To maximise longevity, a conveyor system relies on the quality and reliability of its individual components, with the key parts being the rollers, idlers, drivers, and belts.
Rollers ensure the belt moves smoothly and reduces friction and wear, idlers maintain the belt’s shape and tension to prevent sagging and misalignment, and drives provide power to move the belt with precise speed controls.
Belts are the carrying medium of a conveyor system and their covers are the most replaced component, particularly the top cover which wears out four times faster than the bottom.
The rubber in conveyor belts is the single biggest element of cost when they are manufactured, so extending belt life is a direct way to minimise overall system costs.
Open-cut mining conveyor systems are particularly exposed to conditions that affect the integrity of the belt and limit its life expectancy.
As the wear resistance of the belt is the most important factor determining its operational lifetime and cost-effectiveness, they are designed to withstand mining’s specific conditions including abrasion, temperature, and chemical exposure.
Recent belt innovations include the development of energy-efficient belt covers that wear down slower due to less rolling resistance against the idlers, as well as the use of non-stick belt covers in belt construction.
This belting is created by applying a non-stick coating to prevent the accumulation of carryback material on the belt.
The coating reduces the need for belt cleaning, extending belt life by reducing cover wear, and is also resistant to oil and grease and unaffected by weathering and aging.