Objective: Persistent belt mistracking at this waste-to-energy recycling facility was causing
consistent and problematic spillage and belt damage. These issues lead to safety concerns
from falling material, as well as the need for constant housekeeping, severely impacting
employee morale. Continual belt mistracking also lead to premature belt failure and costly
repair and downtime.
Case Studies (47)
Objective: Persistent belt mistracking at this waste-to-energy recycling facility was causing
Objective: To track and align the conveyor belt on the return side of the belt before the loop
take-up section, while leaving the 6 series deflector pulley system with double speed reducers.
Challenge: The challenge involved an extreme incline conveyor belt 96” wide, with tandem
drives and a 6 pulley take-up system. Due to the nature of this Drive system design, along
with the speed of the belt and together with the high tonnage that this system see’s during
each shift, severe belt mis-alignment was a serious problem. The conveyor belt had
tracking problems on the return side of the conveyor, especially through the 6 pulley
take-up system. This was exaggerated because of the incline and belt speed of this system.
Objective: To provide load zone support, stability, and reliability in the transfer point
with limited access and to be able to service the impact rollers in the future quickly, easily,
and with minimal effort.
Challenge: The challenge was to be able to remove and to replace the impact rollers in
this tail section with access limited to only one-side, while providing an easier alternative
to servicing them in the future. Many of the existing impact rollers had already failed.
Some were stuck, worn flat, shafts broken, and some were even missing. These impact rollers
were at a 10° trough, like many of the tailpiece style sections, where changing one of the
impact beds was very difficult. The ‘off’ side of the transfer was blocked by a concrete
footing or pillar. Any servicing that needed to be done on this side was cumbersome and
in some cases depending on the problem, impossible.
Objective: Bypass the dryer by redirecting product from an incline conveyor onto an adjacent
steep incline conveyor.
Challenge: The customer first came to ASGCO® with the question “how can we eliminate our dryer and the conveyor that feeds it cost effectively.” The largest challenge of this project was the relationship of these two conveyors. They were not exactly perpendicular to each other which made the design of the chute difficult.Download PDF
ASGCO®’s Safe-Guard® Return Roll Changer Allows Idler Change Out in a Fraction of the Time and Under the Most Difficult Environments!
Objective: To Reduce Down Time When Changing Out the Return Rollers While Also Creating
a Safer Working Environment
Challenge: The only way to change the return idlers on this 72” incline conveyor enclosed
in a tube, was to crawl under the conveyor in a curved/sloped application while packing
a 130 pound roller. This was also a very difficult and unsafe environment to work in making
the procedure very timely and energy consuming. This resulted in both lost production
time and maintenance resources.
ASGCO® Tru-Trainer® Tapered Troughing System Eliminates Belt Tracking Issues at This South American Copper Mine.
Objective: To prevent belt tracking issues before the critical curved areas of the belt,
causing belt damage.
Challenge: The challenge was to track a horizontally curved, overland primary
crusher belt before it gets to a critical mis-tracking stage and eventually damages
the belting system. This would be an exceptionally difficult challenge due to the
harsh environmental conditions of the operation. They had been using conventional
guide roller trackers which continually failed, causing belt damage.
Objective: To Greatly Reduce the Airborne Irritable Dust Levels and the Residual
Material From the Belt
Challenge: This Trona mine lent itself to high concentrations of extremely irritable dust.
The mine was over 1500 ft deep, going through the waterline. The existing cleaners were
not heavy duty enough to handle the high speed belt and high pressure water.
ASGCO® Dura-Sleeve® V-Return Idlers Solve Belt Tracking Problems at This High Tonnage South American Copper Mine.
Objective: Provide reliable rollers, better alternative to inadequate rollers that fail consistently.
Challenge: The demanding conditions of heavy tonnage and high speeds would wear out the
previous metal rollers too quickly. The high speed of 23 ft per second per second (7 meters)
and a tonnage capacity of 8000 tons per hour, caused the rollers to fail and fall apart, mainly
due to the rubber ring design. Specifically the problem was the high belt speeds that would
spin the rubber discs on the old rollers resulting in failure. Also the uneven wear was causing
the rollers to spin unevenly and then to overheat the rollers causing failures. The quality
required for this application needed to be extremely durable and wear resistant.
ASGCO®’s Retractable Razor-Back MDX® System with Spring-Shoc Solves Critical Carry-back Problem at Copper Mine
Objective: To prevent carry-back on a conveyor belt with long service hours, while decreasing
housekeeping and efficiency issues.
Challenge: This copper mining facility needed to remove the residual carry-back material from
the primary belt cleaner to run more efficiently and to reduce downtime. They were having to
clean once a week, taking took up to 3-1/2 hours each time, causing increased labor for housekeeping.
Objective: Eliminate belt tracking issues that are resulting in major belt damage and spillage from contact with steel conveyor supports.
Challenge: For many years this conveyor had a hydraulic three return Idler belt training system that wouldn’t properly keep the conveyor belt in line. The plant was facing constantly downtime to repair the hydraulic system. Even when operational, the belt would veer off of center and come into contact with the structural supports, leading to critical damage to the belt and costly material spillage. To further complicate this application, the conveyor also has less than 13” of height to mount any type of return training roller. Options for eliminating the tracking problem were extremely limited by these space restrictions.Download PDF
Objective: Solve belt mis-tracking and off center load issues
Challenge: A major cement processing facility in was experiencing severe belt tracking and alignment problems leading to regular costly repairs and maintenance. This plant was using traditional training idlers in an attempt to control the mis-tracking, however the nature of the aggregate material on the belt lead to continual build up around the pivot point, yielding it ineffective. In addition, the rubber disk return idlers were preventing the belt from re-centering, defeating their purpose.Download PDF
- Restore the pug mill to original operational capacity by replacing worn and heavily
corroded components with new components that are resistant to corrosion in
- Improve the efficiency of the system by eliminating carryback material that causes
accelerated wear and requires excessive downtime to clean up.
Objective: Redesign the chute for better material flow and reduce the dust in the load zone area
Challenge: A high volume paper mill was experiencing constant chute plugging, and leaking in critical areas, causing wood chips and dust to escape containment. A secondary problem was chronic belt mis-tracking and material leakage under ill-fitting rubber skirts. Due to the extreme capacity of this mill and the 24 hour operation, ASGCO® Engineers had only 8 weeks to take field measurements, design and fabricate a new chute and load zone, and have everything installed.Download PDF
Objective: To design a new self-contained material load zone that would eliminate costly spillage and expensive clean up.
Challenge: This customer receives barges several times a month, and sometimes more frequently depending on the demand. The raw material travels on top to feed the silos. This powder has extremely fine properties that were escaping and filling the structure surrounding the conveyor with thick dust and debris that would settle throughout the room, sometimes in upwards of several feet. The floor would become lined with this expensive material, that once exposed, became useless in the cement process.Download PDF
Objective: To prevent spillage at this transfer point and eliminate pulsation of the conveyor belt.
Challenge: This customer has had reoccurring issues with this transfer due to spillage.Download PDF
ASGCO® Helps Midwestern US Coal Handling Operation Reduce Combustible Dust and Spillage in High Volume Transfer Terminal
Objective: To reduce combustible dust spillage and maintenance issues
Challenge: This underground rail car transfer point for Sub-Bituminous Coal was failing due to poor design and inferior components, leading to major dust and spillage.
ASGCO® Helps Northeastern US Coal Burning Power Station Improve Material Flow and Reduce Maintenance Costs
Objective: To improve material flow and reduce dust spillage and maintenance issues
Challenge: Constant abrasion from high moisture bituminous coal was causing serious wear and plugging on flow chutes at a major Northeastern US coal burning power station.
ASGCO® 3-DEM® Designed Flo-Control® Chutes are custom tailored to adapt to unique challenges of any material in any environment.
Objective: To improve the effectiveness, durability and overall cleaning of their belt
Challenge: Constant exposure to salt moisture, copper concentrate and high humidity in a marine shipping terminal cause standard steel components on many belt cleaning systems to decompose and ultimately fail.
Objective: To remove the sticky carry-back from the conveyor belt.
Challenge: Co-mingled materials traveling together along the conveyor to a sorting facility
would constantly leave behind sticky deposits that would accumulate, requiring costly
downtime and maintenance, especially on the return idlers and belt.
Objective: Need for long lasting, lightweight, and good resistance to abrasion and coefficient of friction.
Challenge: Most composite rolls are made from UHMW, Nylon or PVC. Overall lightweight rollers have the advantage, however not all of them are as strong (too much deflection on wider widths) or they don’t provide a good resistance to abrasion. The coefficient of friction is also poor, especially in wet conditions, which makes it more difficult to track or train the conveyor belt.Download PDF
Dual Skalper® Primary Belt Cleaners Solve Major Carry-Back Problems at a Canadian Smelter Complex Nickle Mine
Objective: To remove the sticky carry-back and prevent it from falling off at various points causing major housekeeping problems.
Challenge: The conveyor belt adds the sand to the process for extracting the precious metals. All ore from any of their sites has to pass through this filter plant at some point. This sand belt has become a major problem due to the carry-back issues. The sand is very “STICKY” and therefore very hard to clean. Also there is limited space within the head chute preventing them from using a secondary cleaner. They were currently using a competitor’s pre-cleaner and also an Air Knife. These were not working and a lot of “Man Hours” were being spent shoveling the carry-back material back onto the belt.Download PDF
Excalibur Food Grade Belt Cleaning System used in pastry dough waste conveyor application.
Objective: To provide a solution to a carry-back problem with jelly and dough sticking to the conveyor belt.
Details: Many food processing plants have problems keeping their conveyor belts clean during manufacturing of the food products. A lot of these products have ingredients that contain sticky material that won’t release from the belt. This customer had a carry-back problem with a pastry product containing very sticky jelly and dough like material that wouldn’t release from the conveyor belt causing a major carry-back problem. MoreDownload PDF
Objective: To provide a wear plate that proved to provide both impact and abrasion resistance in tough mining conditions.
Problem: Due to the highly abrasive ore properties and the occasional 2”-3” steel balls from the SAG mills made this application very difficult for the mine. The average life of previous wear plates from two different manufacturers was on average about 6-8 weeks. Both the Sandvik® HX900 and the ESCO® Kwik-Lok® carbide wear plates were cracking due to the high impact of the ore and simply do not provide the wear protection the mine was looking for. MoreDownload PDF
In today’s coal fired power plants, it is important to keep coal dust and coal spillage in the load zone area to a minimum. Many plants struggle to keep these areas clean, due to not having enough time or man power to properly adjust skirt rubber or fix holes in the chutes. Around many load zone areas you will usually find coal piles in between troughing idlers and on the floor. This coal spillage is expensive to remove and if not properly fixed the coal piles will reoccur again and again.
This midwest coal fired power plant had this problem. The skirt rubber wasn’t getting adjusted or changed when needed; piles of coal all around the load zone area floor caused a safety hazard. The existing load zone was missing hoods, dust curtains and was rusting in some areas. All these problems together were causing coal to spill and coal dust to fill the air around the conveyor. MoreDownload PDF
Current guidelines for combustible dust control are critical to any safe operating coal fired power plant or any operation that is handling materials that can create combustible dust. The tripper floor at this power plant had a large unhealthy volume of dust suspended in the air that would make it difficult to see from one end of the room to the other. Operators had to wear dust masks and respirators and at times that wasn’t enough. MoreDownload PDF
ASGCO® Products Solve Fugitive Material Containment Problems at a Northwestern Coal Fired Power Plant.
Industries: Power Industry
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. MoreDownload PDF
Conveyor efficiency, safety and productivity are critical components to any mining operation or bulk shipping terminal. Therefore conveyor belt mis-tracking or mis-alignment can be a major concern. MoreDownload PDF
ASGCO® – Troughing Tru-Trainer® Conveyor Belt Tracking System Solves Belt Tracking Problems at this Copper Mill Process Facility
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. MoreDownload PDF
ASGCO® 3-DEM™ Analysis of Existing Bucket Reclaimer and of a New Bidirectional Design Bucket to Verify the New Design Will Achieve the Same Output as the Existing Design
The driving force behind this project was initiated out of a safety issue. The existing bucket design would require 3 to 4 operators to manually flip the buckets which would put the operators in a dangerous position as the buckets are very heavy and could cause an injury during the process of flipping the bucket to change direction. Therefore corrective actions resulting from an incident investigation were to redesign and re-engineer the bucket to enable the bucket wheel to change direction without flipping the buckets. Due to the split design of the new bucket the challenge was to ensure the same tonnage would flow thru the bucket without any restriction. MoreDownload PDF
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 a 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. MoreDownload PDF
The customer is a larger coal burning power plant that has had FGD Scrubber Conveyors in service for many years to help control the plants emissions. The product that is being conveyed is a synthetic gypsum product that is either conveyed or shipped to a nearby gypsum board plant. This product is very sticky and corrosive and builds up on the conventional return idlers and return trainers. This causes the belt to mis-tracks and rub conveyor structure. MoreDownload PDF
The #1 refuse belt on the ground level is spilling badly and impact rollers cannot keep up with the seven load zones where the material is being dumped. A 28’ span needs to be supported and sealed in a manner as to not increase amperage or draw on the existing belt drive. MoreDownload PDF
Objective: Eliminate carry-back, reduce housekeeping, minimize safety issues, reduce maintenance needs and extend blade life
Challenge: Excessive buildup of material carry-back and dust from inadequate belt cleaners, resulting in housekeeping and safety issues, combined with OSHA’s Combustible Dust National Emphasis Program (NEP) have made things very difficult for this Mid-western coal-fired power plant. The increased labor for housekeeping issues and the possibility of strict fines added increased emphasis for this power plant to improve its belt cleaner systems. MoreDownload PDF
Improving Conveyor Belt Tracking and Reducing Airborne Dust on a Redesign of a PRB Coal-Fired Power Plant Conveyor Transfer System
This transfer point was a major problem area for the PRB coal yard. While in reclaiming operation, the chute would build- up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added, but the problem still remained. Due to the angle of discharge onto the 60” receiving conveyor, off center loading caused serious belt mis-tracking and constant spillage. MoreDownload PDF
ASGCO Fourthane®. A new synthetic rubber with high tear and impact resistance, is formulated to be applied on conveyor systems that operate under high impact and abrasion conditions, resulting in less downtime. MoreDownload PDF
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.
By using various standard sizes of the ASGCO Safe-Guard Modular Conveyor Flat Guards, we were able to protect the hazardous areas and still allow them access as needed by easily removing and replacing the lightweight powder coated panels. MoreDownload PDF
ASGCO Wash Box System Prevents Carry-back and Keeps Dust to a Minimum at a PRB Coal Fired Power Plant
In today’s coal burning power plants, it is essential to keep carryback and dust to a minimum. With power plants having to cut back on maintenance crews to service these conveyors, belt cleaners get overlooked, and very seldom get cleaned or re-tensioned. MoreDownload PDF
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. MoreDownload PDF
A ready-mix plant had difficulty properly tracking the vital conveyor belt that feeds the mixer. The problem was essentially that the conveyor belt was difficult to keep in alignment, which caused serious belt edge damage, and in turn de-lamination and spillage in the conveyor load zone. MoreDownload PDF
A copper mine was experiencing high wear in their “pant-leg” chute liners. A combination of abrasive material and high tonnages was the major factor why the mine was only about to get 4-5 weeks from 1” thick AR500 plates. MoreDownload PDF
This transfer point was a major problem area for the PRB coal company. While in reclaiming operation, the chute would build up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added but the problem still remained. Due to the angle of discharge onto the 60” receiving conveyor, off center loading caused serious belt miss-tracking and constant spillage. MoreDownload PDF
Large Aggregate Plant Eliminates Carry-back Using a Combination of ASGCO’s Skalper IV Primary Belt Cleaner and Razor-Back with Spray Bar Secondary Belt Cleaner
ASGCO has successfully reduced the carry back to levels that far exceed the expectations of the customer. The customer has now installed several other ASGCO cleaners to attack carry back problems throughout the plant. MoreDownload PDF
This area of the coal handling system was a major issue for the plant for several reasons. Due to the current OSHA NEP combustible dust requirements, has made it mandatory for many PRB coal fired power plants to address any airborne dust issues. MoreDownload PDF
Today’s aggregate industry is filled with challenges. Foremost, to produce enough aggregate for cement, asphalt and other products for homes, businesses, schools, hospitals, and infrastructures. Also, operators must address environmental responsibility concerns that dictate the use of best practices to protect both natural resources and future generations of citizens.
Problems of continuous misalignment on a short reversing feeder conveyor belt was causing severe damage to the belts. These were replaced monthly at a cost of $741 USD/each belt, however, down time is $73,059 USD per hour and the replacement of this belt needs a time of 4 hours. That is the equivalent to $292,237 USD of downtime related to the conveyor.
While discussing the challenges with key employees, and doing a thorough analysis of the plant, we discovered some of the problems that were occurring, including; issues with conveyor belts not getting cleaned properly as well as tensioning systems on the primary belt cleaners locking up (or taking a set) and causing major material carry-back problems within the plant. MoreDownload PDF
Reduce wear on pulleys and provide effective coefficient of friction between the drive pulley and the conveyor belt within the copper ore transfer – from mine to leaching area.