Case Studies (27)

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.

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Excalibur Food Grade Belt Cleaning System Solves Carry-back Problem Midwest Bakery

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. More

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Armorite® Increases Wear-Plate Life at Copper Mine Concentrator

ASGCO®’s Armorite® Increases Wear-Plate Life at Copper Mine Concentrator.

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. More

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New Conveyor Technology Improves Environmental, Safety and Productivity for Bulk Material

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. More

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ASGCO® Helps Power Plant Reduce Dust Levels by 60%

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. More

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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. More

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Conveyor Mis-Alignment Inefficiencies at Mining Operations and Bulk Shipping Terminals are Solved

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. More

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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. More

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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. More

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ASGCO® Safe-Guard™ Conveyor Return Idler Cages Solve Safety Issues at this Coal Mining Facility

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. More

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ASGCO® – Tru-Trainer® Belt Tracking Idler Solves Tracking Problem on FGD Scrubbing Conveyor

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. More

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ASGCO® Impact Bed Cradle Solves Aging Spillage Problem at Eastern Bituminous Coal Mine

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. More

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ASGCO Skalper Belt Cleaners Reduce Carry-Back and Dust at Mid-Western Power Plant

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. More

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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. More

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ASGCO – Fourthane Provides Solution for Repairs of Conveyor Belt Covers and Mechanical Fasteners

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. More

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Iron Shipping Terminal Protects Workers with ASGCO Conveyor Guarding & Safety Equipment

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. More

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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. More

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ASGCO Return Roll Changers Provide Safety for Conveyor Maintenance Crews

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. More

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Ready Mix Plant Improves Production by Solving Conveyor Tracking Problem

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. More

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Copper Mine Solves High Wear Areas with Armorite™ Conveyor Wear Liners

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. More

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3-DEM Solves a Major Transfer Chute Problem at Northeast PRB Coal Fired Power Plant

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. More

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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. More

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ASGCO Improves Operating Efficiency of PRB Coal-Fired Power Plants Conveying System

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. More

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Implementing a Six-step Plan for Proper Load Zone Operation

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.

 
ASGCO Tru-Trainers Dramatically Reduce Conveyor Downtime Generating Major Operating Savings

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.

 
3-DEM Solves Another Major Transfer Chute Problem at a Northeast Biomass Power Plant

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. More

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Eliminate Slippage and Excess Wear with Arrowhead Ceramic Lagging

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.