Objective: To minimize the carry-back and load zone spillage on both feeder belts coming from
the train unloader, to prevent contamination from one product to another.
Challenge: Material conveyed was constantly changing and needed to be controlled. The material from the train cars was not throttled at times, allowing for large surges. The solution needed to be versatile due to the constant changing of the material types and sizes. Due to these inconsistent flow rates plant employees were constantly cleaning out the pit spillage. The loss of product due to contamination and the cost of handing the material twice, to be reintroduced back into the material flow process, was increasing the cost per ton affecting a loss of profit. Material build-up behind the transfer that was escaping the existing skirting was wearing out the conveyor belt prematurely.
Solution: After careful inspection the recommendation was made to install a 48” belt width
ASGCO® Chute Tail Box, ½” X 6” beveled Dura-Seal™ ORG skirtboard sealing compound,
complete with an 18” segmented Clamp-Mount® MDX™ to ensure an effective seal at the back
of the load zone. The Chute Tail Box will act as an accumulator and cut down on the amount
of spillage from material being pushed out of the back of the transfer, giving the belt time to
catch up when large amounts of material are introduced from the railcar flop gate. Due to the
change in pitch behind the transfer chute Clamp-Mount® MDX paired with Dura-Seal (ORG)
was suggested for an effective seal as well as for easy maintenance and
adjustments.
Results: The spillage was reduced by as much as 90% at the transfer point! The employees were
having to clean out 2-3 shovel loads of railcar spillage once a week that was coming through the
grating above. The combination of the ASGCO® Chute Tail Box system with Clamp-Mount®
MDX and Dura-Seal (ORG) has sealed the transfer and prevented material rollback, greatly
decreasing cost per ton and eliminating load-zone spillage. No accumulation of material exists.
It has now been completely contained. The Tail Box has also simplified the cleanup by being able
to utilize the inspection door to reintroduce material to the conveyor, preventing belt damage
from the abrasive material being dragged back through the sealed transfer.