Most conveyor-related problems at mines in Africa could be solved through their using simpler systems, says minerals beneficiation, mining and bulk solids handling industry consumables designer Tega Industries SA.

Company business development and marketing manager Vishal Gautam says, when it comes to spares and parts, mining operations in Africa tend to prefer simpler systems that are widely and quickly available, instead of specialised and intricate systems that take time to obtain.

He adds that simpler systems are also convenient for these operations since the shortage of specialised skills on the continent allows for the majority of the workforce to only manage these systems. For example, idlers, which require higher maintenance and lubrication, can be replaced with slider beds, he adds.

Gautam tells Mining Weekly that conveyor components designed to extend the longevity and performance of conveyance systems are becoming increasingly popular with mines aiming to improve efficiencies amid lower global commodity prices.
Therefore, Tega Industries SA offers carefully engineered conveyor components that are especially designed to handle weak points on conveyors and increase efficiency, while increasing the life span of belts and extending service periods, he says.

The solutions, released in 2013, are designed to increase availability and avoid unnecessary downtime at mining operations.

“In addition to being quickly available and simpler to operate, the solutions are also not maintenance intensive,” says Gautam.

Solutions
The Tega Industries FriFlo impact pad system is used to replace standard rollers with a solid impact bed. The specially formulated combination of materials incorporates a low friction surface that enables the belt to glide over the top with little or no friction, while a rubber middle layer absorbs shocks and reduces damage to the belt. Once installed, the system requires no further maintenance.

Gautam says the FriFlo is used to prevent damage to belting at transfer points where impacts from large or heavy items can damage the impact rollers to the extent that they can seize or run unevenly, resulting in the rapid wear of the belt and excessive drag on the rest of the system.

“We designed the FriFlo with a top layer made of ultrahigh molecular weight polyethylene to let the conveyer belt glide over the transfer point. “The middle layer cushions impact, while the lower layer is used to fasten the impact pads onto the support frame that is usually made of aluminium.”

He adds that the pad provides a large contact area that supports the belt, which means there is no undercutting and damage as there are with rollers.

“With no bearings or moving parts, the pads offer a long service life, with no requirement for lubrication or further maintenance other than a quick visual check from time to time.”

Meanwhile, the company’s Spill-EX skirt sealing system is designed to eliminate spillage at transfer points. The system uses specially formulated soft rubber segments that act as a skirt to seal the sides or rear of conveyors, and is adjustable to ensure that each segment makes contact with the belt to form a complete seal.

“Spill-EX replaces the commonly used long rubber lengths, which are comparatively difficult to install and provide little or no settings to adjust the skirt to match the shape of the belt,” says Gautam.

He adds that the system is supplied in short lengths that can be individually adjusted to make light contact with the belt. The specially formulated rubber is softer than the belt, which results in it wearing to the point where it takes the exact shape of the belt to create a full seal. “Thereafter, the blocks can simply be adjusted for wear and individual segments can be replaced if worn or damaged.”

Tega Industries SA also offers the Ceramic Pulley Lagging system that fits into existing or new pulleys to provide increased traction on the belt and prevent slippage even in wet and muddy conditions.

“Belt slippage can cause excessive wear and tear and might even lead to the belt running unevenly or coming off the track in certain conditions. “ To combat this, our system uses a special traction design that has ceramic tiles with traction nubs embedded into a special rubber housing to provide better grip,” Gautam explains.

He says this improves conveyor belt performance, significantly reduces belt slippage, improves tracking and also extends the life of belts and bearings.

Gautam says the system, which can be used on drive pulleys, as well as snub, bend and tail pulleys, is especially suited where slippage and resultant damage render normal rubber lagging ineffective.