Rubber Conveyor Belt for Open-pit Mine Ore Transportation

Project Background

An open-pit iron ore mine runs year-round. The main overland conveyor transports crushed iron ore from primary crusher to ore stockpile. Material includes sharp, angular lumpy ore and fine ore fines, with throughput of 1,200 tons per hour. Loading drop height reaches 2.8 m, bringing heavy impact on the belt surface. The site has harsh open-air conditions: big temperature difference, heavy dust and occasional rain. Old ordinary multi-ply belts were easily gouged, torn or worn through, only lasting 4–6 months. Belt ripping incidents frequently interrupted mining production.

Challenges

• Sharp-edged iron ore causes heavy impact, gouging and cutting damage at loading points
• High tonnage continuous load and long-distance conveying require high tensile strength
• Outdoor environment with large temperature fluctuation and wet ore leads to rubber aging and edge cracking
• Any sudden belt failure will stop the whole crushing & ore handling system.

Solution

Steel cord reinforced rubber conveyor belt with extra thick abrasion-resistant rubber cover was adopted. It features high tear resistance, impact resistance and excellent tensile strength. Impact cradles were fitted at loading zones to reduce lump ore shock. Belt cleaners and skirt seal systems were installed to reduce ore fines buildup and side spillage.

Application Result

The upgraded rubber conveyor belt achieved stable continuous operation. Average service life extended to more than 36 months. Belt tearing and gouging failures decreased sharply. Less maintenance shutdown improved overall mine output. Total operational cost for material conveying was reduced by lowering belt replacement frequency and repair labor.

Have a Similar Application?

Every site is different — material, lump size, drop height, temperature and duty cycle all change the belt specification. Send us your working conditions and we will recommend the carcass, cover grade and cover thickness, with budget pricing.