Mar. 24, 2025
Chemicals
Haulage and transportation expenses can make up a significant portion of your mining project's costs. Correctly designed and installed mining conveyors can slash your out-of-pocket operational costs, but only if you choose the best conveyor equipment for your application.
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In this blog, we take a close look at what goes into selecting the right mining conveyor for your project. We'll explore important factors to consider when choosing a conveyor, as well as lay out a set of best practices for your conveyor procurement and design process. Read on to learn more.
Conveyors play a critical role in many mining applications, providing cost-effective handling of almost any raw material while accessing areas other handling solutions cannot.
Although upfront investment is often significant, purpose-built conveyor systems outperform other alternative, such as haulage vehicles, by:
In many cases, well-designed conveyor systems can significantly boost project throughput and increase overall handling efficiency for long-term returns on investment.
To deliver these benefits, your conveyor needs to be matched to your specific needs and project parameters by an experienced equipment provider. Here are some important things to keep in mind when considering how to design the right mining conveyor.
The material you are handling will affect many aspects of your conveyor design, from belt material and troughing to the overall load capacity of your conveyor's structure. Discuss with your equipment provider how the weight, friability, abrasiveness, and stacking characteristics of your material will affect conveyor design.
What throughput capacity do you require from your new equipment? Larger loads can dramatically increase efficiency but will require heavy-duty construction and more robust belt and drive characteristics, increasing your initial investment.
What sort of environment are you operating in? Will equipment be exposed to high heat, extreme cold, or dust and high winds? Corrosive conditions in very humid or salty environments may limit the life of exposed metal. Your supplier may recommend galvanized or stainless steel construction to increase equipment life and reduce maintenance needs.
Conveyors can manage handling and transfer needs over just a few feet or many miles. For short distances steep inclines and descents may be manageable and cost-effective, but long-distance haulage may require more powerful drive equipment, increased footing, or additional transfer points to manage uneven ground or elevation changes.
Any project needs to meet or even exceed compliance with industry safety standards set by OSHA or the MSHA. Ensure your equipment has fencing to prevent unauthorized access and safety walkways and guarding to prevent falls and entrapment accidents. Add emergency stop controls and pull cords to shut down your line immediately in an emergency.
Good conveyor design should minimize the chance of spills during operation or an unexpected shutdown. Any project should also include comprehensive dust control measures to limit material loss and reduce respiratory hazards to your staff or nearby communities.
Designing your conveyor with robust materials and standardized parts can significantly reduce maintenance costs over the life of your equipment. Consider adding walkways and guarding to make access to critical equipment easier. Additionally, look at the cost involved in keeping an inventory of critical replacement parts on hand to reduce downtime.
Your budget for new equipment is always limited, and conveyors require a larger upfront investment than other haulage options but deliver long-term benefits and ROI. Consider your needs and priorities carefully. Talk to your equipment supplier about how you can save by including more cost-effective materials and standardized parts in your design.
Choosing the right type of conveyor or the best combination of equipment is essential to unlocking all the benefits that conveyor systems offer. Different types of conveyors are designed to handle specific tasks.
Overland conveyors are designed for long-distance material transport. They move large quantities of material over extended distances, often crossing rugged terrains and variable elevations to bring materials from distant sites to a central processing or distribution facility. They're also designed to handle a wide range of material types.
Underground conveyors feature a more compact design and different mounting options for use in the confined spaces of underground mining operations. By automating the movement of materials to the surface, these conveyors reduce the need for manual labor and significantly improve safety underground.
Portable transfer conveyors and radial stackers are ideal for transferring material between longer-distance conveyors, stacking materials, or loading haulage trucks. Without fixed footing, these conveyors provide flexibility and mobility, allowing them to be repositioned as needed. They are particularly useful in aggregate and quarry operations and at temporary setups or sites.
Here are six tips for getting your conveyor procurement process right.
Conversely, you can ensure a smoother and more cost-effective design and installation process by avoiding the following common missteps:
Conveyor systems can offer short-term operation benefits and long-term return on investment when implemented properly. For most operators, installation involves serious capital investment that will add value for years to come.
There's no substitute for experience when it comes to matching conveyors to your operating conditions and project goals. West River Conveyors is a recognized leader in supplying robust, effective conveying solutions for some of the toughest mining conditions.
With experience supplying coal, ores, salt, potash, aggregates, and sand, West River has on-the-ground expertise in your material needs and challenges. Talk to us about your handling, transfer, or long-distance transport needs. We'll help design a safe, efficient, affordable, and scalable solution that will deliver value for the long haul.
Contact us today, or click below to learn about our fully customizable conveyor solutions.
There are multiple moving parts and components that help power a conveyor system. Idlers,
winches, bearings, couplings, gearboxes, motors, fluid couplings, and scrapers work in unison to transport materials from Point A to Point B.
One of the more often overlooked parts of a conveyor setup is none other than the belt itself. This pivotal component helps support and transport the product safely to its intended destination.
Read on to learn more about the various types of conveyor belts and the deciding factors you should consider when selecting one for your conveyor system.
A mining conveyor belt is one of the most essential components of a conveyor system. It transports ore and other materials from the mining site to processing facilities or loading areas.
Conveyor belts are powered by a motor that runs off electricity or other power sources.
Depending on the application and several other considerations, the composition of the belt could include a plastic or rubber compound, fabric materials, and steel cables. It's supported by rollers that allow it to safely and efficiently move ore and other materials at a predetermined speed.
Conventional conveyor belts are comprised of three layers:
It's critical to choose the right type of conveyor belt to ensure safe and reliable operation. Using the wrong belt can lead to catastrophic consequences and unplanned downtime.
These are the different types of conveyor belts available:
For more information, please visit Ore Conveyor Belt.
If you're shopping for a mining conveyor belt, you should first decide your tensile strength requirement, cover thickness, and cover type depending on the material being transported and loaded. Also of particular importance is the operating environment in which the conveyor transports material.
Conveyors that move packaging or light materials in temperature-controlled warehouses won't have the same demands as those transporting heavy products underground in mines and quarries.
This is why the application and environment should be the two top considerations when selecting a mining conveyor belt.
The key difference between above-ground and underground mining belts is the materials used in the manufacturing process. A standard surface or above-ground mining conveyor belt is composed of highly flammable petrochemicals. If used in an underground mining application, there's a good chance that the belt can combust and present a severe safety hazard.
Underground mining belts are made of flame-resistant materials. Special agents, impregnation paste, and rubber components are added during manufacturing to help decrease the friction factor and increase fire resistance.
The selection of an above-ground conveyor belt is mainly determined by the properties of the raw materials you're transporting. The levels of humidity, granularity, and abrasion characteristics are all essential factors in this decision.
For example, highly abrasive materials such as iron ore, metallurgic coke, and quartz will require a much sturdier belt than moderately abrasive materials, such as ash or sand.
Here's a chart that delves into a comparison of the Depreux brand of above and underground mining conveyor belts:
ElementDELTA or DELTA CFW Surface/Above-Ground BeltsFirewall' ' Firewall II' Underground BeltsFiremaster' -PVGUnderground Belts ApplicationTransportation of bulk or other material in various mining and industrial sectors such as quarries, mines, paper and wood, glass, cement, steel, eg.Both Firewall and Firewall II are belts used to transport bulk or other material in various underground mining and quarrying applications or any application in which MSHA Part 14 fire resistance is a requirement.DEPREUX Firemaster-PVG belts offer a longer service life and are ideal for use in severe operating conditions such as moving large material, high-speed systems, long distances, steep slopes, risk of impact damage, edge wear, or longitudinal tearing. Tensile StrengthTensile strength 150 PIW to PIW using 2 to 5 plies.Tensile strength 150 PIW to PIW using 2 to 5 plies.Ranges from a standard of 150 PIW to PIW Width and LengthStandard 18' to 96' maximum. Tolerance +/- 1%. Wider belts are available.Standard 36' to 84' maximum. The width tolerance is +/- 1%. Wider belts are available.Thicknesses and weights vary for different specifications. Contact us for more details. Belt StructureThe DELTA or DELTA CFW belt textile carcase is made up of layers of fabric, from 2 to 5 (or more) plies. Each of these is separated by a rubber layer. This «sandwich» structure enables the belt to absorb shocks.The Fireshield' and Firewall II' belt carcase is made up of layered fabrics, from 2-5 plies. Each ply is separated by a rubber interlayer which enables the belt to absorb shocks.Made out of a textile <> carcase that's impregnated with a special PVC. The carcase is then further protected via a proprietary DEPREUX cover that provides special characteristics to ensure improved performance and longer life. Belt StretchAt 10% of belt nominal tensile strength: 1.5% max. Permanent stretch: around 0.7% and elastic stretch: around 0.5% for a standard carcase.At 10% of belt nominal tensile strength: 1.5% max. Permanent stretch: around 0.7% and elastic stretch: around 0.5% for standard carcaseAt 10% of nominal belt tensile strength: 1% maximum elastic stretch: 0.5% to 0.7% for a standard carcase. Permanent stretch: 0.4% to 0.7% Main Mechanical PropertiesBelt StretchAdhesionBelt StretchAdhesionBelt StretchFastenersMechanical ResistanceDepreaux Underground Safety Belt Information
Depreaux Surface Conveyor Belt Information
Under ideal conditions, the average lifespan of a mining conveyor belt is anywhere from three to ten years, depending on length, transfer design, etc. The nature of the bulk materials you're transporting can also significantly affect belt lifespan.
For example, sharp, jagged, abrasive materials can damage the belt much faster. This is why it's important to choose a belt that's specifically designed for your application and is well-supported in the loading zone.
If your mining conveyor operates in an underground environment, it likely has to comply with MSHA Part 14 fire resistance requirements. Make sure you're fully aware of the rules and regulations that can impact the type of belt you select for your conveyor to ensure you're operating at maximum levels of safety, not to mention staying compliant.
Some belts are made to last longer than others, and certain factors like longevity and durability are important based on the particular type of environment.
Conveyors running underground or transporting material from mines and quarries pose greater demands on the conveyor belt than a line in a factory transporting empty boxes.
Understand your needs when it comes to durability and ruggedness. Failure to consider this could result in productivity loss and increased downtime.
Depending on the thickness of the belt fabric from top to bottom, there is a manufacturer-recommended pulley diameter that you'll need to consider.
Belts can corrode'especially those that incorporate metals into their makeup. While corrosion may not be as much of a worry in a climate-controlled facility, it can pose challenges on underground conveyors where temperatures, UV light, moisture levels, and humidity tend to fluctuate.
Since all belts aren't made for the same applications, they aren't constructed in similar widths or sizes.
For example, the belts you see on the conveyor belt systems in grocery store checkouts are much smaller in width and length than the ones you'd find underground transporting products from the mine.
While many belts can be custom-made to fit a desired length and width, it's always best to know your sizing requirements.
The temperature of the materials you're transporting is another vital consideration. For example, rock and ore that come straight from the ground could be as hot as 220°F. While this is not enough to catch the belt on fire, it could potentially cause irreparable damage.
A belt designed with specific thermal properties can help mitigate damage caused by high-temperature materials.
Check out our Mining Conveyor Belt Maintenance Guide.
Q: What is a conveyor belt for coal?
A: Coal conveyor belts are specifically designed to safely and efficiently move coal from one area to another. West River Conveyors has over 40 years of experience building custom conveyors for the coal mining industry.
Q: Which type of mining uses conveyor belts?
A: Coal, rock, precious metals, iron ore, lead, and lithium are just a few examples of mining operations that use conveyor belts.
Q: What is a quarry conveyor belt?
A: A quarry conveyor belt moves materials, such as sand, gravel, rock, marble, or crushed stone from a quarry site to an endpoint.
Q: What is TPH in a conveyor?
A: The acronym 'TPH' stands for 'tons per hour' and is a critical measurement that determines the ideal conveyor belt to use on a mining conveyor system. It measures how many tons of rock or ore per hour the conveyor belt moves. TPH correlates to belt speed or how fast the belt moves.
Don't overlook the mining conveyor belt when designing the conveyor system for your next project. While there are many different types of conveyor belts to choose from, they are a key piece of the overall puzzle that helps ensure productivity and that your profit goals are not only met'but exceeded.
West River carries a full line of products like Cobra/Depreux Fireshield and Deltatherm belts, conveyor belt replacements, and more. Contact us for more information.
For more Sand Conveyor Beltinformation, please contact us. We will provide professional answers.
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