Nov. 27, 2024
While there are other ways of bringing material to the surface, nothing beats an underground conveyor. A custom-engineered conveyor system is fast, safe, and reliable. It doesn&#;t emit any fumes, can be installed in ways that leave passageways clear for workers and provides the lowest cost per ton moved.
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An underground conveyor is different from those used on the surface, particularly since many underground conveyors are hung from the mine roof. Here we&#;ll review the components included in a complete system and provide some ballpark cost estimates.
The underground areas of a mining operation are an extraordinarily challenging environment. High temperatures, dust, cramped conditions, and poor illumination are all typical and can take a toll on motors, bearings, reducers, and belts. For long-lasting and reliable operation, equipment used underground must be up to the task.
Fire is a particularly serious hazard underground. For this reason, MSHA regulations address methods of fire prevention. This includes the components used in conveyor systems and especially conveyor belt materials. Many conveyor belts used underground must comply with MSHA Part 14 regulations for fire resistance. However, depending on the underground gas classification, another MSHA specification may be required.
A typical underground conveyor brings coal, salt, copper, potash or other material from where it&#;s extracted to the surface. In many mines, this involves a substantial change in elevation which places additional loads on the system.
Once at the surface, the material is typically transferred to an overland(surface) transfer or stacker conveyor. This means there&#;s a rock box or transfer chute at the discharge end of the belt.
Details depend on the specific application, but most underground conveyor systems include the following:
An underground conveyor is inherently more expensive than one designed for overland or surface use. This stems from the need for fire-resistant materials and dust protection. However, the structure can be less complex than that used outside as the passageway floor or roof can provide mounting points.
Here&#;s a look at these points and others that affect system cost:
Structure can be floor or roof mounted. Good quality structure incorporates CEMA standard idler rollers and is powder-coated for corrosion protection. Structure is priced per foot and can range from as low as $40.00 per foot to $150.00 per foot depending on required belt width, CEMA rating, shell thickness, and structural support requirements. The higher the CEMA rating and wider the belt width, the higher the cost.
This is made up of a motor or motors plus couplings and reducers. It also requires a motor starter.
Motors can be pricey: figure about $25,000 for 300 hp.
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Several types of starter are available. VFDs offer the greatest energy savings and control but are higher cost, approximately $50,000-$60,000 for a pair of 300 hp motors. Complex motor control systems will also need a control panel at an additional $20,000.
Across-the-line starters are the least expensive option but use more power and impose higher loads and more wear on the system. These would cost $15,000-$20,000. In between VFDs and across-the-line starters are soft starters. These reduce wear but provide little in the way of energy savings.
The belt is one of the more expensive elements of a conveyor system, especially in underground applications where fire resistance is oftentimes mandatory. Cost depends on belt width, (mining belts usually range from 36-60&#;), strength (expressed in pounds per inch of belt width (PIW), and the number of plies.
Depending on these variables, an underground conveyor belt costs between $25-$100/ft.
The cost of this depends on capacity, height, and design characteristics. A simple rock box could be in the region of $5,000-$15,000 while a more complex transfer chute might be $15,000-$30,000.
The cost of moving underground conveyor systems from our factory in Oakwood, VA depends on distance. For budgeting purposes, use $5,000-$10,000.
While an underground conveyor system may have higher up-front costs than alternative methods of bringing material out of a mine, lower energy, and maintenance costs plus improved safety and avoidance of fumes quickly make it the most economical.
The cost of a complete system depends on the individual application. However, to give an indication, consider a system with a capacity of 300 tph and a belt 30&#; wide moving at 450 feet per minute over 1,000 feet. Here the total cost, including alignment-free drive, takeup unit, tail section, starter, structure, and belt would probably be in the range of $275,000-$400,000.
West Rivers Conveyors are specialists in underground systems and have a long track record of successful projects. Click below to have us quote your next system.
SPEAK TO AN EXPERT
Installing a conveyor system can be a complex process, but with the right information and support, you can choose the right conveyor system for your needs and maximize its benefits. Consider the factors outlined in this guide, work with experienced conveyor installers, and invest in high-quality equipment and maintenance to ensure the success of your conveyor system.
For more information or to request a quote for conveyor system installation or maintenance services, contact Horizon Industrial Services today.
If you are looking for more details, kindly visit Mining Conveyor Belt.
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