Dramatic reduction in energy use and environmental impactEnvironmental Impact can be achieved with sandwich belt high angleHigh angle conveyorsConveyor that serve as the vital link in any In-Pit CrushingCrushing and ConveyingConveying (IPCCIn-Pit Crushing and Conveying (IPCC)) system. These high angleHigh angle conveyorsConveyor are not new at all, but have not found wide use in IPCCIn-Pit Crushing and Conveying (IPCC) systems where they can realize the greatest advantage. IPCCIn-Pit Crushing and Conveying (IPCC) systems were already realized in the 1970s. With the bulk material haulage limited to conventional open trough conveyorsConveyor, the most direct path out of the open pit was not possible, requiring low angle spiral ramps and/or deep slots and/or tunnels through the high wall of the open pit. These excavations, to accommodate the low angle limitations, represented undesirable impact on cost and on the environment. Against this backdrop, a major study in 1979 sought to develop high angleHigh angle conveyingConveying systems that could continuously haul the mined bulk material directly out of the pit, along the high wall—the shortest distance between the two end points. Between 1979 and 1982, that study developed sandwich belt high angleHigh angle conveyingConveying systems that utilized all conventional conveyorConveyor equipmentEquipment, including smooth surfaced rubber belts that could be continuously scraped clean. These systems had all of the positive features of conventional conveyorsConveyor but overcame the angle limitation. By hugging the bulk material between two belts, the material’s internal friction could be developed to facilitate conveyingConveying at any high angleHigh angle up to 90° (vertical). In 1984, the Majdanpek copperCopper mineMine in Serbia, already using pit perimeter crushingCrushing and conveyingConveying, decided to move their primary crusher deep into the pit and to use a sandwich belt high angleHigh angle conveyingConveying system to elevate the ore continuously, directly out of the pit, along the high wall to the pit perimeter where it then transferred to a conventional conveyorConveyor for the remaining haul to the plant. This significant sandwich belt high angleHigh angle conveyorConveyor was only the second commercial saleSales. Many successful sandwich belt high angleHigh angle conveyorsConveyor followed with the currentCurrent count of commercial installations at more than 200. Despite the great success in the Majdanpek system, its use has not been repeated as part of an IPCCIn-Pit Crushing and Conveying (IPCC) system. The high angleHigh angle conveyorConveyor offers the link to optimizationOptimization of any IPCCIn-Pit Crushing and Conveying (IPCC) system, yet that industry continues to struggle with the use of conventional conveyorsConveyor and haul trucks to achieve the high angleHigh angle function. The results are sluggish low angle conveyorConveyor systems of limited flexibility requiring excessive maneuvering time, excessive excavation and fill, re-handlingHandling and gradingGrading in order to accommodate the low angle limitations. Recent studies have represented resurgence in interest in high angleHigh angle conveyingConveying and have demonstrated the technical and economic advantages along with the reduced environmental footprint. Though the primary purpose is to demonstrate suitability for open pit miningMining applications, this writing will first recap the early development of the latest sandwich belt high angleHigh angle conveyorsConveyor and their commercialization over the last 40 years. Particular emphasis will be on who did what, and when, giving due credit. This will show that since 1979, the constant of the development is the invention and the work of the writer. We will highlight the features that make Dos Santos Sandwich Belt high angleHigh angle conveyorsConveyor particularly energy efficient and suitable for use in the harsh requirements of the IPCCIn-Pit Crushing and Conveying (IPCC) systems, highlighting the success in Serbia and in the latest studies. Finally, we introduce the latest structural support systems for long span, high lift high angleHigh angle conveyorsConveyor. These wire rope suspended systems, we call Flying Sandwich Belts.

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High Angle Conveying the Vital (Missing) Link to In-Pit Crushing and Conveying Systems

  • Joseph A. Dos Santos,
  • Amy Duncan

摘要

Dramatic reduction in energy use and environmental impactEnvironmental Impact can be achieved with sandwich belt high angleHigh angle conveyorsConveyor that serve as the vital link in any In-Pit CrushingCrushing and ConveyingConveying (IPCCIn-Pit Crushing and Conveying (IPCC)) system. These high angleHigh angle conveyorsConveyor are not new at all, but have not found wide use in IPCCIn-Pit Crushing and Conveying (IPCC) systems where they can realize the greatest advantage. IPCCIn-Pit Crushing and Conveying (IPCC) systems were already realized in the 1970s. With the bulk material haulage limited to conventional open trough conveyorsConveyor, the most direct path out of the open pit was not possible, requiring low angle spiral ramps and/or deep slots and/or tunnels through the high wall of the open pit. These excavations, to accommodate the low angle limitations, represented undesirable impact on cost and on the environment. Against this backdrop, a major study in 1979 sought to develop high angleHigh angle conveyingConveying systems that could continuously haul the mined bulk material directly out of the pit, along the high wall—the shortest distance between the two end points. Between 1979 and 1982, that study developed sandwich belt high angleHigh angle conveyingConveying systems that utilized all conventional conveyorConveyor equipmentEquipment, including smooth surfaced rubber belts that could be continuously scraped clean. These systems had all of the positive features of conventional conveyorsConveyor but overcame the angle limitation. By hugging the bulk material between two belts, the material’s internal friction could be developed to facilitate conveyingConveying at any high angleHigh angle up to 90° (vertical). In 1984, the Majdanpek copperCopper mineMine in Serbia, already using pit perimeter crushingCrushing and conveyingConveying, decided to move their primary crusher deep into the pit and to use a sandwich belt high angleHigh angle conveyingConveying system to elevate the ore continuously, directly out of the pit, along the high wall to the pit perimeter where it then transferred to a conventional conveyorConveyor for the remaining haul to the plant. This significant sandwich belt high angleHigh angle conveyorConveyor was only the second commercial saleSales. Many successful sandwich belt high angleHigh angle conveyorsConveyor followed with the currentCurrent count of commercial installations at more than 200. Despite the great success in the Majdanpek system, its use has not been repeated as part of an IPCCIn-Pit Crushing and Conveying (IPCC) system. The high angleHigh angle conveyorConveyor offers the link to optimizationOptimization of any IPCCIn-Pit Crushing and Conveying (IPCC) system, yet that industry continues to struggle with the use of conventional conveyorsConveyor and haul trucks to achieve the high angleHigh angle function. The results are sluggish low angle conveyorConveyor systems of limited flexibility requiring excessive maneuvering time, excessive excavation and fill, re-handlingHandling and gradingGrading in order to accommodate the low angle limitations. Recent studies have represented resurgence in interest in high angleHigh angle conveyingConveying and have demonstrated the technical and economic advantages along with the reduced environmental footprint. Though the primary purpose is to demonstrate suitability for open pit miningMining applications, this writing will first recap the early development of the latest sandwich belt high angleHigh angle conveyorsConveyor and their commercialization over the last 40 years. Particular emphasis will be on who did what, and when, giving due credit. This will show that since 1979, the constant of the development is the invention and the work of the writer. We will highlight the features that make Dos Santos Sandwich Belt high angleHigh angle conveyorsConveyor particularly energy efficient and suitable for use in the harsh requirements of the IPCCIn-Pit Crushing and Conveying (IPCC) systems, highlighting the success in Serbia and in the latest studies. Finally, we introduce the latest structural support systems for long span, high lift high angleHigh angle conveyorsConveyor. These wire rope suspended systems, we call Flying Sandwich Belts.