dos santos 2012

High Angle Conveying, Vital Link

to

IPCC Systems (In-Pit Crushing and Conveying)

Joseph A. Dos Santos

Dos Santos International Marietta, Georgia, USA

Sandwich Belt High-Angle

Conveyors

History

The Technology

Installations

From Research To Reality

The DSI Snake Sandwich High Angle Conveyor

Product

of Evolution

History of

Sandwich Belt

High-Angle

Conveyors

Cover Belts of the 1950s

Cover Belt -Schematic

RUBBER TYRES PRESS COVER BELT ONTO MATERIAL

Sandwich Belt Model #1

= Conveying Angle m = Coefficient of friction for bulk material on bulk material b = Coefficient of friction for bulk material on belt N = Normal lineal hugging load exerted by the top belt Wm = Lineal weight of bulk material

1950s - First Sandwich Belt Model

Loop Belts of the 1970s

Loop Belt -Schematic

Loop Belt Demonstration Unit

1970s

First use of Radial Pressure due to Tension

Pr = T

R

Dos Santos Sandwich Belts

of the 1980s

The Prophecy: A Sandwich Belt High Angle Conveyor, rationalized in the

Conventional Conveyor Technology, will have the operating characteristics of a conventional conveyor:

High Reliability and Availability

Low Operating and Maintenance Costs

S-Shape Sandwich Conveyor -Schematic

Snake Sandwich Conveyor -Schematic First disclosure of Snake

Sandwich High Angle Conveyor

Mechanically Presses Sandwich Conveyor -Schematic

First disclosure of Mechanically Pressed Sandwich High Angle

Conveyor

Sandwich Belt Model #2

, m, b, N, Wm are as defined for Sandwich Belt Model #1

Nm = That portion of N which bears directly on the conveyed material Ne = That portion of N which bears directly on the edges of the bottom belt e = Coefficient of friction at the interface of the top and bottom belts

Snake Sandwich Conveyor Model

1

2

3

4

5

6

7

Sample Profile and Details

DSI Snake Sandwich High Angle Conveyor

1

2

3

4

5

6

7

1. Loading onto bottom belt between skirts

1

3

4

5

6

7

2

2. Top belt joins bottom belt to sandwich material

1

2

4

5

6

7

3

3. Curve 1, bottom belt hugs material against top belt

1

2

3

5

6

7

4 4. Inflection 1 between curves 1 and 2

1

2

3

4

6

7

5

5. Inflection 2 between curves 2 and 3

1

2

3

4

5

7

6

6. Inflection 3 between curves 3 and 4

1

2

3

4

5

6

7

7. Material discharges from between belts

Snake Conveyor Profiles

Snake Conveyor Basic Profiles

Snake Conveyor Extended Profiles

Continuity of Hugging Principle

Material Hugging Pressure must be continuous and uniform. It must hug all of the material always, without lapse even at the smallest scale

Radial pressure due to tension is the ideal way to apply hugging pressure

Capacity

Material Size

Belt Speed

Belt Width

Other Characteristics:

Dos Santos Sandwich Belt High Angle Conveyors

for

IPCC Systems

(In-Pit Crushing and Conveying)

The Most Common Concern: Are Sandwich Belt High Angle Conveyors suitable for in-pit mining applications? Particularly: Can they handle very high conveying rates? Are they suitable for continuous operation 24/7? Can they handle large, heavy, primary crushed ore and waste rock?

Subsequent installations will answer these questions

The most important concern: Can they handle large, heavy, primary crushed ore and waste rock?

Large belts can handle large lumps, small belts cannot.

Dos Santos Sandwich Belt High Angle Conveyors

Select Highest Rates, Coarsest Materials

Recommended Maximum Lump Size:

Predominantly Lumpy Material (> 10%) 0.1140 x Belt Width

Occassionaly Lumpy Material (< 10%) 0.1425 x Belt Width

>10%Lumps >10%Lumps

DS 001 1524 174 217 254 0.1667

DS 002 1524 174 217 154 0.1010

DS 003 2000 228 285 250 0.1250

DS 004 1829 209 261 154 0.0842

DS 005 914 104 130 154 0.1685

DS 011 1372 156 196 203 0.1480

DS 012 914 104 130 135 0.1477

DS 022 1219 139 174 100 0.0820

DS 023 1829 209 261 102 0.0558

DS 024 1067 122 152 152 0.1425

DS 026 1524 174 217 203 0.1332

DS 027 1219 139 174 203 0.1665

DS 030 1524 174 217 228 0.1496

DS 036 1219 139 174 250 0.2051

DS 037 1372 156 196 152 0.1108

DS 038 1372 156 196 203 0.1480

DS 043 1067 122 152 152 0.1425

DS 051 1372 156 196 152 0.1108

DS 065 2134 243 304 305 0.1429

DS 077 2134 243 304 152 0.0712

DS 078 762 87 109 102 0.1339

DS 079 762 87 109 100 0.1312

UHAC 2600 296 371 350 0.1346

Belt WidthRecc Max Lump Size Design

Lump SizeDSSBI

Max Lump /

Belt Wdth

BW/9

BW/7

Sandwich Conveyor Test & Demonstration

Materials - Various, from light weight wood chips

to heavy course ores

- Density - 0.27 to 2.4 t/cu-m (17 to 150 PCF)

- Size - To 254 mm (10) minus Conveying Rate - To 2700 t/h (3000 STPH)

Conveying Angle - Variable 30 to 60 degrees

Belt Width - 1524 mm (60) Belt Speed - Variable to 6.1 m/s (1200 FPM)

Lift - Variable 7,900 to 19,50032 mm (26 to 64) Length - 35,000 mm (115) Drives

- Top Belt - 74.6 kW (100 HP)

- Bottom Belt - 111.8 kW (150 HP)

DS

001

DS 001 1524 174 217 254 0.1667

Sandwich Conveyor

for

Coal Mine, Western USA

Material - Coal

Conveying Rate - 2540 t/h (2800 STPH)

Conveying Angle - 60 degrees

Belt Width - 1524 mm (60) Belt Speed - 5.33 m/s (1050 FPM)

Lift - 32,900 mm (108) Length - 35,000 mm (115) Drives

- Top Belt - 149 kW (200 HP)

- Bottom Belt - 224 kW (300 HP)

DS

002

DS 002 1524 174 217 154 0.1010

Sandwich Conveyor

for

Copper Mine, Eastern Europe

Material - Copper Ore

- Density - 2.08 t/cu-m (130 PCF)

- Size - To 250 mm (10) minus Conveying Rate - 4000 t/h (4409 STPH)

Conveying Angle - 35.5 degrees

Belt Width - 2000 mm (78.7) Belt Speed - 2.85 m/s (561 FPM)

Lift - 93,500 mm (307) Drives

- Top Belt - 450 kW (600 HP)

- Bottom Belt - 2x450=900 kW (1200 HP)

DS

003

DS 003 2000 228 285 250 0.1250

DS

004

Sandwich Conveyor

for


Material - Coal





- Top Belt - 149 kW (200 HP)


DS 004 1829 209 261 154 0.0842

Sandwich Conveyor

for

Metro Project, Los Angeles, CA, USA

Material - Excavated Earth





- Top Belt - 22.4 kW (30 HP)


DS

005

DS 005 914 104 130 154 0.1685

DS

011

Sandwich Conveyor

for


Material - Raw Coal


- Size - 203 mm (8) minus Conveying Rate - 1089 t/h (1200 STPH)




- Top Belt - 93.2 kW (125 HP)


DS 011 1372 156 196 203 0.1480

DS

012

Sandwich Conveyor

for

Coal Prep Plant, Eastern USA

Material - Refuse


- Size - 135 mm (5.3) minus Conveying Rate - 454 t/h (500 STPH)

Conveying Angle - To 41 degrees



- Top Belt - 186.5 kW (250 HP)


DS 012 914 104 130 135 0.1477

Sandwich Conveyor

at

Underground Gypsum Mine, Eastern USA

Material - Gypsum Rock






- Top Belt - 37.3 kW (50 HP)


DS

024

DS 024 1067 122 152 152 0.1425

Unit 026

Material - Raw Coal






- Top Belt - 93.2 kW (125 HP)


Unit 027

Material - Oversize Coal


- Size - 2033X51mm (8x2) Conveying Rate - 272 t/h (300 STPH)



Lift - 14,900 mm (49) Length - 38,200 mm (125.5) Drive

- Top Belt - 14.9 kW (20 HP)


Sandwich Conveyors

for


DS

026

DS

027

DS 026 1524 174 217 203 0.1332

DS 027 1219 139 174 203 0.1665

Sandwich Conveyor

for

Gold Mine, Western USA

Material - Gold Ore





Lift - 28,900 mm (95) Length - 58,400 mm (191.5) Drives

- Top Belt - 37.3 kW (50 HP)


DS

036

DS 036 1219 139 174 250 0.2051

Sandwich Conveyor

at

Tunnel Excavation Project, Midwest USA

Material - TBM Muck






- Top Belt - 186 kW (250 HP)


DS

037

DS 037 1372 156 196 152 0.1108

DS

051 Sandwich Conveyor

at

Oil Refinery, Pet Coke Plant, Southern USA

Material - Hot Petroleum Coke

- Density - 0.85t/cu-m (53 PCF)


Conveying Angle - 72.5 degrees


Lift - 26,200 mm (86) Length - 53,000 mm (173.9) Drives

- Top Belt - 56 kW (75 HP)


DS 051 1372 156 196 152 0.1108

Sandwich Conveyor

for

Self-Unloading Ship, Great Lakes USA

Material - Coal, Limestone, Iron Ore


- Size - To 305 mm (12) minus Conveying Rate - To 3993 t/h (4400 STPH)




- Top Belt - 186 kW (250 HP)


DS

065

DS 065 2134 243 304 305 0.1429

Sandwich Conveyor

for

Self Unloading Ship, Great Lakes USA

Material - Various


- Size - 152 mm (6) minus Conveying Rate - To 4264 t/h (To 4700 STPH)



Lift - 18,300 mm (60.3) Length - 166,000 mm (545) Drives

- Inner Belt - 298 kW (400 HP)

- Outer Belt - 298 kW (400 HP)

DS

077

LOADING

DISCHARGE

DS 077 2134 243 304 152 0.0712

Dos Santos Sandwich Belt High Angle Conveyor in IPCC System

Majdanpek Copper Mine, Serbia, Yugoslavia

Majdanpek Mine

Rock Belt Feeder

The Majdanpek IPCC System, first five years performance 1992-1997: Precluded tripling of the truck fleet (eliminated 10 trucks) Precluded the need for 4 km of haulage ramps, 3.5 km of which would be of constant ascent Savings of US $12 million per year

UHAC

The vital link for a versatile IPCC System in Western Australia

Are Sandwich Belt High Angle Conveyors suitable for in-pit mining applications? Yes! The many installations presented demonstrate: They can handle very high conveying rates They are suitable for continuous operation 24/7 High tonnage requirements are handled by wide belts which can easily handle large, primary crushed material Conscientious design by DSI will ensure long life with minimal maintenance

Thank You

dos santos 2012

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