CONVEYOR TECHNOLOGY
fieldbus interfaces . By default , it comes with the web server and Modbus TCP / IP connectivity . indurad ' s iBelt solution is used in bulk handling processes such as loading and unloading of materials in ports and in a variety of other processes that take place in harsh environments . indurad ' s proprietary sensors are part of a multi-purpose solution family that covers real-time inventory control , 2D and 3D stockpile visualisations , machine positioning with high accuracy , speed and volume flow control for conveyor belts , ship loaders and more . indurad solutions are widely used in the mining , marine and bulk materials handling industries on all continents and has local offices in Australia , Brazil , Canada , Chile , Russia and South Africa .
Fenner Dunlop ’ s BeltGauge performs in the Pilbara
Fenner Dunlop has for some years used its Online Thickness Tester ( OTT ) technology to scan conveyor belts but the system has been redesigned to incorporate the latest technology and has been renamed BeltGauge . It measures both belt thickness plus belt tracking and width . With several other solutions it comes under Fenner Dunlop ’ s own iBelt brand for intelligent conveying , all brought together by DigitalHub , its new digital intelligence platform that connects the iBelt technology tools and data sources to mining customer applications . “ It allows you to understand real-time predictions and performance of your assets and effectively plan for maintenance activities .”
“ BeltGauge is our belt wear and forecasting solution . Highly precise sensors continuously measure the belt , predicting the remaining life and identifying atypical wear events allowing you to rectify the issue and elongate the life of the belt . BeltTrack is our belt identification system . Using RFID technology , customers can track their belt and other products with precision from cradle to grave . It also allows you to position the belt in the right location for inspection and repair . CordScan is our steel cord scanning solution . Using the Magnetic Flux Leakage ( MFL ) technology , the conveyor ’ s steel cords are continuously scanned and monitored . It also produces high-resolution maps of the cords condition . RipSaver is our belt rip detection solution . Using inductive loop technology , the belt is continuously monitored for rips . When an event is detected it automatically shuts down the conveyor , reducing the damage and elongating the life of the belt .”
One iBelt solutions client is among the largest producers of iron ore in the world – with their mine in the Pilbara , Western Australia , producing 80 Mt a year . “ Our client was experiencing abnormal wear with one of their main conveyor belts and could only conduct thickness testing every 12 weeks during shutdowns , limiting the visibility and progression of the issue . Specialist resources were needed to analyse and review the data captured manually , and reports were sent by e-mail . The client was seeking an all-encompassing system to automatically measure the wear profile of the cover rubber without stopping operations so that an accurate life prediction could be made .”
Fenner Dunlop installed the BeltGauge device on the troublesome conveyor system and stabilisers were installed to mitigate belt harmonics in the testing area . An autocleaning system was also supplied with BeltGauge to regularly clean sensors and increase maintainability in the very dusty environment with lots of spillages . Client users were setup in DigitalHub , allowing the onsite maintenance team to monitor the wear though the web application portal .
Abnormal skirt wear was identified on the belt following the installation of the BeltGauge and the client organised the belt repair of the skirt areas on the following shutdown , elongating the life of the belt by over 30 %. The mining customer has access to DigitalHub portal , allowing the site personnel to review the current profile of the belt and the latest belt trends . The portal also allowed the maintenance teams to manage belt replacements in a single location and with concise views . The client also receives SMS messages and e-mail if belt wear , tracking or width thresholds were exceeded . “ Despite the very dusty environment , the sensors of BeltGauge performed exceptionally with minimal manual cleaning and without stopping the belt .” There are now zero hours downtime attributable to belt damage . Fenner Dunlop says this project demonstrated an integrated approach between client and OEM to successfully deliver on clients KPIs .
Siempelkamp helps Fenner Dunlop guarantee quality
Siempelkamp has helped Fenner Dunlop expand its Kwinana facility in Western Australia with the delivery of a new steel cord conveyor belt press line including a multi-cylinder press . Fenner Dunlop recently announced it would again expand this facility , with a third steel cord press line set to boost capacity by 50 %.
With this new project , both companies continue their long-standing cooperation in the production of high-quality steel cord conveyor belts , Siempelkamp said . The scope of supply includes the whole production line , especially the multi-cylinder press , which provides , as with both existing press lines from Siempelkamp at this facility , an “ outstanding pressure distribution ” during the full curing process , it said .
“ This state-of-the-art press technology enables our
BeltGauge is part of Fenner Dunlop ' s new iBelt brand for intelligent conveying`
customer to cure conveyor belts from 5-50 mm thickness , providing a unique process accuracy and stability which cannot be achieved with other , traditional press concepts ,” the company said .
The entire machine and process control technology has been developed , tested and implemented by Siempelkamp when it comes to hardware and software . Installation and start-up of the new press line is scheduled for this year .
“ With the new Siempelkamp press line , Fenner Dunlop once again demonstrates its commitment to the growing market for conveyor belts in Australia , a country rich in raw materials ,” Siempelkamp said . “ The use of conveyor belts , compared to the conventional ‘ truck and shovel operation ’, results in considerable CO2 savings when transporting the billions of tonnes of kilometres of bulk materials within the mines , between mine loading stations , and within the loading ports .”
Since 2006 , companies of the Fenner Dunlop Group in Australia and the USA have been relying on Siempelkamp expertise in the area of presses for textile or steel cord conveyor belts , Siempelkamp said .
In 2011 , the Fenner Dunlop Australia subsidiary placed an order for a complete steel cord line for conveyor belt production as part of an initial expansion of the Kwinana plant . With this first line , Siempelkamp said it set three records at once : the world ’ s largest conveyor belt press , the strongest press in the plastics and rubber industry , and the first multi-cylinder press for the Australian market .
“ The multi-cylinder press concept provides plant operators with a particularly even pressure distribution which leads to a more stable process control and thus to more uniform product qualities ,” Siempelkamp said . “ With this new production line , as in both the existing press lines at this manufacturing facility , the creel is equipped with twice the required
46 International Mining | FEBRUARY 2021