CONVEYING
quartile globally ; improve its profitability and cash flow generation ; and cement its position as a leading pure play steelmaking coal producer , the coal producer says .
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Conveyor systems are the backbone of many
BEUMER Group secured an order from Warrior Met Coal to design and supply a single-flight 14 km curved overland conveyor
industries , yet issues like belt rips and unplanned downtime can result in high costs and significant risks . Intelligent monitoring systems , especially those supported by AI , are unlocking new possibilities - not only for maintenance but also for improving safety and operational efficiency .
The Becker Mining Systems BRS4.0 it says goes far beyond simple belt rip detection . By integrating additional sensors , it monitors critical conditions such as belt contamination , heat , vibration , and misalignment . This comprehensive view of the system ’ s health enables preventive maintenance before major damage occurs .
Beyond belt monitoring , AI can significantly enhance workplace safety . By analysing camera image streams and sensor data , it detects when people enter hazardous zones , triggering warnings or even stopping the conveyor in critical situations .
Becker has partnered with AlwaysAI Inc ., a leader in vision AI , to create powerful AI applications for the mining sector . One focus is around belt conveyor surveillance and so the current product portfolio will grow with additional AI features throughout 2025 .
In operation centres , AI reduces the burden on personnel by identifying potential hazards or malfunctions and directing attention to critical events . Instead of monitoring numerous screens and cameras continuously , staff can respond more effectively to focused alerts . This minimises response times , reduces human error , and increases efficiency .
With AI and sensor fusion , belt monitoring is becoming increasingly proactive and versatile . Next-generation systems can not only detect anomalies but also initiate automated countermeasures and provide precise recommendations for action . This ensures operational efficiency while maximising safety . Becker Mining Systems told IM that it is continually working to make its proven BRS4.0 system future-ready . " Our goal is to seamlessly integrate the benefits of artificial intelligence with a wide range of sensors to further enhance efficiency , safety , and sustainability . Companies adopting such technologies not only secure a competitive edge but also lead the way in advancing digitalisation and workplace safety ."
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With consulting firm PWC highlighting cost inflation in mining as a growing risk in recent years , mines are focused on operational efficiency that directly improves project viability , life of mine , and the financial bottom line . A productivity game-changer in materials handling has been Railveyor ’ s hybrid system that leverages the best aspects of rail and belt conveyor technology – while avoiding their limitations . These efficiency benefits also contribute to meeting strategic sustainability targets for lower carbon emissions .
Russ Pietila , Vice-President of Product Development at Railveyor told IM : “ While mining has long relied on rail , conveyors and trucks for materials handling – and developed a close familiarity with these technologies – financial and environmental pressures are leading to a growing appetite for transformative technologies like the Railveyor .”
Particularly where conditions demand the movement of material over steeper gradients and through tighter curves , the Railveyor provides much more flexibility than conventional rail or conveyor systems . While traditional conveyors
52 International Mining | FEBRUARY 2025