MINE MAINTENANCE
A conveyor belt cleaning system that is not‘ off the shelf’ but engineered for the application delivers longer life, less carryback and a cleaner, safer conveyor system overall, according to Richwood
engineered cleaning systems that don’ t require constant adjustment or replacement.“ When a belt cleaner needs frequent attention, operating costs add up in labour, clean up, replacement parts and downtime,” it says.“ By contrast, a cleaning system that is not‘ off the shelf’ but engineered for the application – matched to belt speed, material flow, belt condition, splice type and other specific factors – delivers longer life, less carryback and a cleaner, safer conveyor system overall.”
The best performance starts with a robust self-adjusting actuating system; next is the right blade shape and media. Straight or arrow-shaped blades suit tight, new belts, while contoured forms compensate for belt stretch. Blade materials make a difference as well – durable rubber that is belt- and splicefriendly and composite media like rubber / ceramic or rubber / tungsten carbide can provide exceptional carryback remediation and great wear life, according to the company. Properly specified and engineered belt cleaners will protect pulleys and idlers from trapped debris and extend component life.
In a three-year study of 28 transfers at an underground coal mine in eastern USA, a comparison was made between typical scrapers with standard polyurethane blades and engineered cleaners using rubber and rubber / tungsten carbide blades on belts with multiple mechanical splices. The conveyors operated at 550-600 FPM( 2.79-3.05 m / s) and carried 800-900 tons per hour( 726-816 t / h).
“ Though initially less expensive, the conventional blades required monthly changes, while the engineered system, which seemed more costly on the initial investment, needed only one or two blade changes per year – saving an estimated $ 11,500 per year, per transfer with total savings of $ 960,000 over three years just in
parts( not counting labour and downtime).
“ Fewer interventions also improved safety by reducing time spent on maintenance and clean-up.”
In another client operation – one of the largest copper mines in the world – Richwood engineers developed a cleaning system specifically designed to fit and perform in a very tight conveyor transfer application. The solution included precleaner and secondary cleaner assemblies engineered to fit within the tight chute space, with proper tensioning and blade selection to match belt conditions. This customised approach optimised cleaning pressure and improved contact across the full belt width, ensuring consistent performance even under challenging operating conditions, the company says.
“ The results were measurable and impressive,” Richwood said.“ After installation, carryback was reduced by 160.5 tons per year, and belt availability improved from 96.73 % to 97.14 %. Cleaner blade service life was increased by 50 %, reducing maintenance significantly. The return on investment was immediate – a payback period of only 9.48 months.”
Out for a quick change
Filter press maintenance has long been a leading source of downtime in mineral processing operations, with traditional cloth replacement methods requiring extensive manual labour, specialised lifting equipment and significant safety precautions. The
Strengthening mill liner supply in South America
Last year, Bradken Peru announced a significant investment in South America with the construction of its new, energy-efficient, future-ready foundry in Chilca, Peru.
This expansion, which is already underway, marks a significant milestone in the global growth of Bradken, supporting customers by boosting its capacity to deliver more mill liners to the global market, and underscoring a wider commitment to innovation, sustainability and community development, the company said.
Bradken’ s latest facility has been designed to meet the highest technological and environmental standards. It will have a production capacity of up to 20,000 t / y of steel mill liners, enabling faster, more efficient and more sustainable manufacturing to supply both regional and international markets.“ Utilising the largest equipment in South America and backed by cutting-edge technology that drives energy efficiency and minimises environmental impact, our latest foundry has been designed with a goal of achieving 99.5 % of electricity from renewable sources,” the company says.
The facility will operate within a circular economy framework, focusing on custom alloy production, reducing waste and enhancing recycling practices.
This steel mill liner focused foundry builds on the successful expansion of Bradken’ s composite mill liner capacity at its Lima facility, enabling the efficient delivery of a full range of locally manufactured mill liners to support all mining applications in the South American region, it added.
Bradken will soon be able to deliver a full range of locally manufactured mill liners to support all mining applications in the South American region
The foundry is expected to be fully operational early this year and is projected to create approximately 200 direct and 1,200 indirect jobs.
The company added:“ With more than 103 years of experience and knowledge in foundry and manufacturing operations worldwide, across all conditions, Bradken’ s teams have leveraged the success of their existing four foundries to develop the new facility at Chilca, Peru, ensuring it utilises best practices in process control and quality.”
48 International Mining | JANUARY 2026