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Innovative Conveyor Solutions for Enhanced Efficiency and Safety

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Project Overview

  • 1125 Hours Saved from Flaking vs Traditional Roll Install & Splice
  • Increased Uptime
  • Reduced Total Belt Life Costs
  • Performance Guarantee With Fenner Extended Warranty

The Challenge

Carborough Downs is an underground coal mine located in the Bowen Basin, Queensland. The site’s drift conveyor, which brings all of the underground coal to the surface for processing, was nearing the it’s end of life.

The belt had deteriorated, suffering significant damage and requiring regular, stoppages, repairs and ongoing monitoring. On top of this, the site was also having issues with damaged and faulty rip loops.

Outside regular planned maintenance, a four meter rip occured in the drift belt forcing operations to halt completely. The site was suffering extensive production-loss so could not afford to stop operations for long and required a solution fast. Stopping the drift belt brings the entire operation to a stand still, so replacing the full 3,330 metres as quickly as possible can save hundreds of thousands of dollars.

The Solution

  • Fitzroy Mining called Fenner Conveyors, who immediately sent out a site team to monitor the belt in the lead up to changeout (24/7 monitoring over four days)
  • Due to the significant production loss already suffered, the site suggested completing the changeout in-line with a scheduled long wall move
  • This provided a 90-day window for Fenner to manufacture the steel cord drift belt, complete the changeout plan and schedule, join and lap the belt, and deliver the install before the longwall was complete
  • The belt was manufactured in Australia, decreasing lead-time and allowing Fenner to incorporate built-in rip loops
  • Fenner coordinated large-scale specialised belt handling equipment from across Australia, including Belle Banne manufactured turning frames, flaking stations, and a belt puller from WA
  • Fenner delivered specialised components for the job including a Belle Banne-designed sacrificial base, and ACE-designed hold-down roller frames and pulley structures

The Results

  • Fenner sucessfully delivered the changeout - the first complete steel cord drift belt manufactured for an underground application
  • 1125 hours were saved (equivalent to 18 shifts or 9 days) from flaking the belt, compared to the traditional single roll install and splice method for underground applications
  • The site experienced significantly less breakdowns following the drift belt changeout, significantly reducing the total belt life cost
  • In the 26 week period leading up to belt change out, the conveyor was stopped twice a week. Therefore the changeout saved the site from significant lost-revenue
  • Increased overall uptime of the site by eliminating conveyor down-time associated with rips, tears and busts in the belt
  • The install was completed on-time and in-line with the completion of the the long-wall move, meaning no delays to the production schedule
  • Zero injuries occured during changeout delivery from using Belle Banne & ACE equipment, and Fenner belt reduced safety risks for site personnel moving forward