Spiral Rollers and Polyurethane Discs on a Pebble Belt
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In early 2025, a major client in northern Chile informed CPS of the issues they were experiencing with the steel return rollers on one of their belts in the pebble circuit, as the rollers were failing prematurely due to wet abrasion against the metal surface. The belt transports ore containing a large amount of water during the process.
The Challenge
In the return section of the pebble belt, conventional steel rollers show signs of abrasive wear within a short period of time due to mineral buildup, leading to premature replacement and operational risks.
The Solution
CPS conducted an on-site assessment during which it gathered valuable information about the defects detected in the rollers and the cause of their premature wear. At that time, it was proposed to use a mix of CPS rollers. It was determined that Polyurethane Spiral Rollers and Polyurethane Disc Rollers would be installed depending on the location.
It was decided to use Spiral Rollers in the area near the head pulley to remove as much material as possible that the scrapers fail to remove. Similarly, it was proposed to install Polyurethane Disc Rollers downstream, where the ore had been removed, given their excellent abrasion resistance in the event of material buildup on the structure.
With this product combination, the belt cleaning has improved, thereby helping to maintain belt reliability. Both roller models also contribute to improved ergonomics, especially in high-altitude and hard-to-reach areas. The CPS rollers stand out for their low weight and high reliability, increasing the time between stoppages for replacement, as well as enabling more efficient, productive, and safe maintenance.
The Results
After more than 10 months of operation, no roller replacements have been reported, and they continue to operate effectively, achieving three times the service life of conventional steel rollers to date.
CPS will continue to work with the customer, proposing improvements based on the experience gained at various plants and conveyor systems.
