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CPS Rollers Increase Reliability of Critical Belt in Pebbles Circuit

A major customer in Chile approached CPS to address issues related to a critical 42” wide belt part of their pebble circuit. The system was experiencing significant problems with roller reliability, leading to frequent replacements and lost production.

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The Challenge

The conveyor faced two main challenges:

  • Roller Seizures - The load rollers were experiencing seal failures, resulting in frequent seizures. This problem required regular maintenance and caused operational disruptions.
  • Rapid Wear and Material Buildup - The flat return rollers with rubber discs, especially on the convex curve, were wearing rapidly, with an average life of only 42 days.

The Solution

A thorough analysis of the conveyor belt was carried out to propose efficient solutions, and to reduce roller change-outs.

Loading Zone Solution:

CPS recommended the installation of Yeloroll-HD Premium rollers near the head pulley where the ore is transferred to a silo. The composite roller technology significantly extended the life of the rollers, eliminating the need for frequent replacements.

In addition, it improved the safety of maintainers in high altitude areas, as the weight of the rollers was reduced from 13kg (steel) to just 7kg (Yeloroll HD).

Return Zone Solution:

To address the problems of rapid wear and ore build-up, CPS proposed a two-pronged solution.

  1. PU Spiral Rollers: For the mineral build-up area, CPS installed PU spiral rollers which help clean the belt and prevent mineral build-up. This helped maintain smooth conveyor operation in that specific section.
  2. PU Disc Rollers: The previous rollers in the high abrasion areas were replaced with CPS PU Disc Rollers, resulting in extended roller life in fines and high humidity operating conditions. After installation, these CPS rollers operated effectively for over 100 days without showing signs of premature wear or experiencing leaks or water ingress problems that are particularly common in pebbles circuit belts.

The Results

 The implementation of CPS PU Spiral Rollers and PU Disc Rollers yielded significant improvements. The new rollers have extended the wear ratio by five to six times compared to the previous roller configuration. This improvement has substantially reduced the frequency of roller replacement, saving time and costs for the customer. All CPS rollers include a fixed cover that protects the SKF bearings installed in all units. This preventative measure prevents damage to the bearings, ensuring improved roller performance and service life.