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Only 1 Roller Replaced in 2 Years: Yeloroll-HD and PU Disc in Copper Mine

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Lightweight CPS rollers still going strong in Chile copper mine after 2 years in service.

In 2023, a major copper mining customer in Chile contacted to CPS for assistance to assist with the problems they were experiencing with return rollers on their overland conveyor. Despite being designed for durability and resilience, the belt which transports dry ore and produces a large amount of fine dust was experiencing premature wear and frequent roller failure, impacting belt productivity.

The Challenge

In the conveyor’s return area, the rubber disc rollers which were part of the original project specification were showing exhibited premature and uneven wear as well as disc failures, increasing maintenance replacement times and impacting the plant’s committed production times.

The Solution

CPS conducted an on-site assessment, to investigate the failure modes of the rollers in operation and the reasons for wear and premature failure. Following this evaluation CPS proposed a
combination of return rollers tailored to specific locations along the conveyor: Yeloroll HD rollers and polyurethane (PU) disc rollers, depending on the location.

PU disc rollers were considered in high-stress and dirt areas, as they offer excellent resistance to fine abrasion, facilitate belt cleaning, and prevent build-up. In straight areas and outside of high-stress area, Yeloroll HD composite rollers, weighing only 9 kg,
were recommended. This significantly improves ergonomics, especially in difficult-to-reach areas.

Both roller types are of great benefit due to their low weight and high reliability. This combination reduces the frequency of roller change-outs, resulting in more efficient, productive, and safer maintenance operations.

The Results

With more than 200 CPS rollers installed on the conveyor belt to date, only one replacement has been reported since the initial installation. CPS will continue to collaborate with the customer, proposing improvements informed by the extensive experience gained across multiple
plants, where we have extended the lifespan of their conveyor systems.