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Reduced Total Cost of Ownership (TCO) on Copper Leach Pad Conveyor

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A client contracted CPS to investigate their high usage of steel garland idlers in order to improve the reliability of the conveyor. CPS recommended the use of a triple labyrinth sealing arrangement, alongside Yeloroll HD carry rollers and polyurethane spiral rollers, which led to a significant cost saving alongside improved conveyor output and reliability.

The Challenge

Site operations were experiencing particular difficulty with a highly abrasive leach pad conveyor. Rollers from various manufacturers had been installed on site to try and fix the high failure rate, however, they were still replacing the best garland sets out 4 times per year. This caused significant conveyor downtime and expenses incurred with changing out the rollers.

 

The Solution

CPS investigated the failure mode of the installed rollers and proposed a small scale trial to prove the concept of premium composite rollers to the client. Yeloroll HD carry rollers were installed on the carry side of the belt in a garland arrangement. These rollers were 32% lighter than the existing steel rollers and provided the client with a risk free roller option due to the belt friendly qualities of the composite rollers.

Polyurethane spiral return garlands were installed on the return side of the belt. This was to combat the abrasive characteristics of the material and provide extra cleaning for the dirty belt.

6 months since installation and after processing 9,443,979 tonnes, the Yeloroll HD rollers and polyurethane were in excellent condition with minimal signs of wear.

CPS determined the rollers would last at least 1 year and deemed the trial successful. On publication of this document, the trial rollers are still installed on the conveyor 18 months later with no issues, further improving the return on investment.

Total Cost of Ownership

Considering the useful life of the CPS rollers, versus the rollers currently in use.

Considerations:
  • Estimated durability of CPS garlands, 12 months
  • CPS cost, according to prices of load and return garlands installed, 
  • (16 Yeloroll HD Carry garlands / 8 Spiral PU return collars)

Cost analysis excludes:

  • Cost of labour
  • Cost relating to operational continuity (Unscheduled maintenance). 
  • Elimination of conveyor belt damage risk. 
  • Reduction of physical exposure of accidents for fitter.

The Results

CPS determined the rollers would last at least 1 year and deemed the trial successful. On publication of this document, the trial rollers are still installed on the conveyor 18 months later with no issues, further improving the return on investment.