Power consumption is a major cost consideration with conveyor systems typically consuming the most power on a mine site. This is why Fenner Conveyors have developed a best-in-class offering for energy-saving conveyor solutions through GreenSeries.

We combined real data from a number of sites and projects from across our operational portfolio to create a computer model of a 9km overland conveyor system, running at 4.5m/s with a capacity of 2,500tph. In this instance, the model was built on data from overground and underground coal mining, however many of the technologies and benefits are transferable to operations mining other commodities. The example overland conveyor system is part of an underground coal mine in Australia, utilising less intrusive underground extraction using “bord and pillar” and “longwall” mining methods.

This mine produces high-quality coals with at least 75% of coal produced capable of being used in the making of steel (coking or metallurgical coals), and the balance is exportable thermal coals suitable for the new-generation high efficiency, low emissions power generators. Fenner Conveyors performed static and dynamic power and tension calculations on this system which allow us to make the following assumptions for reduction in power consumption which can be achieved from utilisation of Fenner Conveyors’ GreenSeries conveyor products.

Drawing on our experience across the Fenner Conveyors Group in Australia, a series of calculations were completed to determine the potential power saving opportunities available to the mine through selection of GreenSeries conveyor products.

A thorough understanding of the visco-elastic properties of conveyor belting covers, along with the importance of idler frictions and frame tolerancing, allowed Fenner Conveyors to refine results and compare to other proven systems operating in the field. For this mine application, our best-in-class offering is based on combining the following products: