The Challenge

Our client operates a 155mtpa iron ore port facility in the Pilbara Region WA. Their existing outload conveyor belts required change out after each 12 week cycle, due to wear in a highly abrasive environment. The client was seeking a 20% improvement on conveyor belt wear performance i.e. belt life mm wear/MT.

Key Benefits

• >20% Reduction in Conveyor Belt Wear
• 50% Reduction in Number of Scheduled Belt Change Outs
• Doubled Shut Cycle Duration

The Solution

• A review to determine optimum belt type for the specific application, and analysis and benchmarking of historical baseline performance data to allow accurate comparison of the results
• Design & manufacture of a high abrasion resistant rubber compound to enable the client to extend belt life and the time between belt change outs
• ITP/QA testing of belt to confirm product designation and compliance
• An embedded engineering resource provided by Fenner Conveyors managed the product life cycle of the belt from “Cradle to Grave”
• Installation & commissioning of the belt on-site (including splice QA & baseline thickness testing)
• Ongoing inspection and monitoring, data collection (BTT and SCADA – tonnes over belt)
• Onsite resource allowed performance optimisation whilst belt is operational
• Belt removal and final testing in a controlled laboratory environment
• Report compiled and presented to client

The Results

• Lost time injury free
• Extended the customers shut cycle from 12 to 24 weeks
• Exceeded the clients KPI of 20% improvement on conveyor belt life performance i.e. belt life mm wear/MT (Top cover wear measured in mm per million tonne of product carried on the belt)
• Belt life increase of 50%, or an additional shutdown cycle of availability @ 84 days
• Reduced the number of scheduled belt change outs – resulting in cost savings and reduced exposure to risk of injury.
• Collection of accurate data from the conveyors, enabling Fenner Conveyors to make recommendations and execute a stepped approach for continuous improvement aligned with client’s needs.
• This project demonstrated an integrated approach between client and OEM to successfully deliver on clients KPI’s
• The client has replaced competitor belts with Fenner Conveyors Ultra
• TuffTM belting on all short cycle belts in their Port Facility operation.