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UsFlex Optimising Performance in ROM Conveyors

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The Challenge

Saraji mine is an open-pit coal mine located in Queensland’s Bowen Basin. One system on-site transports coal at 2400tph in a high impact ROM application, with 95% availability for 8,000 hours per year.

This system was already using a high-quality 5-ply Crows Foot Weave carcass with 8mm M grade covers, suitable for tear resistant applications. However ROM metallurgical coal contains heavy impact material which was causing cuts and gouges to the belt. The excessive tramp metal feeding through the ROM was regularly gouging, cutting and ripping the previous belting, leading to downtime, repairs and eventually belt replacement.

The belting was holding an average life of 23 months (sometimes as little as 15 months), with regular and ongoing repairs from as little as 6 months from installation.

The site needed a solution suited for both tear resistance and high impact resistance.

Key Benefits

  • Belt Life Improved by 289%
  • 36 Hrs Saved From Repairs & Avoided Maintenance
  • Lost Revenue Saved
  • Reduced Total Belt Life Costs

The Solution

  • The site team contracted Fenner Conveyors to trial a solution. Fenner recommended a new belt with an UsFlex carcass for superior rip resistance, and ArmorShield high impact resistant covers.
  • The belt was manufactured in Australia, decreasing lead-time and allowing Fenner Conveyors to custom-make the carcass and covers.
  • In December 2020 of the trial, tramp metal caused damage to the carcass (a gouge 400mm long and 10mm wide) - damage which would typically have torn the full length of most other belts. However due to the impact and rip resistance combined, UsFlex stalled the conveyor, saving the site approximately 2 shifts (24 hours) of unplanned repair works.
  • On multiple occasions during the trial, the UsFlex belt has been exposed to damage, but has endured with basic repairs and continued to operate.
  • In March 2022, the conveyor belt experienced gouging from a large section of wear plate going through the ROM, with minimal damage.
  • The belt was installed in February 2020, and after 42 months is still in operation with minimal ongoing repair work required.

UsFlex Belt 2.5 years after installation with next to no cuts or gouges.

The Results

  • The UsFlex belt more than doubled the belt life, compared to the previous Crows Foot Weave belt.
  • The site experienced less downtime and unplanned maintenance.
  • Repairs, re-splices, inserts take upwards of 36 hours. With current record coal prices, this downtime would quickly run into the hundreds-of-thousands in lost revenue - of which Fenner helped the site avoid.
  • Fenner Conveyors was able to reduce total belt life costs for site.
  • The belt has been in operation for 31 months, enduring severe cuts and gouges with only basic repairs required.
  • The client was extremely satisfied with the performance of the UsFlex belt.