Engineered Conveyor Solutions for Mineral Sands Operations
Reliable, efficient, and high-quality conveyor systems designed for the unique requirements of mineral sands projects.
Conveyor Solutions Powering Mineral Sands Operations
Mineral sands operations rely on conveyor systems capable of handling fine, high-value materials with fluid-like behaviour and highly specific physical properties. Materials such as rutile, zircon, and ilmenite present unique conveying challenges, from low angles of repose and fluidised material flow to severe spillage and carryback. Fenner Conveyors delivers purpose-engineered conveyor systems designed to prevent material loss, withstand chemical degradation, and protect product integrity across wet and dry mineral sands processing environments.
Fenner Conveyors delivers engineered mineral sands conveyor solutions across both wet and dry processing environments. Combining specialised belt cover chemistry, advanced component engineering, and complete turnkey installation, our purpose-built systems prevent material loss, maintain high throughput, and lower total lifecycle costs from pit extraction to heavy mineral concentrate (HMC) separation and export loading.
Core Operational Challenges
Handling Free-Flowing Materials
Fine, dry mineral sands behave like liquids, demanding precise belt carcass construction and custom troughing to control flow and maintain throughput.
Spillage & Carryback Control
Low angles of repose cause material to shift rapidly, requiring engineered belt scrapers, skirt systems, and specialised profiles to eliminate carryback.
Unique Material Properties
Rutile, zircon, and heavy mineral concentrates require specialised engineering to accommodate high bulk densities and abrasive wear profiles.
Chemical and Process Resistance
Reagents, flotation oils, and processing chemicals rapidly attack standard rubber compounds, necessitating custom chemical-resistant belt covers.
High-Value Product Protection
Spillage and degradation of costly mineral sand concentrates directly erode profit margins and create site safety hazards.
Conveyor Solutions for Mineral Sands
- Turnkey Conveyor Systems & Engineering
- Bucket Elevators
- Custom Belt Cover Compounds
- Chevron Belting for Steep Inclines
- Conveyor Belt Refurbishment Services
Turnkey Conveyor Systems & Engineering
Managing mineral sands projects through separate equipment vendors introduces project risks, operational mismatches, and fragmented accountability. Fenner Conveyors simplifies project delivery by providing end-to-end turnkey conveyor solutions—incorporating belt manufacturing, structural design, pulleys, idlers, electrical automation, and on-site commissioning under a single Australian engineering team. Our integrated approach ensures all components are balanced for fine mineral handling, reducing downtime, streamlining installation, and optimising long-term plant performance.
Bucket Elevators
Transporting fine, heavy minerals vertically requires specialised bucket elevator belting designed to prevent material rollback and product loss in tight processing layouts. Fenner’s bucket elevator conveyors feature high-tensile carcass constructions fitted with custom bucket attachments engineered specifically for fluid-like materials such as rutile and zircon. Built with chemical- and oil-resistant cover compounds, these continuous-duty vertical handling systems minimise carryback, resist abrasive wear, and integrate seamlessly into wet separation plants and dry product storage facilities.
Custom Belt Cover Compounds
Processing chemicals, flotation reagents, and natural mineral oils quickly penetrate standard rubber belting, causing severe swelling, cover softening, and premature belt failure. Fenner Conveyors formulates custom belt cover compounds engineered to withstand specific chemical environments, high temperatures, and severe abrasive wear from sharp mineral sands. By tailoring rubber chemistry to the exact chemical composition of your ore stream, Fenner extends belt service life, protects internal carcass fibers, and prevents costly unplanned downtime.
Chevron Belting for Steep Inclines
Conveying fine heavy minerals on steep inclines requires positive profile engagement to prevent material rollback and spillage. Fenner Chevron belting features one-piece moulded cleats integrated directly into the top cover, allowing smooth transport of rutile, zircon, and wet concentrate on inclines up to 40 degrees. Available in open and closed profile designs, our chevron belts utilise high-performance, abrasion-resistant compounds that reduce plant footprint, eliminate cleat detachment, and cut overall capital installation costs.
Conveyor Belt Refurbishment Services
In mineral sands operations, surface cover wear often occurs while the underlying belt carcass remains structurally sound. Fenner’s Conveyor Belt Refurbishment Service strips away damaged rubber covers, inspects internal carcass integrity, and applies fresh, chemically engineered cover compounds tailored to your operational needs. This sustainable, cost-effective service restores belt performance at a fraction of the cost of new belting—reducing capital expenditure, minimising waste, and ensuring rapid turnaround times for critical processing lines.
Frequently Asked Questions (FAQ)
Heavy mineral sands (such as rutile, zircon, and ilmenite) are often conveyed wet or alongside processing chemicals, flotation reagents, and mineral oils. Standard natural rubber belts absorb these oils and chemicals, leading to cover swelling, softening, and premature failure. Custom-engineered synthetic compounds (such as oil-resistant and chemical-resistant polymers) maintain mechanical strength and prevent delamination under continuous chemical exposure.
Because fine mineral sands behave almost like liquids on inclined conveyors, flat belts experience severe material rollback and edge spillage. Fenner Chevron belting incorporates one-piece moulded rubber cleats that trap fine particles and elevate them smoothly on inclines up to 40 degrees—reducing required conveyor footprint and capital installation costs.
Bucket elevator conveyors offer enclosed, space-saving vertical transport for fine, free-flowing mineral concentrates. By housing heavy-duty bucket attachments on high-tensile FRAS or oil-resistant belting, bucket elevators move material vertically without dust emissions, edge leakage, or rollback—ideal for space-constrained separation plants and silo loading.
In many wet mineral sands applications, the rubber top cover wears down from abrasion while the internal fabric or steel cord carcass remains in excellent condition. Fenner’s refurbishment service strips the old cover, inspects the carcass using advanced non-destructive testing, and re-covers the belt with fresh rubber. This restores full belt performance at significantly lower cost than purchasing new belting.
