Case study of improving coal drop prevention in a coal conveyor line - JRC

Mining Category Application

Issues in Coal Conveying Lines at Mining Sites

Frequent Coal Adhesion on Belt

Coal frequently adheres to the belt underside due to material characteristics.
Detached coal falls (spillages）when passing over return rollers, accumulating below the conveyor.
Wet or fine coal increases adhesion, worsening the work environment and increasing cleaning workload.

Safety Risks During Cleaning

Detached coal may accumulate in areas with poor footing or near moving parts.
Cleaning in these locations poses safety hazards to operators.

Controlled Coal Spillage for Optimized Cleaning and Enhanced Safety

By intentionally controlling where coal spillage occurs, cleaning operations can be concentrated and limited, minimizing workload and cleaning area.
Dedicated rollers are used in areas where spillage should be prevented, avoiding unnecessary accumulation.
As a result, risks during cleaning in hazardous locations are significantly reduced, contributing to improved surrounding environment and maintenance efficiency.

fall prevention return roller significantly reduce spillage and depositional on the roof of the building!

Conveyor mistracking and belt lift-off are suppressed, improving stable operation and maintainability.

Suppress Belt Misalignment and Lift-Up for Stable Operation and Improved Maintainability

Issues in Coal Conveying Lines at Power Plants

Belt lift-off at angle change points and forced suppression with wheels, leading to frequent belt damage and mistracking
Belt mistracking before the tail pulley, resulting in reduced conveying stability
Frequent conveyor stops for mistracking correction, causing lower work efficiency and safety

*These issues caused not only conveying troubles but also increased operational costs due to frequent shutdowns and maintenance.

Steel Category Application

Prevent Belt Mistracking and Spillage for Stable Operation and Cleaner Worksite

Issues in Coal Conveying Lines at Steel Plants

Belt Mistracking Caused by Uneven Loading

Belt mistracking occurred due to uneven loading.
This led to material spillage and material loss.
Dust around the conveyor worsened, affecting the work environment.
Prolonged mistracking accelerated wear on belts and rollers, increasing equipment failure risk.

Spillage at the Chute Section

Spillage occurred through the gap between the skirt rubber and rollers.
Frequent cleaning was required.
Dust dispersion negatively affected the work environment.