Whether the concerns are safety, maintenance or dust control, several suppliers have solutions
By Steve Fiscor, Editor-in-Chief
Conveyors serve as arteries for the mines. They deliver to the surface the coal that is won underground. They also move coal from the stockpiles to the prep plants and power plants. Because they operate in series, the loss of one conveyor can bring an entire operation to its knees.
For coal operators, dust control and spillage is a hazard. Fine coal dust can ignite with catastrophic results. Spillage causes excessive wear and downtime.
Recently, several component suppliers and fabricators announced new products and services. What follows is a collection of those announcements.
The Pro-Zone is a fully-enclosed, skirtless transfer. (Image: ASGCO)
ASGCO Offers Load Zone Options and More
Using its decades of experience in conveyor technology, ASGCO has developed several options for transfer points, including impact beds and the Pro-Zone enclosed load zone system. The company’s impact beds, as the name implies, are designed and engineered to protect the conveyor from damage caused by the impact of material falling onto the conveyor at the transfer point. The impact bars, which are manufactured from 40-durometer rubber, are mounted on a heavy-duty, powder-coated steel framework.
The Pro-Zone is a modular load-zone system that is sealed for dust control. ASGCO said that it is the world’s first advanced containment and dust control solution for conveyed bulk materials. The ProZone is skirt-less. Instead, it relies on the company’s Slide-N-Roll beds that employ removable, “slide-out” steel side supports with ultra-high molecular weight (UHMW) bars and an easily removable center roll. The system is completely enclosed and uses curtains to still dust.
The Grip-Trac Rubber Tru-Trainer. (Photo: ASGCO)
The “slide out” allows the UHMW support bars to be changed easily. A new center roll design also allows easy change out. Maintenance techs simply remove the retainer clips and pop the center roller out.
Angled hoods can be easily mounted to the side guards that attach to the Slide-N-Roll frame. The hoods, which can be made out of aluminum or steel, completely enclose the entire system. Inspection doors can be added to the hoods for quick inspection. Inside the Pro-Zone, dust curtains and an internal splash sealing rubber system help contain coal dust.
During September, ASGCO added the “Grip-Trac” Rubber Tru-Trainer Conveyor Belt Tracking Idlers to its line of conveyor accessories. The Grip-Trac tracking idlers combine the company’s patented Tru-Trainer technology with a new, improved design and molded rubber manufacturing process. The new rubber design includes a unique arrowhead design on the ends of the rolls with cross-linked sipes. They are specially engineered on the outer ends of the rolls and inner ribs to reduce slippage and increase grip in wet conditions. This manufacturing and design innovation improves the overall adhesion of the Grip-Trac rubber to the Tru-Trainers, delivering enhanced grip, durability and wear resistance.
ASGCO also maintains a large supply of conveyor belting at its factory in Nazareth, Pa.
The J-Walk installs easily to provide a safe way for miners to cross the conveyor. (Photo: Jennmar)
Jennmar Supplies Conveyor Structure
When it comes to conveyor structure, Jenmar has a large selection, including ground-mounted structure, hanging structure, quick-lock systems, straight return idler assemblies, V-return idler assemblies, offset troughing idlers and in-line troughing idlers.
Jennmar’s conveyor idlers use centrifugal self-cleaning seals, which ensure that bearings reach their designed life. The company said the grease-free sealing elements result in much lower friction values than conventional designs. Jennmar also offers an adjustable top troughing assembly, which adjusts from 10° to 35°.
Jennmar said it can quickly deliver top quality replacement parts. They offer a high level of customization, including large hex, small hex, slot ends, different bearings, idler wall thickness, overall lengths, sizes and shaft requirements. Each idler is tested immediately following the installation of the bearing. This allows them to confirm the quality before they ship any items. The company also offers powder coating, which adds life to the components.
Jenmar offers impact disc rolls with steel reinforced rubber. The impact discs are press fitted onto a conventional steel roller body. Each rubber disc is positively located and there is no possibility of rubbers moving due to impact loads. Spacers and end-stops are not required.
The J-Walk crossover systems are reusable crossover structures and are designed and built with ladders and handrails for extra safety when traversing conveyors. They are quick and easy to install, extremely strong and rugged. Jennmar offers them unpainted, painted or powder coated.
A string of hanging troughed idlers support an underground conveyor. (Photo: Jennmar)
In addition to conveyor accessories, Jennmar stocks belting.
Richwood Offers On-Site Inspection Services
To meet the efficiency and productivity goals of coal operators, Richwood offers inspection services for conveyor systems. Technicians from the company provide a focused, experienced evaluation. The conveyor efficiency survey covers material flow, belt cleanliness, belt misalignment and other factors that may lead to unscheduled downtimes.
Once the inspection is completed, the operator receives a full report along with recommendations based on Richwood’s experience and CEMA standards.
Richwood’s engineered solutions convert problem load zones into worry free zones. They also have accessories that eliminate carryback on conveyors and keep them aligned and on track. The company has products that protect chutes from wear and impact, reduce noise and provide long-term cost savings.
Vayeron Partners With RAM
Vayeron Pty Ltd., based in Mackay, Queensland, announced that it entered a strategic partnership with RAM Enterprise, Inc., a U.S.-based provider of conveyor installation and maintenance services.
Under the agreement, RAM Enterprise will serve as the preferred authorized service provider for Vayeron’s smart conveyor monitoring technology in the USA. The partnership aligns Vayeron’s Smart-Idler technology with RAM Enterprise’s service capabilities to deliver advanced, data-driven solutions for conveyor systems.
West River displays a low-profile conveyor drive at the Bluefield Coal Show. (Photo: Steve Fiscor)
“This partnership reflects our commitment to delivering scalable predictive maintenance solutions to drive operational efficiency,” said Ryan Norris, president of Vayeron. “RAM Enterprise brings deep expertise in conveyor servicing, and together we will help operators reduce downtime, and improve safety and performance.”
Smart Idler enables 24/7 wireless monitoring of conveyor rollers, helping users mitigate fire risk, reduce manual inspections and extend roller life.
Component Compatibility
Mismatched or incompatible conveyor components create more than just minor inconveniences, according to West River Conveyors (WRC). They can lead to unexpected downtime, reduced efficiency and even safety concerns.
For mine operators and maintenance managers, that means lost productivity. For procurement teams, it means sourcing headaches and cost overruns. Ensuring compatibility is critical to extending the life of a system, optimizing performance and keeping production on schedule.
Legacy equipment often adds an extra layer of complexity, WRC explained. Most of the rolls WRC produces are designed to fit seamlessly into legacy systems, and their team can machine or adapt parts as needed to ensure a precise fit.
Beyond rollers and frames, this same compatibility expertise is essential for terminal equipment like drives, where gearboxes and motors must be coupled correctly. While not all components are interchangeable right out of the box, WRC has the in-house capabilities to machine or modify parts so they work seamlessly together.
PM Consulting displays a conveyor transfer at the Bluefield Coal Show. (Photo: Steve Fiscor)
PMC Engineers Conveyor Equipment
Based in Flat Top, W.Va., PM Consulting, LLC (PMC) engineers and manufactures conveyor equipment. The company offers turnkey engineering, conveyor design, parts procurement, drive assembly and delivery. PMC also offers in-house repair services with warranty, new conveyor belt drives, take-ups and tailpieces.
PRC is an Original Equipment Manufacturer (OEM) for multiple power transmission suppliers. The company said they regularly source high-quality parts from Dodge Industrial, Martin Sprocket & Gear, General Electric, Voith and many more leading manufacturers.
The PMC engineering team has more than 40 years of experience in belt design and applications. They work closely with coal operators to understand their needs and develop solutions that meet specific requirements.
Source: www.coalage.com
