Bulk material handling is an integral part of quarry mining operations. From the time the material is excavated from the ground to the time, it is transported to its final destination, bulk material handling equipment is used to move, control, and process the material.
There is a variety of bulk material handling equipment available, each with its own unique set of features and benefits. They are used to transport, process, and store materials such as coal, ores, concrete, and cement in industrial facilities.
8 Commonly Used Bulk Material Handling Equipment
A conveyor system is one of the most commonly used pieces of bulk material handling equipment. It is used to move products and materials from one point to another and can be either stationary or mobile.
Conveyor handling systems can be made up of multiple parts, including:
- Belts
- Rollers
- Pulleys
- Motors
- Drivers
- Frames
Here are various equipment used by processing plants in the mining industry:
Overland Conveyors
Conveyors are used to transport bulk materials from one point to another. They can be used to transfer material over long distances or to move material up an incline.
Overland conveyor systems are a type of conveyor that is commonly used in the mining industry. They are designed to transport bulk materials over long distances. Overland conveyors are typically composed of a series of trusses that support rollers that carry the material.
Downhill Conveyors
Downhill conveyors are a type of conveyor that is used to transport bulk materials down an incline. They are typically used in mining operations to transport material from the mining site to a processing plant. Downhill types are handling systems that are typically composed of a series of trusses that support rollers that carry the material.
Curve Conveyors
Curve conveyors are a type of conveyor that is used to transport materials and/or minerals around curves. They are typically used in mining operations to transport material from one section of the mine to another.
This type of conveyor system is more suitable for a range of materials that are not too heavy or bulky and can be easily transported around curves.
In-Plant Conveyors
In-plant conveyors are a type of conveyor that is used to transport materials and minerals within a processing plant. They are typically used in process operations to transport material from one stage of the process to another.
Ship Loaders
Ship loaders are a large type of conveyor that is used to load materials onto ships. They are typically used in ports and docks to load cargo such as coal, ores, cereals, and other kinds of dry bulk minerals.
As a part of a larger material handling system of processing plants, ship loaders are connected to land-based conveyor systems that transport the material to the ship loader via a tripper car. They are often positioned at dock or port locations where they can load the material and products onto the ship.
Ship Unloaders
Ship unloaders are a type of conveyor that is used to unload materials and minerals from ships. They are used in ports and docks to unload cargo such as coal, ores, cereals, and other kinds of minerals.
As a part of a larger material handling system of processing plants, ship unloaders are connected to land-based operating systems that transport the material away from the dock or port and to the trucks of various manufacturing and/or mining companies. They are often positioned at dock or port locations where they can unload the material and products from the ship.
Stackers and Reclaimers
Stackers and reclaimers are a type of material handling equipment that is used to stack materials and minerals and then reclaim them later. They are typically used in mining operations to store material that has been mined and processed. Stackers are used to stack the material, while reclaimers are used to retrieve it.
Stackers and reclaimers are often used in conjunction with each other. Stackers are used to stack the material in piles, while reclaimers are used to retrieve it from the piles.
Both stackers and reclaimers can be either stationary or mobile. Stationary stackers and reclaimers are typically used in large-scale applications such as mining operations, while mobile units are used for smaller applications such as construction sites.
Power Generating Conveyors
Power Generating Conveyors are conveyors that are capable of generating electricity while the material is being conveyed. These conveyors have a downhill route. In order to prevent the system from over speed caused by natural gravitation force, the potential energy has to be “pulled out” of the system. Therefore a control system with electronic brake system has been developed by QM.
With that system, it is possible to brake the downhill conveyor electrically and wear-free. In addition the potential energy of the material is converted into electrically energy, which is feed back to the grid and can be used for other plants. With that solution a negative energy balance of the conveying system can be realized. This means not only the material transport is completely energy free; in addition electrical energy can be generated from the transportation.
In case of power failure a special brake system ensures the safe stop of the complete system. Highest safety standards have been met. Frequency converters are used as drive unit to ensure smooth start and stop of the more than 700m long conveyors
Advantages of Using Conveyor Over Truck Transport
It’s recommended to use systems of conveyor machines and equipment for transporting, loading, and handling material from mining operators and industries.
The belt conveyors as well as overland are some of the most common handling components of all big mining company operators in the world.
Although there’s an option to use truck transport, there are many advantages that make this method a compelling option for big companies. Here we will look at some of the reasons that explain why:
Cost
The first advantage is the cost. The total cost of ownership (TCO) for a truck transport system is much higher than for a conveyor system.
This is because of the high maintenance costs associated with trucks, as well as the high fuel costs. In contrast, conveyor handling systems have much lower fuel and maintenance costs. As a result, the TCO for a conveyor system is much lower than for a truck transport system.
Capacity
The second advantage is the capacity. Conveyor handling systems have a higher capacity than truck transport systems. This is because trucks are limited by the number of axles they have, while conveyor handling systems are not. As a result, they can transport more material than truck transport systems.
Speed
The third advantage is the speed. Conveyor handling systems can operate at much higher speeds than truck transport systems of material handling.
This is because conveyor belts can move much faster than trucks. As a result, they can transport material much faster than truck transport systems.
Safety
The fourth advantage is safety. Conveyor systems are much safer than truck transport systems. This is because there is no risk of a rollover, and the material is always securely fastened to the conveyor belt.
In contrast, truck transport systems can be very dangerous, as there is a risk of a rollover.
Environmental Impact
The fifth advantage is the environmental impact. Conveyor systems have a much lower environmental impact than truck transport systems.
This is because conveyor belts generate very little pollution, while trucks generate a lot of pollution. As a result, they are much better for the environment than truck transport systems.
Efficiency
The sixth advantage is efficiency. The systems can operate 24 hours a day, 7 days a week, which increases productivity.
It can also be used in all types of weather conditions. The systems are not affected by snow, rain, or wind.
Flexibility
And the last advantage is its flexibility. The system can be easily modified to meet the changing needs of the company.
Positive Environmental Aspects of Using Efficient Material Handling Equipment and Design
Quarry mining operations can have a negative impact on the environment if they are not properly managed. However, there are a number of ways to mitigate these impacts and create a more positive environmental footprint.
Here are some reliable and common practices used in various mining services and designs:
Encapsulation
Encapsulation is a common solution for quarry mining operators to lower noise and airborne pollution levels at the worksite. This method involves completely sealing off the work area from the rest of the quarry using a large curtain or tarp.
The tarp is placed around the work area and connected to a vacuum system that pulls all of the contaminated air out of the work area and exhausts it away from the site. This leaves only clean, fresh air for the workers to breathe.
Using Other Energy Sources
Another great way to reduce environmental impact is to use electric-powered material handling equipment. This not only cuts down on emissions but also reduces the amount of fuel needed to run the machinery components. Electric-powered equipment is also much quieter than gas-powered options, so it won’t disturb the peace and quiet of the surrounding area.
Water Spraying
Lastly, one of the most effective ways to reduce the amount of dust that is generated by quarry mining operations is to use water sprays. Water sprays help to settle the dust particles that are created when the material is moved around. This helps to keep the dust from becoming airborne and causing pollution.
Material Handling Solutions with Quarry Mining LLC
There are many things to consider in material handling operations and that’s why there are always on the lookout for solutions to make work more efficient and decrease impacts on the environment.
One example is how Quarry Mining LLC made a project of a conveyor system that can generate power at the same time. The firm has created a technology to extract energy from the material transport, resulting in zero energy expenses and also the production of electrical power. The transportation costs per ton may be drastically reduced by utilizing the QM’s own developed and customer-specific conveyance system.
