Using mobile conveyors to simplify processes

From port terminals to quarries, conveyors and feeders can been found transferring large amounts of material owing to their operating efficiency and cost effectiveness.

Conveyors are a cost-effective means of transferring or stockpiling material. When used in the aggregate industry, mobile conveyors offer operators an efficient, reliable, robust material-handling solution while offering less downtime and a greater lifespan.

The abundant list of conveyor types and options available to operators are a testament to the benefits they bring to operations. Differing discharge heights, transfer lengths, condition of terrain, availability of power, frequency of repositioning, throughput and budget are all factors that have driven the market to create a range of mobile conveyor models. Various conveyor solutions exist in order to meet different challenges faced by operators, not to mention the never-ending list of materials that are being transported.

Quarry operators constantly strive for improved productivity while attempting to bring their overall cost per ton down. For this reason, a number of quarries have turned to the use of mobile crushing and screening equipment much more frequently in the last few decades. Having a mobile plant that follows the quarry face has become a more common sight in operations across the globe to the extent that its utilization is no longer questioned. It is now a well-proven, operational model.

The transition from bringing the plant to the material rather than transporting material to the plant has obvious cost-saving benefits, but what about the material being processed? Static conveyors previously relied upon to move hundreds of tons per hour and that have been the mainstay of many quarrying operations for decades now find themselves moving further away from the action.

To benefit from the efficiencies and cost savings resulting from the integration of conveyors to move or stockpile material, operators have turned to mobile stockpile conveyors to complement their fleet of mobile crushers and screens.

Conveyor stockpiling benefits

With short discharge conveyors generally found on most mobile screeners or crushers, sites that traditionally employ wheel loaders to move or stockpile material tend to be constantly moving material from the screener or crusher that can only handle a small stockpile. Material is moved from one stockpile to another larger stockpile, and then onto loading the trucks. Effectively, quarries that employ this system handle finished products at least twice.

By introducing mobile conveyors into their processing line, operators can now leave crushers and screens running, moving finished product just once with the wheel loader straight to delivery trucks. Ultimately, the introduction of conveyors results in the elimination of the double handling of material in many cases. Therefore, this cuts an operator’s cost per ton.
Bigger throughput

Production improvement proves to be another advantage enjoyed by operations using conveyors to create stockpiles. With crushers and screeners no longer starved, operators can focus on continuously loading feed material, which allows conveyors to create larger stockpiles in a much smaller area. This is achieved by a stockpile conveyors’ ability to reach much higher discharge heights.

In many circumstances, improved production can eliminate expensive overtime needed to meet productivity demands and reduce maintenance work that results from increased running hours.

There are also health and safety benefits associated with integrating mobile conveyors into the processing line. By eliminating the use of loaders when stockpiling materials, the volume of moving traffic on the site is reduced.

Studies in the United Kingdom have shown that more than 40 percent of waste and recycling site accidents occur due to maneuvering and operating vehicles. Along with the environmental benefits, stockpile conveyors can contribute significantly toward the improvement of health and safety issues such as reduced noise, dust and emissions levels.

Having the ability to be flexible and adopting to new challenges is vital for any successful business. Cash flow is a common problem for some small business owners. Larger businesses are also just as likely to encounter cash flow problems as smaller companies.

Stockpile conveyors represent a significant financial saving alternative, freeing funds to help a business expand. Along with this, fuel consumption is also drastically reduced when compared with equipment you might otherwise use.

Also, conveyors can diminish the need for high-priced labor due to the fact that they reduce the number of wheel loaders and drivers required to operate at a site. Secondly, conveyors have the ability to operate at maximum efficiency every hour of operation with minimal supervision, thus reducing labor costs further.

Considering conveyor models

Even when an operator decides to use a mobile conveyor solution, there are further considerations to take into account: does the operator opt for a wheel or track-mounted conveyor? Every operator has different needs and challenges to overcome.

First, consider the chassis format. Depending on how an operator wants to integrate the conveyor into an existing system and how he or she wishes to stockpile will determine the conveyor type the operator is seeking. There are pros and cons to every conveyor format.

The track option is ideal for operators who frequently reposition their conveyors. A track stockpile is a self-propelled, independent unit that can be easily and quickly maneuvered across rough terrain with increased operator handling. However, it may not be the ideal product for the creation of radial stockpiles.

Mobile stockpilers give the operator the added advantage of a radial stockpile function but they must be towed by another self-propelled vehicle on site.

Another solution is to combine the best of both formats into one unit. A radial track stockpiler encompasses a track unit with radial stockpile functionality.

Additional considerations

Operators must also consider other factors such as loading methods and applications.

If the conveyor were to be loaded directly by an excavator or wheel loader, then a feed conveyor would best suit this application. If an operator wishes to load directly with a wheel loader on all three sides of the hopper but does not want the extra cost of constructing ramps, then a low-feed track stockpile is a fit. If an operator wishes to run a constant feed of material yet retain the ability to track parallel to a barge, then a conveyor with 360-degree slew functionality would provide the flexibility required.

In addition, the manner in which operators wish to power their conveyors varies due to application and material being transferred. Other determining factors may include the availability of diesel or electricity, the current power source being used, the ability of the customer’s service staff, throughput required and the operator’s past experiences.

The biggest advantage of a diesel/hydraulic-driven conveyor is that it can be operated in remote locations because it’s self-contained with only fuel being required. Diesel/hydraulic-powered units can be simpler to service than electric-driven counterparts.

Yet, the advantages of electric-powered equipment over diesel models can extend beyond the savings on diesel fuel, with savings on operating and maintenance costs. They also provide dependability and uptime.

Adrian Donnelly is marketing manager at Edge Innovate.