A method for investigating the influence of rainwater on the useful life of idlers in pipe belt conveyors during seasonal operations

Santos, Leonardo dos Santos e; Soares, Werner Kleyson da Silva; Filho, Paulo Roberto Campos Flexa Ribeiro

doi:10.1016/j.engfailanal.2022.106702

Cited by 4 publications

(5 citation statements)

References 12 publications

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“…This may reduce the opening force of the belt on the enclosed section and the troughability of the belt placed on the transition flights. In addition, the rotational resistance of idlers increases owing to weathering and long-term storage [31], for which additional time may be required to stabilize the friction loss at a constant value after a prolonged shutdown [37].…”

Section: Prolonged Shutdownmentioning

confidence: 99%

“…Failed idler rolls change the contact forces and cross-sectional geometry of the enclosed belt in a pipe conveyor. Typical failures include tube wear, bearing jamming, and shaft fixing failures, with consequent missing or seized idler rolls [31], the identification of which is difficult and may simultaneously affect different sections of the enclosed flight [15]. Ref.…”

Section: Missing or Seized Idler Rollsmentioning

confidence: 99%

“…The geometry of the hexagonal housing (60 • for lateral rolls) favors the retention of contaminants and water ingress, for which primary (an outer protective shield) and secondary (a low-friction dust lip seal) sealing play an essential role in protecting the idler's bearings from premature weathering. Storage conditions (sheltered from sunlight and weathering), proper empty-run routines in the case of prolonged shutdowns, and quality-assurance procedures on manufacturing processes also maximize the useful life of idler rolls [31].…”

Section: Missing or Seized Idler Rollsmentioning

confidence: 99%

“…Fire on the pipe belt: Premature failures in idler rolls caused by pinching or friction between the belt and the idler housing may trigger conveyor fires that easily propagate within the facility owing to the belt's movement [31].…”

mentioning

confidence: 99%

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Belt Rotation in Pipe Conveyors: Failure Mode Analysis and Overlap Stability Assessment

et al. 2023

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Pipe conveyors provide sustainable solutions for environmentally sensitive or topographically complex powdered and bulk-solid handling processes; however, belt rotation is among the most critical failure modes of these equipment, influencing engineering, operational, and maintenance activities throughout the conveyors’ lifecycles. Position changes in the overlap are mechanical responses to uneven contact forces between the vulcanizing rubber belt and the idler rolls, owing to the highly nonlinear process of the belt folding from a trough to a tubular shape, and no method for quantifying the belt’s stability is currently available. In this study, we analyzed the failure mode of belt rotation and proposed a linearized model of an overlap stability index to evaluate the resilience of the overlap position through a case study of a short-flight curved pipe conveyor. Our proposal considers an interference model between the simulated torque of a curved flight in a pipe conveyor and the calculated torque of its equivalent straight flight by using kernel-smoothed density functions. It is adapted to incorporate adjustment factors for the filling degree based on simulations, the effect of the overlap in the forming force of the belt, the remaining useful life of the belt, and the coefficients of friction between the belt back cover and the idler rolls due to adhesion and hysteresis. An application was developed to calculate the belt’s rotational holding torque and rotary moment by processing real operational data, simulated contact forces, and the relevant equipment parameters. This analysis identified the reduced transverse bending stiffness and increased belt tension forces as the root causes for position changes with a loss of contact in the upper idler rolls of curved flights 10, 13, 15–16, and 17. The contributing factors included spots of augmented contact forces during the initial stages of the belt lifespan in curved flights 15–16, which presented unstable conditions due to increased opening forces, with an OSI of 0.8657. Furthermore, we proposed corrective and preventive action plans, an optimized replacement interval for the belt, and recommendations for design changes according to the relevant standards.

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Section: Prolonged Shutdownmentioning

confidence: 99%

Section: Missing or Seized Idler Rollsmentioning

confidence: 99%

Section: Missing or Seized Idler Rollsmentioning

confidence: 99%

mentioning

confidence: 99%

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Belt Rotation in Pipe Conveyors: Failure Mode Analysis and Overlap Stability Assessment

et al. 2023

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“…Regarding developments with conveyor systems, a new generation of "pipe" or "tubular" conveyor belts is a viable alternative to use with filtered tailings, allowing a confined transport that does not allow the liberation of dust emissions in very windy areas [72,73].…”

Section: Outlook and Future Directionsmentioning

confidence: 99%

Dry Stacking of Filtered Tailings for Large-Scale Production Rates over 100,000 Metric Tons per Day: Envisioning the Sustainable Future of Mine Tailings Storage Facilities

Cacciuttolo,

Atencio

2023

Minerals

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Communities and authorities have been dismayed by globally recorded tailings storage facility (TSF) failures in recent years, which have negatively affected the safety of people and the integrity of the environment. In this context, obtaining the social and environmental license to operate TSFs has become a challenging process for mining companies. This has promoted the trend of using mine tailings dewatering technologies in the mining industry, with dry stacking of filtered mine tailings being recognized worldwide as one of the most acceptable, safe, and environmentally friendly solutions. This article presents a new paradigm in managing mine tailings, with disruptive and futuristic characteristics, considering the dry stacking of filtered mine tailings for large-scale industrial production rates over 100,000 metric tons per day (mtpd). Aspects of filtered tailings management are discussed, such as (i) dewatering process plant with thickening/filtering equipment, (ii) conveyance using fixed and movable conveyor belts, (iii) construction of dry stacking of filtered mine tailings facility, and (iv) implementation of Industry 4.0 technologies for automation of the mining processes. Finally, the article discusses how the large-scale filtered mine tailings solution is applied, considering the advances in the equipment’s performance and implementation of Industry 4.0 technologies as well as the experience gained worldwide in several mining operations. The future global trend is that mining operations with high daily production of mine tailings will apply dry stacking technology without dams to guarantee sustainability, promote continuity of the mining business, ensure the safety of communities, and conserve the environment.

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Belt rotation in pipe conveyors: Development of an overlap monitoring system using digital twins, industrial Internet of things, and autoregressive language models

dos Santos e Santos,

Ribeiro Filho,

Macêdo

2024

Measurement

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A method for investigating the influence of rainwater on the useful life of idlers in pipe belt conveyors during seasonal operations

Cited by 4 publications

References 12 publications

Belt Rotation in Pipe Conveyors: Failure Mode Analysis and Overlap Stability Assessment

Belt Rotation in Pipe Conveyors: Failure Mode Analysis and Overlap Stability Assessment

Dry Stacking of Filtered Tailings for Large-Scale Production Rates over 100,000 Metric Tons per Day: Envisioning the Sustainable Future of Mine Tailings Storage Facilities

Belt rotation in pipe conveyors: Development of an overlap monitoring system using digital twins, industrial Internet of things, and autoregressive language models

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