ROXON Overland Conveyor modernization to gearless drives

Since the 1980s, ROXON has delivered long overland conveyors to all major companies in the Nordic countries. One example is a 3km-long overland conveyor delivered in 1988 which is still in operation in Sweden. For the first time, ROXON changed the belt on this same conveyor in 2022.

The history and track record of ROXON in deliveries of overland and high- capacity conveyors is long. LKAB Malmberget, ROXON’s customer since the 1970s, purchased a 1.7km-long underground conveyor which was delivered in 1999. LKAB has recently decided to change the original drives to direct drives, more precisely permanent magnet motors. At the same time the capacity of the conveyor is increased from 3,000tph (tonnes per hour) to 3,600tph.

LKAB Project Manager Pär Sundqvist explains the background of the modernization. “The upgrade of the drivetrain for this conveyor is done primarily for capacity reasons, but also from the perspective of energy efficiency. By doing this upgrade we expect a possibility to increase the utilization of the whole production line of the mine by somewhere around 2–5%.”

The change from traditional geared drives to gearless drives is creating significant changes to conveyor dynamics since the inertia of drive station is significantly reduced. Therefore, LKAB ordered expert services from ROXON to execute the dynamic analysis of the conveyor. In a dynamic analysis starting, stopping, emergency stop — and all other possible scenarios — are simulated to find out transient tensions during the specific event.

Dynamic analysis answers the following questions:

How should the braking be done to v minimize the maximum transient belt force but holding sufficient minimum tension considering all cases?

What will be the counterweight v movements in all situations?

Is there a need for a capstan brake? v How to execute an emergency stop v without risking safety or harming the conveyor etc.

ROXON optimizes all overland conveyors using dynamic analysis tools (>1km in length, very high capacity or exceptional geometry). These conveyors are complex machines and the results from a dynamic analysis define the conveyor function in detail to ensure high availability and safe operation for decades.

Teemu Lahti, Product Manager for belt conveyors was responsible for the dynamic analysis and has executed many projects in co-operation with LKAB.

“It was a privilege to be part of this project and help LKAB who we have long history together. Obviously, the calculation and conveyor design has developed a lot in the last 25 years but still it’s great to see that the original design has offered great reliability and safe operation for the customer. The modernization project was started by reviewing all original data and then evaluating proposals from LKAB, taking into consideration how the modernization was planned and which components were preliminarily selected. Together we found out the suitable technical solution and LKAB can proceed with the execution.”

ROXON is also delivering a new drive pulley and renovating the old one to act as a spare part for LKAB. ROXON fabricates and renovates the pulleys in Haparanda very near to the company’s major customers in northern Sweden.

Companies looking for expertise on overland conveyor solutions can trust ROXON which provides the full range of services from basic design to deliveries and even modernizations of existing equipment.

Mastering conveyor belt misalignment: how Tru-Trac’s innovations enhance bulk material handling efficiency

In bulk material handling operations, conveyor systems play a pivotal role in ensuring the efficient and safe transportation of materials. These systems, crucial to industries like mining, port terminals and power plants, face numerous challenges that can significantly impact their operation — key among these being belt misalignment.

Dry Cargo International spoke to Shaun Blumberg, COO of South Africa-based original equipment manufacturer Tru-Trac, about the complexities of these systems and the importance of engaging with a knowledgeable conveyor solutions provider.

“Conveyor systems are critical to the functioning of any bulk material handling operation, but belt misalignment can lead to material spillage and loss, belt slipping accelerated wear and tear on components and excessive dust,” says Blumberg. “It can even cause belt and structural damage, which inevitably means costly production downtime, increased power consumption and higher labour costs.”

He explains that the off-centre travel of the conveyor belt along the conveyor system can be caused by a number of factors. The conveyor structure could be damaged, the foundation may not be level, there may be ill-fitting components or belt splices may be of a poor quality. Other possibilities include improper belt storage which leads to warping or bowing, the excessive tensioning of the belt, pulleys being out of alignment with the conveyor centre line, or return idler spacing being too wide to track the belt. Misalignment can also be caused by the uneven placement of load on the belt.

Addressing these challenges requires a multifaceted approach, he argues, combining technical expertise, applications knowledge and the latest technology to deliver fit-for-purpose solutions. Blumberg emphasises the importance of partnering with a conveyor solutions provider that has the necessary capabilities to address conveyor related challenges through its level of experience and technical expertise in such applications.

“Furthermore, leveraging the experience of conveyor specialists to identify and resolve common conveyor related problems will enhance efficiency, reliability and the capability to meet the evolving demands of the industry” he continues.

Tru-Trac’s commitment to providing fitfor-purpose conveyor misalignment solutions means delivering proven solutions for this prevalent problem that not only address immediate issues but also contribute to overall productivity and efficiency. This approach, Blumberg says, helps reduce wear and tear on components, minimise unscheduled downtime and ensure compliance with industry standards and regulations, while enhancing workplace safety and positioning businesses for long term competitiveness and sustainability.

Belt misalignment occurs where the belt drifts off centre, causing numerous issues that translate into operational inefficiencies. Designed to correct misalignments and keep conveyor belts centred, Tru-Trac® Belt Trackers provide a permanent solution to this common challenge. These high performance tracking solutions do not damage the conveyor belt in any way and activate automatically to provide immediate and continuous adjustment to recentre the belt.

The design features include a unique centre pivot, maintenance free operation with no need for edge contact and a vibration free rolling action that ensures the tracker operates in all conditions, including on reversible belts. The trackers can be installed above or below the belt on the return side, making them suitable for varying applications.

“By ensuring the conveyor belt remains precisely aligned, our high performance tracking solutions mitigate the risk of accidents and optimize the efficiency and cost effectiveness of bulk material handling operations,” Blumberg says.

A Tru-Trac impact bed absorbing impact at a transfer point.

With almost three decades of experience, Tru-Trac has evolved into a global belt tracking specialist with exceptional expertise in the design and manufacturing of conveyor belt misalignment solutions. “Our patented selftracking roller systems have evolved into the gold standard for addressing conveyor belt misalignment challenges globally,” he explains. “Our customers also appreciate how user-friendly our solutions are, allowing for easy and versatile installation with low maintenance.”

He highlights that efficient performance of these belt trackers ensures they are cost effective and deliver the lowest total cost of ownership. They are also versatile in their application, being able to performs in all conditions from wet to dry, from underground to above ground, and even on reversible belts.

“Tru-Trac Trackers only need to be installed where misalignment occurs, and one tracker can align 50 meters of belt, or up to 100 meters on overland belts,” says Blumberg. Among the variety of tracking solutions is the Tru-Trac Return Tracker, which has an inner stationary drum that pivots laterally with the belt, and an outer rotating drum that tapers towards the ends – creating a smaller diameter on the edges.

“When the belt drifts off-centre, it encounters the tracker’s tapered ends, causing a change in peripheral speed,” he explains. “This compels the tracker to pivot in the opposite direction, guiding the belt back towards the centre.”

The complexities associated in managing dry cargo handling operations underscore the need for effective tracking solutions. Established almost 30 years ago, Tru-Trac has the depth of industry knowledge, technical expertise and operational scale to service and support customers across the globe. The company has a sales and distribution network spanning 80 countries, and its innovative solutions are specifically aimed at addressing these challenges, providing efficient and reliable enhancements to conveyor system performance.

Group secures major project award with SNIM for F’Derick iron ore project in Mauritania — conveying systems are an integral part

Continued success in West Africa:TAKRAF Group has signed a contract for a complete iron ore in-pit crushing, screening and material handling system together with a train loading station in Mauritania. Conveyor systems represent a major part of this contract.

TAKRAF Group, a world leader for innovative technological solutions for the mining and associated industries, has signed a major contract with Société Nationale Industrielle et Minière (SNIM) for the supply of a complete iron ore crushing, screening, and material handling system, along with a train loading station for the F’Derick project in Mauritania.

The F’Derick iron ore deposit, known for its natural richness in hematite, is part of SNIM’s iron ore complex in Mauritania. With current production of approximately 12mt (million tonnes) per annum, SNIM aims to increase this to 18mt through the development of the F’Derick project, thereby contributing to the country’s iron ore production.

The contract, signed at the end of 2023, marks a key milestone as SNIM begins development work on site. An inauguration ceremony was held in the presence of Mauritanian President of State Mohamed Ould Ghazouani, underscoring the importance of this collaboration

Highlights of TAKRAF’s scope of supply include:

LOT 1 primary crushing plant; v apron feeder; v belt conveyor CV-1; v secondary crushing plant with pre- v screening; belt conveyor CV-2 and transfer tower v TT-1; and required auxiliary systems and v accessories.

LOT 2 belt conveyor CV-5; v train loading (loadout) station; and v required auxiliary systems and v accessories.

TAKRAF designed the system in order to feed the train load-out station with an average loading rate of 100 wagons per hour.

Delivery of the equipment to the port of Nouadhibou is expected to be completed in approximately two years.

Commenting on the award, Thomas

Jabs, CEO of TAKRAF Group, said: “This project is of paramount importance to the country of Mauritania and is a testament to the excellent co-operation and expertise of SNIM and the TAKRAF Group. Our teams from Europe, South Africa, North America and Asia will work seamlessly to leverage their skills and knowledge. We would like to thank SNIM for their trust in our capabilities, the State of Mauritania for their support and all the planning and design teams involved. This award underlines our global strength in delivering complex bulk handling systems.”

Norbert Neumann, TAKRAF Group Sales Manager responsible for securing the project, adds, “The F’Derick project deepens our longstanding partnership with SNIM, which began over a decade ago and further strengthens TAKRAF’s commitment to contribute to the growth and prosperity of the region. SNIM remains an important client for TAKRAF, and we expect many more success stories to come. Our collaboration, dating back to the early

2000s, demonstrates our reliability, successful project implementations, and service-oriented approach. We would like to thank SNIM for their continued trust and constructive collaboration.”

About Takraf Group

TAKRAF Group, through its established and well-known brands, TAKRAF and DELKOR, provides innovative technological solutions to the mining and associated industries. With experience acquired over more than a century, the Group is well positioned to provide equipment, systems and services that best satisfy its clients’ mining, comminution, material handling, liquid/solid separation and beneficiation requirements. Servicing owners and operators around the world, TAKRAF Group’s engineered solutions are customized to the unique project requirements and are aimed at lowering the total cost of ownership and reducing environmental impact by improving efficiency with safe and reliable equipment.