Page 71 - HUB-4 Issue 98

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Cement plant turns to ProSpare to
improve belt conveyor performance
Stand F6
The challenge
A major UK dry process cement plant, operating since the
50’s, extracts over 1m tonnes of carboniferous limestone
annually. A network of +40 belt conveyors operate across the
quarry and cement plant that are critical to the success of the
entire facility.
Belts 3A and 3B, transporting 100mm limestone from quarry
to cement plant, were a constant source of maintenance.
Collectively, the belts are approximately 175m long drum-to-
drum and handle 700-800 tonnes per hour, 40 hours per
week.
POOR BELT CLEANING CAUSED STOPPAGES
The conveyors had to be stopped prematurely on a weekly
basis to allow cleaning and maintenance to be carried out.
Although each belt featured both primary and secondary belt
cleaners, significant carryback was experienced each week
that the quarry team were required to clean. Furthermore, one
of the conveyors is located above a road, so extra safety
measures were required when cleaning in this area.
INEFFECTIVE LOADING POINT SEALING
The quarry team were also required to clean around six
wheelbarrows of spillage at the loading point, as part of the
weekly clean. The rudimentary rubber skirt seal installed was
not only ineffective, but also required replacing every two
months due to excessive wear. This task was undertaken by
the maintenance team and took around four hours to
complete.
MISTRACKING LED TO OPERATOR
INTERVENTION
Largely due to the effect of off-centre loading, the belt would
mistrack by up to 100mm, exacerbating the poor performance
of the sealing system. A ‘homemade’ solid steel roller was
installed to try to mitigate the mistracking. Despite this, the
maintenance team still spent two hours per month
maintaining the steel roller to realign the belt, often
disrupting production.
The solution and improvement
The Maintenance Manager contacted our Bulk Materials
Handling Division, looking for a continuous improvement plan
for their belt conveyors. A service engineer visited site, and
after scoping the belts, it was agreed that 3B would be
upgraded with STARCLEAN® belt cleaners, a CenTrax tracking
roller and SealTek sealing system, with 3A requiring
STARCLEAN® belt cleaners.>
www.hub-4.com May/June - Issue 98
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