Pipe Conveyor ensures dust-free Transportation of Ore Concentrates
Transportadora Callao S.A., the logistics operator of a special cargo terminal in the port of Callao, Peru, relies on a Beumer Group pipe conveyor for the transportation of zinc, copper and lead concentrates of different mining companies from the warehouse to the terminal.
(ed. WoMaMarcel - 06/4/2017)
Due to its enclosed transport, the pipe conveyor not only protects the environment against harmful impacts during the transport of the lead concentrate, it also allows conveying over long distances and navigation through tight curve radii. Due to its ability to navigate curves, this belt conveyor requires a lot less or no transfer towers at all, depending on its length and the available curve radii. This results in substantial cost savings for the customer, and allows Beumer Group to easily customise the system to the individual routing. Durable conveyor belts guaranteeing tensile strength are used. The engineers use different dimensioning programs to determine the ideal belt design. They use them to calculate tractive forces and forces that arise during acceleration and deceleration and also to determine possible curve radii.
The pipe conveyor passes the naval port of Callao: this is the last curve section before the transfer tower towards the port terminal.
Beumer Group provides tailor-made feasibility studies for each project. Another advantage is the reduced noise emission that the system provides. This is ensured by special idlers, as well as low-noise bearings and selecting the right conveying speed. “This improves the quality of the employees’ day-to-day work environment,” says Beumer engineer Wolf. Victor Sams adds that the “noise measurements along the pipe conveyor resulted in values that are consistently far below the permitted limit values.”
Conveying Capacity: 2300 tph
Beumer Group supplied and installed a pipe conveyor with a centre distance of 3195 m. “Due to the system design and the required system capacity, we designed it with a diameter of 400 mm,” explains Helmut Wolf. “The conveyor transports 2300 tph at a speed of 4.5 m/s and is driven by three motors with a capacity of 650 kW each. We equipped the system with filters, strippers, a dedusting unit and a control system.” Beumer Group was responsible for engineering and automation, and supplied the steel structure and the necessary components. The site managers supervised the installation and put the system into operation.
The process is practically free of faults and, above all, safe: trucks or trains transport the mining commodities from the mines to the ore storages, from where they are transported to the open access station. Here, the concentrates are received by a feeding 43 m belt conveyor that transfers it to the pipe conveyor at a height of 6 m. A dedusting unit ensures that no material is emitted during this process.
“We equipped the feeding belt conveyor with a metal detector and an electric magnet,” explains Helmut Wolf. “This prevents damage of the downstream Pipe Conveyor by metal parts.” At the end of the route, the conveying system runs along the seaside in the naval port of Callao to the transfer tower. Here, the belt opens automatically. It transfers the material to another belt conveyor that conveys the ore to the ship loading system.
At the pipe conveyor loading point, a magnet separator removes tramp metal from the ore concentrate.
Victor Sam: “This modern system, in operation now for 17 months, caused a significant increase in speed by 500% for loading concentrates and reduced the ship’s waiting time until loading by more than 80%. These advantages lead to savings for the exporters and improve the competitiveness of the country’s mining industry.”