Overcoming a Mines Embankment

IPCC-system with new Belt Conveying Concept for steep Opencast Minewalls

Overcoming a Mines Embankment

In order to allow for a continuous high capacity conveying system out of steep walled open pit mines Thyssenkrupp together with Contitech and Siemens developped the Chevron Megapipe conveyor with an up to 900 mm outer diameter. The pipe belt features highest tensile strength as well as a ribbed carrying side to hinder the transported bulk material from rolling back.
(ed. wgeisler - 30/11/2017)
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Cost Comparison: Chevron-Megapipe vs. conventional HD-Trucking

The cost-effectiveness of continuous conveying technology in opencast mining is compared to discontinuous transport using heavy-duty traffic involving trucks and rail. Through a primary crusher at the base of the opencast mine, a Megapipe conveyor provides the steep transport at right angles to the opencast mine embankment. Comparison calculations here are based on conveying capacities using heavy-duty trucks and rail in a well-known iron ore surface mine in Eastern Europe.

In this opencast mine with the dimensi­ons L ≈ 5000 m x W ≈ 3000 m x H ≈ 480 m, approximately 50 million metric tons of material per year are transported out of the mine by 27 heavy-duty trucks (payload 120 metric tons) and 36 hopper trains (payload 1000 metric tons).

Alternatively, using a single Chevron-Megapipe with a diameter of 900 mm and a conveying speed of 4 m/s and a fill factor of approx. 50%, the equivalent annual conveying capacity of 50 million metric tons could be transported with an operational availability of 8322 hours.

Utilising an IPCC-system (here with Chevron Megapipe conveying out of the opencast mine) reduces operating, personnel and maintenance costs while simultaneously reducing the mines CO2 footprint.


This article describes the results of experimental investigations of the conveying characteristics of steep inclined conveying systems, as well as the results of the impact-resistance, bonding-strength and wear-resistance tests of the newly developed chevron cleat ribs.

The published findings of the DEM-FEM simulations for a deep trough belt and a Megapipe belt with and without a chevron cleat-ribbed carrying side cover [2] were verified.

The Chevron-Megapipe conveyor developed jointly by the consortium enables enclosed steep conveying or primary crushed ore or rock overburden at an angle of elevation of up to approx. 45°. The conveyor therefore enables an important contribution to reducing heavy-duty traffic, CO2 emissions and, as a result, operating costs in surface mining.

An 830 mm diameter Chevron-Megapipe prototype was presented to the public for the first time at BAUMA 2016-fair in Munich.


[1] Patent no. WO 2014180585 A1 and no. PCT/EP2014/054296: Tubular conveyor belt or pocket conveyor belt having a chevron profile arrangement on the carrying side thereof cross reference to related applications (ContiTech, A. Minkin, 2013)

[2] Minkin, A., Börsting, P., Becker, N.: Pipe Conveying the next Stage – A new Technology for Steep Incline High Capacity Open Pit Conveying. Bulk Solids Handling, Nr. 2/3, 2016

[3] Minkin, A.: Cost Reduction in Belt Conveying. Bulk Solids Handling, Nr. 2, 2015.

[4] Patent application no. PCT/EP2017/ 053852: Förderanlage zum För­dern von Fördergut [Conveyor system for conveying material] (Thyssen­krupp Industrial Solutions AG, G. Michaeli and F.-M. Wolpers, 2017)

[5] Patent no. WO 2013/026672 A1: Belt-conveying installation, method for operating the same, and use thereof [Bandförderanlage, Verfahren zu deren Betrieb sowie deren Verwendung] (Siemens AG, 2013) 

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