Belt conveyor systems are the heart of mining operations. By constantly pumping vast amounts of material across massive sites, and efficiently delivering product to end-use customers in a timely manner, conveyors ensure that plant managers actually get paid for the jobs they take on.
However, these systems are often complicated, and when they fail, the consequences can be severe. Whether it is lost productivity, expensive emergency repairs, or the ever-present significant safety risk, a sloppy conveyor system can be the root of a site’s pain points. The longer that a conveyor sits unaddressed, the greater the impact on operational efficiency, and, therefore, profitability.
To minimise the amount of unplanned downtime a site may experience, mining operation managers should take a proactive approach to maintenance, integrating both preventative strategies and predictive technologies to keep conveyor systems running at peak performance.
By exploring essential maintenance practices, considering the role of predictive monitoring, and taking steps to build a well-tailored maintenance plan, the mining industry can keep material off the floor and money in their pockets.
Key preventative maintenance practices for mining conveyor systems
Implementing routine maintenance is essential for extending conveyor equipment lifespan, improving operational efficiency, and reducing overall downtime.
Focusing on high-impact areas like belt cleaners, endless splicing and mechanical belt fastening systems, and key belt transfer points helps to ensure that the conveyor system can continue to operate smoothly under such harsh mining conditions.
Getting started with building a plan can be the most challenging part, but by homing in on those areas, site managers can more easily limit their maintenance-related downtime.
Belt cleaner maintenance: The first line of defence
One of the most common causes of material buildup and conveyor inefficiency is an improperly maintained belt cleaner. Over time, carryback – the residual material left on the belt after discharge – accumulates, leading to excessive spillage, belt mistracking, and increased wear on system components. If left unaddressed, this can result in operational slowdowns, increased cleanup efforts, and even compliance issues with regulatory agencies.
However, by incorporating routine belt cleaner inspections, mining operations can significantly reduce these risks and improve overall system performance.
A critical part of maintaining belt cleaners is ensuring proper tensioning. Regular adjustments allow the cleaner to maintain consistent contact with the belt, maximising its ability to remove residual material effectively. Without this routine tuning, a cleaner may either press too lightly, allowing material to pass through, or too firmly, leading to premature blade wear and potential belt damage.
Worn-out cleaner blades are another common issue, as dull or damaged blades reduce scraping efficiency, allowing more carryback to escape. Not only does this contribute to material loss, but it also creates maintenance challenges as spilled material accumulates around the conveyor system, exposing workers to harmful airborne dust, and creating a mess that workers will have to clean.
This is a preview of an article that was originally published in Issue 1 of World Coal 2025.
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