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Use of Composite Conveyor Roller


In pursuit of excellence in efficiency, Lorbrand Composites South Africa explains to African Mining Brief how Composite Conveyor Rollers made of enhanced proprietary materials address the limitations of standard Conveyor Roller products in mines worldwide.

In recent years, the mining industry has faced demand from conveyor roller producers, who offer low-cost hdpe and steel conveyor rollers as alternatives to OEM equipment. The challenge is to determine whether these options will enable coal mines to comply with safety and environmental regulations, increase operating costs and add value to the value chain of conveyor systems.

The consensus is that the range of low-cost steel rollers and hdpe or other plastics options is limited because they can only work best in some areas while being eclipsed in others.

newsAlthough steel rollers have undisputed structural strength, they are more susceptible to corrosion and wear in humid environments. These high wear conditions make it possible for damaged or worn rollers to cut the belt, resulting in rapid and significant damage to the belt. In addition, the steel coils are heavier and require more lift, injuring the workers handling them. Unconsciously, this situation increases the possibility of mine accident compensation cost. Steel rollers are also difficult to recycle because they require a lot of input before they are recycled.

In high performance applications, the typical hdpe rolls cannot compete with steel rolls of similar size in handling loads. Under these conditions, few composite drum manufacturers provide Cema E and Cema F load capacities on typical belt widths. Advanced composite plastic rollers are designed to compete with high quality steel rollers in the highest load and fastest belt applications, and will match or exceed the properties of steel.

Practical choice

Two companies at the forefront of composite technology, Lorbrand and Lorbrand Composites, have been researching ways to improve the composition of composite rollers for years to improve their durability. Lorbrand Composites's team Shared their views on the region with African mining briefings, particularly their in-field experience. They say the company has gone further, offering composite rollers of various materials including nylon, sintered reinforced hdpe and new FRZ materials approved through polymer technology for use in underground applications. This gives the product broad advantages in terms of safety, operational benefits, significant cost savings and carbon footprint reduction.

Security interests

The user needs to choose the right material for the environment. Flame retardant materials should be used in mines where fire risk assessment is high .HDPE or composites should be used where fire risk assessment is low.

Most hdpe cannot be made into refractories without significant loss of mechanical properties. Nylon based products are best suited for fire presence applications because its standard form is fireproof V2 / V3.If static electricity and fire are the problem, then custom-made composites (usually nylon) are the right material to choose from. Antistatic and flame retardant rollers will combine the flame retardant ability and the actual electrical conductivity of the whole shell. If the shell is not conductive, the typical copper wire passing through the bearing housing is virtually useless in causing static charge accumulation.

At the high end of the compound roller, few rollers meet FRAS requirements. Drum manufacturers who meet the requirements usually go through the requirements of the Australian underground mining authority, which is the most stringent specification.

The toxicity of combustion materials should not be neglected. Many materials are flame retardant, but to achieve this added chemical, flame retardants release very toxic gases when burned.In tragic incidents of land-mine deaths related to underground fires, deaths are often caused by asphyxiation caused by the presence of harmful gases. These gases need to be kept below a significant rate, and only advanced materials can achieve this effect.

Operating efficiency

Advanced composite rollers consistently show that in most test environments, composite rollers will be more durable than steel or more advanced carbide rollers. This means longer uptime, less roller replacement, less stock holding, less belt damage from rollers, lower noise emissions and, most importantly, significantly lower power consumption.

Significant cost savings

Cost savings are another area where composite rolls are more valuable than steel or typical hdpe substitutes. The average mining customer should be able to save a significant amount of cost when using high quality composite rollers in the following factors:

§ dropped due to the replacement and cost reduction

§ start due to reduced stress, reduce the power consumption and may reduce the service costs of the motor and drive

§ reduce noise

§ reputable manufacturers will provide more than the typical the warranty period of 12 months - in a few cases the warranty can be increased from 12 months to 36 months or, in some cases, 60 months (if the inspection and maintenance of mine conveyor belt and create accurate records)

Easy to recycle

news aThe compound roller can also help mines achieve "green dots or reduce carbon footprint" through recycling. The composite roller material has high quality and has important value in the recycling market. The structure also makes disassembly easier to recycle, simpler and more energy efficient than typical steel rollers.

'not all composites are created equal'

Typical hdpe rollers are made from off-the-shelf pipes commonly used in pipe or rain water industries. The tube is typically made from a combination of hdpe materials, designed to keep costs low. This tube does not have the mechanical properties needed to make the roller. The requirements are stiffness, straightness, roundness and some heat resistance. In some cases, hdpe rollers have been seen to go beyond the tolerable limit of 0.5mm per meter to spend only a few minutes in the sun, which will soon affect the integrity of the bearings and rollers.

Ordinary users of the above composite high-performance roller should seek the following benefits:

§ roller life cycle is far more than the typical steel or hdpe roller

§ improve life expectancy and reduce cost of ownership - for example, the lowest life for 3 to 5 years, conveyor roller to reduce more than 20% a year

§ casing wear at least 40%

Number of § roll change significantly reduced

§ roller significantly reduce the damage to the belt

§ reduce energy costs - during the startup and operation

§ reduce noise - at least 60%

§ is easy to handle

§ recycling and waste management

Research and development research and development is the key. The conveyor roller industry needs to contribute to the profitability of mining and developing products that outlive their predecessors and are key to ensuring sustainable mining. Simply tweaking existing designs doesn't do that. The commitment to state-of-the-art design software and the technology and research of qualified designers is the only way for the conveyor roller industry to move forward and play its role.

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