During phosphate mining and transportation conditions, large ore particle size, high blanking drop, and strong impact are common characteristics in the industry. The buffer protection equipment in the conveyor blanking area directly determines the operation stability and operation and maintenance costs of the entire transportation line. Buffer traditionally used in most domestic phosphate minesidlerGroup, frequent damage under heavy load and strong impact conditions not only leads to faults such as longitudinal tearing of the belt and dust leakage, but also causes frequent shutdowns and high operation and maintenance costs.
This paper introduces in detail the MC-HD composite model based on Wuhan Junwei's transportation system transformation project in a large phosphate mine in southwest China.buffer bedThe customized solution for heavy-duty blanking conditions of phosphate ore provides a practical reference for the transformation of similar working conditions in the same industry.
1. Project overview
This renovation project is the main transportation line of a large open-pit phosphate ore in southwest China. The transportation materials are high-hardness phosphate ore.The maximum material particle size reaches 300mm, and the vertical drop of blanking material is 8.6 meters, the conveyor bandwidth is 1200mm, the belt speed is 2.5 m/s, the conveying capacity is 1500t/h, and it runs continuously for 24 hours.
Before the transformation, the blanking station used traditional 6 sets of buffer roller groups as buffer protection equipment. Under the continuous and strong impact of large particle size and high drop of phosphorus ore, equipment failures occurred frequently, which has become a constraint on the stable operation of the entire production line. Core bottleneck.
2. Core pain points of the original system
Based on the on-site working conditions survey, we summarized the four core pain points of the original buffer roller group, which are also common problems in the domestic phosphate ore industry transmission lines:
The buffer rollers are frequently damaged and replaced frequently
Phosphorus rock falling with high drops has extremely strong impact. Traditional buffer rollers are supported in line contact, and the impact force is concentrated at a single point, resulting in frequent damage to the roller bearings and deformation and fracture of the roller body. On average, one group of rollers has to be replaced every 15-20 days. During peak periods, they have to be stopped and replaced every week, which seriously affects the continuous operation of the production line.
The risk of longitudinal tearing of the belt is extremely high and the economic loss is large
After the carrier roller breaks or falls off, the sharp corners of the metal brackets will directly cut the conveyor belt. Coupled with the continuous cutting of sharp phosphorus ore after penetrating the belt, this station has an average of 2-3 longitudinal tearing failures per year. The cost of replacing the conveyor belt exceeds 300,000 yuan and will also cause long-term unplanned downtime.
The belt is partially sunken, causing a serious problem of dust leakage when spreading materials.
When materials impact, the belt between the buffer rollers has no support and obvious local depressions appear. A gap is formed between the anti-overflow seal of the guide chute and the belt. A large amount of phosphate rock powder and finely divided ore overflows from the gap. The dust concentration at the on-site post far exceeds environmental protection standards, and at the same time causes material waste and creates a huge amount of cleaning work.
Operation and maintenance costs remain high, and personnel workload is saturated
Frequent replacement of idler rollers, belt wear maintenance, and on-site spraying cleaning occupy more than 60% of the operation and maintenance team's work energy. The annual parts replacement costs, downtime losses, and labor costs remain high, becoming the core point for reducing costs and increasing efficiency in the mine.
3. Customized solutions
For the heavy load and strong impact working conditions of the phosphate mine, Wuhan Junwei technical team customized theMC-HD composite buffer bedAs the core full protection solution for the blanking area, it completely replaces the original buffer roller set to solve the above pain points from the source.
The MC-HD composite buffer bed selected this time is an upgraded product specially designed by our company for heavy-duty blanking points of belt conveyors. The core advantages are perfectly suitable for the harsh working conditions of phosphate rock with high drop, large particle size and strong impact:
HD heavy-duty modular structure suitable for heavy load and strong impact conditions
The overall buffer bed adopts a thick heavy-duty steel structural frame. The modular design can be flexibly adapted according to the site bandwidth and groove angle. It is firmly installed and fixed. It can withstand the continuous and strong impact of large-particle-sized phosphate ore without deformation or loosening, completely avoiding the risk of traditional rollers breaking and falling off.
Upgrade elastic module + secondary buffer design to absorb impact energy
The product is equipped with an upgraded elastic buffer module and combined with ultra-high molecular weight polyethylene buffer strips to form a dual buffer system that can achieve92% of impact energy is efficiently absorbed, evenly disperse the strong impact force of the falling phosphorus ore across the entire belt width, upgrade from line contact to surface contact support, completely eliminate the problem of local subsidence of the belt, and provide all-round protection for the conveyor belt.
Long service life, greatly reducing operation and maintenance frequency
The core elastic module adopts high-quality ROSTA elastic elements with a designed service life of up to 8 years. The wear resistance of the ultra-high molecular weight polyethylene buffer strip is more than three times that of ordinary steel. It can still maintain long-term stability under high wear conditions of phosphate rock. Operation, no need to replace parts frequently.
Perfectly adapted to the guide chute sealing system to solve dust spillage problems
The buffer bed is combined with the angle fine-tuning structure to ensure that the buffer strip and the conveyor belt are completely bonded face-to-face, ensuring the material guide groove.Anti-spill skirtAlways fit closely with the belt without gaps, solving the problems of material spreading, air leakage, and dust diffusion from the source, and helping the site meet environmental protection standards.
At the same time, based on the blanking height and material characteristics of the phosphate ore, we have made special customized optimization of the buffer bar arrangement and frame structure of the buffer bed to ensure 100% compatibility with the on-site working conditions.
4. Application effect after transformation
After the renovation of the project was completed, after 6 months of continuous operation testing, all indicators far exceeded customer expectations. The core effects are as follows:
Equipment failure rates have dropped significantly: Since the renovation, there have been no structural damage or deformation failures in the buffer bed, which has completely solved the problem of frequent replacement of buffer rollers. The frequency of parts replacement has been reduced from once a month to only once a year, and unplanned downtime has been reduced by 95%.
The belt has remarkable protective effect: The risk of longitudinal belt tearing caused by the breaking of the idler is completely eliminated. The wear rate of the conveyor belt covering rubber is reduced by 70%, and the service life is increased from the original 1.5 years to more than 4 years, which greatly reduces the high cost of belt replacement.
Environmental protection and on-site management fully meet standards: The problems of material spreading and dust spillage in the material guide trough have been completely solved. The dust concentration at on-site posts has been stably reduced to within national environmental protection standards. There is no need to manually clean and disperse materials every day, and the on-site working environment has been greatly improved.
Operation and maintenance costs have been significantly reduced: According to customer calculations, the annual operation and maintenance costs of the workstation have been reduced by more than 85% after the renovation. With only two items of parts replacement and downtime losses, customers can save more than one million yuan in costs every year, and the renovation investment can be recovered in less than one year.
Conclusion
The buffer protection of phosphate rock heavy-duty blanking stations has never been a problem that can be solved by replacing a single accessory. A customized system solution must be made for on-site working conditions. Wuhan Junwei MC-HD composite buffer bed, with its elastic modular design, dual buffer system, and super impact absorption capacity, perfectly solves the pain points of transportation equipment under high drop and strong impact conditions such as phosphate ore.
As a one-stop service provider focusing on bulk material conveying systems, Wuhan Junwei has been deeply involved in core industries such as mining, building materials, steel, and electric power for more than ten years. It can provide customers with customized buffer protection, sealing and dust suppression, and rectification and cleaning for different working conditions. The full-process solution helps mining companies achieve multiple goals of production safety, environmental protection and compliance, and cost reduction and efficiency increase.
