CHALLENGES

A coal mine supplying a power station was experiencing severe wear issues in its overburden conveyor discharge chute. The chute was exposed to a highly abrasive mix of sandy material and varying rock sizes, creating an inconsistent and high-impact material flow environment.

Traditional chute liners struggled to withstand the combined effects of abrasion and impact, leading to rapid wear, frequent liner replacement, and repeated structural repairs. This resulted in increased maintenance demands, unplanned downtime, and reduced operational efficiency.

Key challenges included:
• Managing heavy impact from mixed-size abrasive material.
• Reducing excessive wear to chute liners and steelwork.
• Minimising frequent maintenance and unplanned downtime.
• Extending chute service life in a harsh operating environment.

SOLUTION

To address these challenges, a conveyor impact curtain manufactured by Forech was supplied through our trusted channel partner Reglin Rubber (Australia).

The impact curtain was engineered to absorb and disperse the energy generated by impacting ore and rocks before they contacted the chute walls. Manufactured using high-performance SAR 60 rubber, the curtain featured a reinforced SAR 60 rubber block strategically positioned in the main impact zone to provide additional protection.

The flexible curtain design allowed it to move with the material flow, significantly reducing direct impact forces and wear on the chute structure.

OUTCOME

Following installation, the mine achieved the following outcomes:
• Effective absorption and dispersion of impact energy from falling material.
• Significant reduction in liner wear and structural damage to the chute.
• Lower maintenance frequency and reduced downtime.
• Extended service life of the chute lining system.
• Improved operational efficiency within the material handling system.

CONCLUSION

By installing a Forech-manufactured conveyor impact curtain featuring SAR 60 rubber, supplied via Reglin Rubber (Australia), the coal mine achieved a durable and effective solution for managing high-impact, abrasive material flow. This case study highlights the importance of selecting engineered rubber impact protection systems to optimise wear performance, reduce maintenance costs, and enhance productivity in demanding conveyor applications.