Conveyor Design

ALCOA Rockdale, Texas, USA

Commissioned in 2005, this 19.3 km single flight conveyor was the longest conventional conveyor in the world. It also included one intermediate drive and 11 horizontal curves. In order to negotiate 11 horizontal curves, power was distributed between the head, tail, and halfway point on the conveyor. The intermediate drive is one of the first of its kind on a surface operation. OCC provided intermediate drive support as well as the control algorithms for starting and stopping.

Date

Commissioned 2005

Role

Designer

Client

Thyssenkrupp Robins

Lehigh Cement, Union Bridge, USA

Overland Conveyor Company was selected as the owner's technical representative for this 7km overland conveyor carrying 2500 mtph of crushed limestone. Snaking through populated areas of rural Maryland, this conveyor includes 5 horizontal curves and 27 vertical curves. OCC developed the design used to select the contractor and supported Lehigh through detail design and commissioning.

Date

Commissioned 2016

Role

Owners Consultant / Designer

Client

Lehigh Cement

Reliance Sasan UMPP, India

Overland Conveyor Company designed the 14 km overland conveyor from the port to the new Ultra Mega 3960 MW power plant. The overland includes head and tail drives with two horizontal curves. The project required significant cooperation between diverse multi-national engineering teams.

Date

Commissioned 2014

Role

Designer

Client

Northern Heavy Industry China

Barrick Gold, Cortez Hills, USA

Overland Conveyro Co was selected to provide specialized design and commissioning support for the development of unique and custom control algorithms for an 11.6 km overland conveyor. The system consists of several individual conveyors totaling over 14.5 km in length with the 11.6 km centerpiece curving horizontally down a large hill. Conveyor capacity is set at 1000 tons per hour.

Date

Commissioned 2009

Role

Designer

Client

Thyssenkrupp Robins

Heidelberg Cement, Cadman, USA

This downhill conveyor was designed for Cadman's new limestone quarry in Washington state. The conveyor handles material in both directions and is designed to carry 1000 tph down the hill and 400 tph back up the return side. It overcomes difficult terrain over its length of 2 km, including a vertical drop of 274 m with 14 vertical and 2 horizontal curves, and a maximum slope of 18 degrees.

Date

Commissioned 2006

Role

Designer

Client

Thyssenkrupp Robins

Chinalco, Toromocho, Peru

Overland Conveyor Company was selected to provide preliminary design, technical bidding documents and bid review to Aker Solutions (working for Chinalco) for the 10 km conveyor from this greenfield mine to processing plant over the Andes Mountains. The conveyor reaches elevations of 5000 m, and OCC's design featured a unique mid-drive solution which reduced overall conveyor capital cost by approximately 40%.

Date

Commissioned 2013

Role

Designer

Client

Aker Solutions

 

Studies

Sirius Minerals, North Yorkshire, UK

Sirius Minerals' Woodsmith mine targets the extraction of polyhalite, a unique multi-nutrient fertilizer. Sirius Mineral's selected thyssenkupp and Overland Conveyor Company to provide a design study for the design and budgetary costing of a 37 km, single flight, underground conveyor to transport material from mine to processing facilities near the port. OCC supported both thyssenkrupp and Sirius minerals with the difficult balance of mixing long distance conveying with the underground environment.

Date

Design Study 2016-2018

Role

Designer

Client

Thyssenkrupp

Dead Sea Works, Israel

In 2012, the Israeli government made plans to fund and implement the Dead Sea Salt Recovery Project. a permanent solution for stabilizing the water level of the Dead Sea Works' Pond #5. The solution includes removing 20 million tons of salt annually and transferring it 25 km to the northern basin of the Dead Sea. OCC was selected to supply overland conveyor technology to the project study team. Project options included multiple conveying technologies and single flights over 20 km in length.

Date

Design Study 2015

Role

Designer

Client

Dead Sea Works

Tarong Transport Alliance, Australia

The Tarong Transport Alliance selected Overland Conveyor Company to design a belt conveyance system for a 71 km long haul. This ground breaking 71 km system consisted of three flights of 30 km, 30 km, and 11 km would include the 2 longest single flights in the world. They included intermediate drives and horizontal curves to fit within a narrow corridor between Tarong and the New Acland coal supply.

Date

Feasibility Study 2007

Role

Designer

Client

Tarong Transport Alliance

Rio Tinto, Simandou, Africa

Overland Conveyor Co researched and evaluated Doppelmayr's proprietery RopeCon technology for its application for a project conveying over 9000 mpth of material over extremely difficult terrain from mine to rail loadout.

Date

Design Study 2012

Role

Designer

Client

Doppelmayr

Hamilton County Coal, Illinois, USA

Overland Conveyor Company performed a feasibility study on a stacking tube throughput tonnage. The stacking tube window height and shape of the sills were modified to observe the corresponding flow rate. Off center loading into the stacking tube was considered to analyze the throughput difference between windows.

Date

Feasibility Study 2017

Role

Designer

Client

Alliance Resource Partners

 

Transfer Chute Designs & Audits

Torr Aggregate Industries, United Kingdom

Overland Conveyor Company supported Komatsu with troubleshooting, designing, and evaluating 4 transfer chutes that were experiencing continual blocking and plugging potential. DEM parameters were optimized by modeling the existing material build up on the spoon. The 4 transfer chutes were redesigned to alleviate plugging potential and minimize chute wear.

Date

Commissioned 2019

Role

Designer

Client

Komatsu

Mont Wright, Canada

Overland Conveyor Company worked with ArcelorMittal to redesign 8 transfer chutes. Excess chute wear, belt ripping and plugging were observed due to large slabs of material measuring as large as 50 inches or 1270 millimeters. The rockboxes for each transfer had to be modified to adequate space for the large lumps and gently load the receiving conveyors.

Date

Commissioned 2014

Role

Designer

Client

ArcelorMittal

South Flank, Australia

Overland Conveyor Company was selected to design a belt conveyance system and 4 transfer chutes. The emergency stop case was analyzed to determine how the outby transfer chute would handle the surge of material and verify the receiving conveyor could be restarted to draw the material away. Each conveyor was simulated with ramped belts observing full belt speed to an emergency stop based on the analyzed emergency stop time during the conveyor analysis.

Date

Design Study 2016

Role

Designer

Client

Jacobs

Round Mountain, Nevada, USA

Overland Conveyor Company was selected to provide an audit of 2 transfer chute designs. A range of material properties were considered from dry to wet clay and the DEM parameters were optimized accordingly. Gates were installed for redirecting and splitting the material flow to two receiving conveyors. Equal tonnage throughput towards each receiving conveyor was desired and analyzed.

Date

Design Study 2015

Role

Consultant/Auditor

Client

Smith Monroe Gray

 
Overland Conveyor Company, Inc.

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Phone: +1 303 973 7357

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