Dos Santos Overland Conveyors
Background and Qualifications
We are well qualified to engineer and supply the most complicated high powered high-tech conveyor systems. We have extensive experience in analysis and design of high-tech conveyors of all types, utilizing our ExConTec proprietary analysis program. Our work has included engineering, supply, commissioning, and field testing and monitoring of new and existing complex slope belts, overland and downhill conveyor systems throughout North America, South America and in Europe. These have featured:
-
- Decisively regenerative drives with backup braking systems
- Flywheels with braking
- Booster drives, of the tripper type as well as the belt-on-belt type, with and without belt tension feedback and control
- Two-way conveying (carrying material on both the upper and return belt strands) with:
- Multiple horizontal and vertical curves
This post contains the following more specific sections detailing our experience:
- ExConTec Expanded Conveyor Technology (in-house proprietary analysis program)
- ExConTec Projects list (since 1998)
- J. A. Dos Santos Conveyor Projects (pre 1998)
Follow the links below for case studies of projects that benefited from our expertise:
- ExConTec at USM (Overland Conveyor System)
- ExConTec at Essroc (Two-Way Conveyor)
- ExConTec at TECO (Dock Conveyor with Tripper)
- ExConTec at Los Filos Overland Conveyor System
We look forward to the opportunity to discuss with you in detail the various installations listed and described and their relevance to your particular project.
ExConTec Expanded Conveyor Technology
More than an analysis tool, the Expanded Conveyor Technology reflects a philosophy. Our comprehensive approach takes the conventional conveyor technology beyond the currently perceived limits. Utilizing derived load equivalents we are first to address and predict the extra flexural and shear resistances along vertical and horizontal curves. Our analysis models and software incorporate added features including the “Engineers Discretionary Factors”, an allowance for incorporating the results of field testing or simply our client’s philosophy.
Special Features of ExConTec
- Each run produces a complete tension and power analysis under steady state, starting and stopping conditions. Stopping is by braking and by drifting. Starting and stopping analyses utilize rigid body dynamics.
- Sequential runs, using macros, allow real time analysis and graphical display of changing load conditions including load-on, trailing-off and any discontinuity of material flow. This feature allows us to spot, quickly, the aggravations of flow discontinuities.
- Virtual material loads, or “load equivalents” are used to account for belt line resistances associated with the curving profile or plan of the conveyor line. These (previously unaccounted for) resistances become significant at horizontal curves where the effect is always increased resistance.
- Ky, flex and shear resistance factors differ from CEMA reflecting our experience and philosophy.
- In the analysis, belt tension becomes negative (compressive) when it drops below 0. This, though not realistic (as belt becomes slack), allows continued analysis indicating the tension increase required to correct the slack belt problem.
- An input section entitled “Discretion by Responsible Engineer” offers the user an opportunity to affect the analysis by use of adjustment factors on the Ky and Kx values and on the terminal resistances. These factors can be used to alter the results according to known characteristics of the conveyors being analyzed, to reflect the user’s design philosophy or to achieve matching of field monitored data.
Real time analysis quickly reveals the tension and power aggravations due to flow discontinuity at an overland conveyor with a “smart” booster drive.
Discretionary input factors can reflect the customer’s experience and engineering philosophy.
ExConTec Projects
|
Item |
Company/Location |
System |
||||||||
|
Flight No. |
Material/ Rate |
Belt Width/Speed |
Length |
Net Lift |
Max Lift |
Drives/ Brakes |
Year |
|||
| (t/h) | (mm)/(m/s) | (m) | (m) | (m) | (kW)/ (kN) | |||||
| 1 | US Steel Mining /AL, USA | OL Conveyor 3-Flight System. Each Flight has Dual Pulley Drive, Head End, Remote | 1999 | |||||||
| Flt 1 | Coal / 1270 | 914 / 3.8 | 2812 | 23.5 | 73.1 | 298+224 / — | ||||
| Flt 2 | 914 / 3.8 | 2628 | 19.2 | 52.4 | 298+224/ — | |||||
| Flt 3 | 914 / 3.8 | 2751 | 23.5 | 37.8 | 298+224/ — | |||||
| 8191 | 1566 kW | |||||||||
| 2 | Troy Belt / NY, USA | OL Conveyor, U-Profile, with Single Pulley Remote Drive, Tail Pulley Brake | 1999 | |||||||
| Stone / 1134 | 1219 / 1.8 | 1180 | -3.1 | -35.4 | 149/ 35.6 | |||||
| 3 | Acadia Equip / Ont, CN | OL Conveyor with 2-Horiz Curves, Dual Pulley Drive, Head End, Remote | 2000 | |||||||
| Slag / 2722 | 1219 / 3.1 | 1363 | 4 | 4 | 2@224/ — | |||||
| 4 | AIMCOR/ TX, USA | OL Pipe Conv, Dual Hd Dr, Tail Take-Up, Auto Hyd Winch, 3 Horiz Curves | 2000 | |||||||
| Coke / 500 | Ø305/ 4.3 | 914 | 6.7 | 6.7 | 280/ — | |||||
| 5 | Acadia Equip / Ont, CN | Underground Slope Conveyor, Single Head Pulley Drive | 2001 | |||||||
| Ore / 1451 | 1067 / 2.7 | 579 | 105.4 | 105.4 | 597/ — | |||||
| 6 | Cherry Hill Construction / MD, USA | OL Conveyor 5-Flight System. Each has Single Pulley Drive, Head End, Remote | 2002 | |||||||
| Flt 1 | Soil / 1592 | 914 / 3.9 | 549 | 10.4 | 10.4 | 187/ — | ||||
| Flt 2 | 914 / 3.7 | 626 | 1.2 | 1.2 | 149/ — | |||||
| Flt 3 | 914 / 3.8 | 938 | 1.2 | 1.2 | 187/ — | |||||
| Flt 4 | 914 / 3.2 | 789 | 1.2 | 4.6 | 187/ — | |||||
| Flt 5 | 914 / 3.1 | 359 | 1.2 | 1.2 | 112/ — | |||||
| 3261 | 822 kW | |||||||||
| 7 | BMH Systems / Ont, CN | Underground Load-out Conveyor, Dual Pulley Drive, Head End, Remote | 2002 | |||||||
| Ore / 703 | 1067 / 2.5 | 709 | 127.3 | 127.3 | 2@224/ — | |||||
| 8 | Continental Conveyor and Machine Works / Que, CN | Two-Way OL Conveyor, Horizontally Curving (9 horiz curves compounded by numerous vertical curves), with Smart and Natural Booster (Intermediate) Drives at Carrying and Return, Carrying Limestone from Quarry to Cement Plant #1, Returning Clinker to Cement Plants #2 & #3 | 2003 | |||||||
| Carry | Stone / 1320 | 1067 / 3.4 | 2752 | 46.8 | 57.8 | 298 Smart Booster 298+149 Dual Hd | ||||
| Return | Clinker/ 420 | 149 Dumb Booster | ||||||||
| 894 kW | ||||||||||
| 9 | BMH Systems / Ont, CN | Underground Load-out Conveyor, Single Pulley Head Drive | 2003 | |||||||
| Ore / 200 | 1067 / 1.6 | 1216 | 180 | 180 | 187/ — | |||||
| 10 | TECO Terminal / LA, USA | Tripped Dock Conveyor to Shiploader, Dual Pulley Remote Drive | 2003 | |||||||
| Coal / 6845 | 1829 / 4.5 | 430 | 8 | 8 | 522/ — | |||||
| 11 | Bonem Corp / Ont, CN | Reclaim Conveyor with Single-Head Pulley Drive, Tail Take-Up, Horizontal Gravity | 2004 | |||||||
| Ni-Cu /2550 | 1067 / 2.6 | 342 | 9.9 | 9.9 | 186 / — | |||||
| 12 | Bonem Corp / Ont, CN | Tripper Conveyor, with Single-Head Pulley Drive, Gravity Take-Up, Remote | 2004 | |||||||
| Ni-Cu / 400 | 762 / 1.4 | 414 | 23.4 | 23.4 | 75/— | |||||
| 13 | Energy Assoc/ NJ, USA | OL Pipe Conv, Dual Hd Dr.+Single Tail Drive, Tail Take-Up, Horiz. Gravity, 2 Horiz Curves | 2004 | |||||||
| Alum / 800 | Ø440 / 2.6 | 1800 | -25 | -25 | 3@ 150/ — | |||||
| 14 | Pinnoak /AL, USA | Underground Slope Conveyor, Single Head Pulley Drive, Tail Take-Up, Horizontal Gravity | 2005 | |||||||
| Coal / 2413 | 1524 / 3.4 | 1194 | 361 | 361 | 2@1865/ — | |||||
| 15 | Bonem Corp / Ont, CN | Underground Slope Conveyor, Dual Pulley Drive at Head, Tail Take-Up, Horizontal Gravity | 2005 | |||||||
| Sulfide /703 | 1067 / 2.5 | 710 | 127.3 | 127.3 | 2@224 / — | |||||
| 16 | Goldcorp, Los Filos Gold Mine/ Mezcala, MX | 8-Flight Overland Conveyor System, 6-Downhill-Regen, 3/w Horizontal Curves | 2009 | |||||||
| Flt 1 | Au Ore/1043 | 914 / 2.3 | 41.2 | 5.5 | 5.5 | 44.7 / — | ||||
| Flt 2 | 914 / 2.3 | 248 | 26.5 | 26.5 | 149 / — | |||||
| Flt 3 | 1219 / 1.2 | 213 | -20.9 | -20.9 | Regen 44.7 / 17.9 | |||||
| Flt 4 | 914 / 2.3 | 243 | -24.6 | -24.6 | Regen 74.6 / 34.5 | |||||
| Flt 5 | 914 / 2.3 | 476 | -43.7 | -43.7 | Regen 149 / 63.7 | |||||
| Flt 6 | 914 / 2.3 | 201 | -14.3 | -14.3 | Regen 44.7 / 21.4 | |||||
| Flt 7 | 914 / 2.3 | 84.5 | -9.8 | -9.8 | Regen 44.7 / 13.3 | |||||
| Flt 8 | 914 / 2.3 | 148 | -4.1 | -4.1 | Regen 44.7 / 8.3 | |||||
| 1655 | 596 kW | |||||||||
| 17 | HSGP Project Abu Dhabi, UAE | 9-Flight Conveyor System | 2012 | |||||||
| 5010CV0101/0201 | Sulphur/840 | 1000 / 2.7 | 219.7 | 9 | 9 | 110 / — | ||||
| 5010CV0102/0202 | Sulphur/4000 | 2200 / 2.5 | 653.2 | 26.8 | 26.8 | 710 / — | ||||
| 5015CV1001 | Sulphur/4000 | 2200 / 2.5 | 238.7 | 20.3 | 20.3 | 400 / — | ||||
| 5015CV0101/0201 | Sulphur/2000 | 2200 / 0.9 | 13.4 | 0 | 0 | 110 / — | ||||
| 7015CV1100/1200 | Sulphur/2000 | 2200 / 0.9 | 17.7 | 0 | 0 | 110 / — | ||||
| 2047 | 2480 kW | |||||||||
| 18 | SHAH Project Abu Dhabi, UAE | 7-Flight Conveyor System | ||||||||
| 7010CV1100 | Sulphur/720 | 1000 / 2.4 | 218.1 | 7.2 | 7.2 | 110 / — | 2013 | |||
| 7010CV1200 | Sulphur/720 | 1000 / 2.4 | 216.3 | 7.3 | 7.3 | 110 / — | ||||
| 7010CV2100 | Sulphur/4000 | 2200 / 2.5 | 706.4 | 26.8 | 26.8 | 710 / — | ||||
| 7010CV2200 | Sulphur/4000 | 2200 / 2.5 | 687.6 | 26.3 | 26.3 | 710 / — | ||||
| 7015CV1100/1200 | Sulphur/2000 | 2200 / 0.9 | 13.4 | 0 | 0 | 110 / — | ||||
| 7015CV1300 | Sulphur/4000 | 2200 / 2.5 | 238.7 | 20.4 | 20.4 | 500 / — | ||||
| 2094 | 2360 kW | |||||||||
| 19 | Newcrest Mining, Dome Mine, WA, Australia | 2-Flight Underground Collecting Conveyor System, Flight 2 with Trip Type Booster | 2013 | |||||||
| Flt 1 | Au Ore/2000 | 1200 / 2.5 | 785.5 | 37 | 37 | 355 / — | ||||
| Flt 2 | 1200 / 3.0 | 1974.8 | 371.9 | 371.9 | 2600 / — | |||||
| 2760 | 2955 kW | |||||||||
| 20 | Ma’aden Gold, Kuwait | 2-Flight Underground Collecting Conveyor System, Flight 2 with Trip Type Booster | 2013 | |||||||
| CV002 | Au Ore/451 | 900 / 1.0 | 2042 | 44.8 | 44.8 | 110 / — | ||||
| CV003 | 900 / 1.0 | 19.3 | 0 | 0 | 7.5 / — | |||||
| 2061 | 117.5 kW | |||||||||
| 21 | Hansen Aggregates at Lindisfarne Quarry, Hobart, Tasmania | 4-Flight Downhill-Regen Conveyor System | 2013 | |||||||
| Flt 1 | Dolomite/ 450 | 900 / 1.2 | 135 | -30.2 | -30.2 | 37 / — | ||||
| Flt 2 | 900 / 1.2 | 352 | -62.8 | -62.8 | 75 / — | |||||
| Flt 3 | 900 / 1.2 | 185 | -30.9 | -30.9 | 37 / — | |||||
| Flt 4 | 900 / 1.2 | 158 | -0.2 | -0.2 | 22 / — | |||||
| 830 | 171 kW | |||||||||
Conventional Conveyor Projects – pre-1998
|
Item |
Company/Location |
System |
Material/Rate |
Belt Width |
Length |
Drives/Brakes |
Year |
||
| (mm) | (m) | ||||||||
| 1 | Zinc Mine / TN, USA | Underground slope conveyor | 1993 | ||||||
| Single flight | Zinc Ore / 227 | 914 | 1591 | Single pulley head / remote drive | |||||
| 2 | Phosphate Mine / Venezuela | Overland conveyor system, decisively-downhill regenerative system | 1993 | ||||||
| 6 flights | Phosphate rock / 735 | 762 | 2279 | Single pulley tail drives / low speed disc, caliper brakes | |||||
| 3 | Coal Mine / AL, USA | Underground slope conveyor, dual pulley drive, had end, remote, tail take-up | 1993 | ||||||
| Single flight | Coal / 4990 | 1828 | 1356 | 4@1492 kW = 5968 kW | |||||
| 4 | Coal Mine / Colombia | Overland conveyor | 1994 | ||||||
| Two flights | Coal / 1451 | 1524 | 1652 | ||||||
| 5 | Dam construction / CA, USA | Overland conveyor, alluvial fill system, with tripper-booster drive at flight 6 | 1995 | ||||||
| 6 flights | Alluvium / 1089 | 914 | 4663 | 448 kW head drive, 224 kW tripper-booster drive | |||||
| 6 | Dam construction / CA, USA | Overland conveyor, rock fill system, with tripper-booster drive at flight 4 | 1995 | ||||||
| Four flights | Rock / 2177 | 1219 | 3200 | 896 kW head drive, 448 kW tripper-booster drive | |||||
| 7 | Copper Mine / Eastern Europe | Overland conveyor, with single head drive and three tripper boosters | 1997 | ||||||
| Single flight | Overburden / 4700 | 1600 | 2786 | 1000 kW head drive, 3@1000 kW tripper booster drives = 4000 kW | |||||