1288 SMe Mining engineering handbook

when uncrushable objects enter the crushing chamber. Foreign

objects, such as steel, can cause extensive damage to a cone
crusher and additional costs in lost production. Advancement
in hydraulic relief systems has greatly reduced downtime and
improved the life of these machines.

ConveyoRS
Mine conveyor systems have been utilized in underground
mass mining for many years. Conveyor systems are com-
monly found in underground continuous coal mining opera-
tions, which use longwall and room-and-pillar methods. More
recently, underground conveyor systems have been employed
in large-scale, long-life metalliferous mines. Conveyors are
more commonly used in operations where mine geometry and
production flow allow conveyor haulage to be more efficient
or cost-effective than other methods.
Inclined, troughed belt conveyors are more frequently
being selected from a range of alternatives, which include
shafts and trucks, for ore haulage in underground mass min-
ing projects. Belt conveyor haulage systems are being oper-
ated with lifts exceeding those normally associated with truck
haulage systems and approaching the limits of shaft haulage
systems (Spreadborough and Pratt 2008).
Continued development of conveyor technology has
resulted in increased confidence in and reliability of these
systems. Reliability of conveyor-based haulage systems as a
whole is impacted by the complexity of larger configurations
constructed of multiple units or lifts. Modern conveyor instal-
lations have proven high availabilities (>85% are achievable
in underground operations), which has added confidence to
their use in recent times.
Figure 12.8-16 shows a typical conveyor in an under-
ground metalliferous mine operation.

Safety Considerations
In the selection of conveying options for an underground oper-
ation, several risk areas must be addressed, including
• Belt fires managed by self-extinguishing belt covers and
auto detection and suppression systems;
• Belt failures addressed by belt-rip detection systems,
monthly belt scans, and concrete bulkheads;
• Guarding requirements to prevent injury to personnel;
• Audible start-up alarms where personnel work near the
belt;
• Emergency stop provisions in areas where access by per-
sonnel is required; and
• Dust management.
Selection Criteria
The selection of haulage systems for underground mass min-
ing has historically focused on shaft haulage, trucks, and
belt conveyors. The application of these alternatives in the
Australian mining industry is summarized in Figure 12.8-3.
Troughed belt conveyors are shown in this figure to be applied
in the range up to 8 Mt/a production rate and 1,200-m lift.
Selection criteria for underground conveyor haulage include
• Inherent safety;
• Capacity (steady state and surge flow);
• Simplicity in design and operation;
• Dimensions (length, height, and width);
• Maneuverability/adaptability to various layouts;
• Cost (capital and operating);
Courtesy of BHP Billiton Olympic Dam.
figure 12.8-16 Typical conveyor in an underground metal-
liferous mine operation
• Reliability/availability;
• Operating life;
• Size of product handled, spillage, and carry-back;
• Dust and noise generation; and
• Automatic, remote operations.
The advantages of conveying material include high auto-
mation, minimal operational labor requirements and lower
operating costs, and high reliability/availability.
The disadvantages of conveying material include high
capital cost (therefore lower probability of duplication), a
large footprint, and limited flexibility.
Belt conveyors for underground service usually have a
more rugged design and operate at slower speeds than a com-
parable overland conveyor. Hard-rock mine belt conveyors
normally require the ore to be crushed before it is conveyed
or at least sized through a grizzly. Reasons for this include
increased belt life due to reduced impact from lumps and
elimination of tramp material, including rock bolts, rebar, drill
steels, and scaling bars, which can seriously affect the integ-
rity of the belt system.
Belt conveyor systems are less flexible than truck haul-
age and require a high initial investment. This generally
means that belt conveyors are the economical choice when the