Conveyor systems in mining operations are a business in their own right. These systems are often expensive pieces of equipment that can take weeks to assemble. The aim of this article is to provide insight into the costs involved in installing conveyor systems.
According to West river conveyors (admin, 2021), the cost of setting up a conveyor system for a mine is structured as follows:
Structure cost
Structure can be floor or roof mounted. Good quality structure incorporates CEMA standard idler rollers and is powder-coated for corrosion protection. Structure is priced per foot and can range from as low as $40.00 per foot to $150.00 per foot depending on required belt width, CEMA rating, shell thickness, and structural support requirements. The higher the CEMA rating and wider the belt width, the higher the cost.
Alignment-free drive cost
This is made up of a motor or motors plus couplings and reducers. It also requires a motor starter.
Motors can be pricey: figure about $25,000 for 300 hp.
Several types of starter are available. VFDs offer the greatest energy savings and control but are higher cost, approximately $50,000-$60,000 for a pair of 300 hp motors. Complex motor control systems will also need a control panel at an additional $20,000.
Across-the-line starters are the least expensive option but use more power and impose higher loads and more wear on the system. These would cost $15,000-$20,000. In between VFDs and across-the-line starters are soft starters. These reduce wear but provide little in the way of energy savings.
Conveyor belt cost
The belt is one of the more expensive elements of a conveyor system, especially in underground applications where fire resistance is oftentimes mandatory. Cost depends on belt width, (mining belts usually range from 36-60”), strength (expressed in pounds per inch of belt width (PIW), and the number of plies.
Depending on these variables, an underground conveyor belt costs between $25-$100/ft.
Discharge unit/rock box/transfer chute
The cost of this depends on capacity, height, and design characteristics. A simple rock box could be in the region of $5,000-$15,000 while a more complex transfer chute might be $15,000-$30,000.
Transport and delivery costs
The cost of moving underground conveyor systems from our factory in Oakwood, VA depends on distance. For budgeting purposes, use $5,000-$10,000.
Total package cost
While an underground conveyor system may have higher up-front costs than alternative methods of bringing material out of a mine, lower energy, and maintenance costs plus improved safety and avoidance of fumes quickly make it the most economical.
The cost of a complete system depends on the individual application. However, to give an indication, consider a system with a capacity of 300 tph and a belt 30” wide moving at 450 feet per minute over 1,000 feet. Here the total cost, including alignment-free drive, takeup unit, tail section, starter, structure, and belt would probably be in the range of $275,000-$400,000.
Reference
admin. (2021, June 3). What Does An Underground Conveyor System Cost? West River Conveyors. https://www.westriverconveyors.com/blog/how-much-underground-conveyor-system-cost/
