How a Mine Conveyor System Increased Efficiency by 30% with Carbide Conveyor Scrapers

The Challenge

A large mining operation was experiencing significant efficiency losses in its conveyor belt system due to:

Excessive material carryback (estimated 3-5% of transported material)
Frequent downtime for cleaner maintenance (every 2-3 days)
Premature belt wear requiring replacement every 6 months
Energy losses from belt slippage and additional friction

The Solution: Tungsten Carbide Scrapers Implementation

The mine replaced their conventional polyurethane scrapers with tungsten carbide-tipped conveyor belt scrapers, offering:

Key Advantages of Carbide Scrapers

Superior Material Removal – Carbide’s hardness (90-92 HRA) provides excellent scraping efficiency
Extended Service Life – Lasts 3-5 times longer than polyurethane alternatives
Self-Sharpening Design – Maintains optimal cleaning edge throughout lifespan
Reduced Belt Wear – Precise angle control minimizes belt surface damage
Corrosion Resistance – Ideal for wet or abrasive mining environments

Implementation Process

Assessment Phase:
- Analyzed belt speed (3.5 m/s), material type (iron ore), and conveyor incline (18°)
- Measured existing carryback rates (average 4.2%)
Customization:
- Selected 60° scraper angle for optimal cleaning
- Installed primary and secondary scraper configuration
- Used carbide with 10% cobalt binder for toughness
Installation:
- Retrofitted existing cleaner mounts
- Adjusted tension to 25-30 N/cm
- Implemented in all 12 conveyor transfer points

Results After 6 Months

Metric	Before	After	Improvement
Carryback	4.2%	0.7%	83% reduction
Cleaner Replacement	Weekly	Quarterly	85% reduction
Belt Life	6 months	11 months	83% increase
Energy Consumption	185 kW	162 kW	12% reduction
System Efficiency	72%	94%	30% overall increase

Additional Benefits

Reduced Maintenance Costs: Saved $48,000 annually in labor and parts
Improved Safety: Less spillage reduced slip/fall hazards
Environmental Impact: 28 tons/year less ore lost to carryback
Downtime Reduction: 15 fewer hours/month for cleaning maintenance

Belt conveyors and roller conveyors are essential components of modern bulk materials handling systems, widely used in mining, assembly lines, and various industrial processes. A well-designed conveyor system ensures smooth materials flow and significantly increases productivity while reducing manual labor. At critical transfer points, a high-quality mining conveyor belt scraper removes carryback, prevents material buildup, and extends the life of wear parts. For heavy-duty applications involving abrasive bulk materials, troughed belt designs and stainless steel construction provide superior durability and corrosion resistance. By integrating a variable frequency drive (VFD), the entire conveying system can adjust speed dynamically to match production demands, making belt system operation more cost-effective and energy-efficient. Ultimately, understanding the different types of conveyor systems and how conveyor systems work allows engineers to select and maintain the optimal solution that improves efficiency, minimizes downtime, and delivers long-term value.

Conclusion

The switch to tungsten carbide scrapers transformed the mine’s conveyor performance, delivering a 30% overall efficiency gain while reducing operating costs and improving safety. The project paid for itself in just 3.2 months, demonstrating how advanced material selection in wear components can dramatically impact mining operations.

“Zhuzhou Old Craftsman Precision Alloy Co., Ltd. could make tungsten carbide wear parts and make your equipment use life is tens of times longer than before! We specialize in providing customized carbide wear products solutions to meet the demanding requirements of industries such as aerospace, automotive, mining, and precision machining.”