Optimization of conveyor belt
transfers through contactless sealing systems
Conventional sealing systems are generally based on mechanical contact between the seal and the conveyor belt. Although this contact is necessary to limit material spillage, it inevitably leads to abrasion. Conventional side seals wear out, need to be regularly adjusted or replaced, and cause not only maintenance costs but also damage to the conveyor belt itself. In addition, fine particles in particular escape as dust, which is a burden on both occupational safety and the environment and causes valuable conveyed material to be lost unused.
The new concept is based on the patented contact-free AirScrape sealing system. This system completely eliminates mechanical contact between the seal and the conveyor belt. Instead, specially arranged, hardened lamellas are used to generate a directed air flow via the Venturi effect. This air flow acts as an invisible barrier: fine particles and dust that would escape at the transfer point are directed back onto the conveyor belt. In this way, the sealing function is achieved not by friction, but by the Venturi effect.
The key features of such a system can be summarized as follows:
non-contact operation without mechanical contact with the conveyor belt
special blade geometry to generate a directed air flow
no measurable wear and no readjustment required
maintenance-free operation over several years
no energy costs
Initial situation: Losses due to dust, wear, and downtime
In typical conveyor systems with multiple transfer points, conventional seals regularly cause problems. The continuous abrasion of the rubber seals necessitates frequent maintenance. In practice, this means unplanned downtime every few weeks, which can last several hours each time. In addition to the direct costs of lost production, there are additional expenses for personnel, spare parts, and maintenance.
However, the gradual loss of material is particularly critical. Fine particles that escape as dust add up to considerable amounts over the course of a year. Even a seemingly small loss of dust and material of around 2 % of annual production can have a noticeable economic impact, depending on the value of the material. At the same time, dust emissions worsen working conditions and increase the cleaning effort along the entire conveyor route.
Results after installing a contact-free sealing system
After installing a contact-free sealing system, the effects can be clearly quantified. Dust emissions are reduced by more than 95 %, and sealing-related downtime is completely eliminated. Since there is no contact between the seal and the belt, there is no wear on the seal or damage to the conveyor belt. Production reliability increases significantly, and maintenance work in the transfer area is practically no longer necessary.
Another decisive advantage is the recovery of previously lost material. Fine dust that used to leave the plant now remains in the process and contributes directly to the usable production volume. This effect has a direct impact on the economic efficiency of the entire conveyor system.
Increased efficiency in copper mining
To illustrate the economic effects of non-contact sealing systems, an example from copper mining is used below. A modern conveyor system with an annual capacity of around 300 000 t of copper loses around 2 % of its production due to dust emissions at conveyor belt transfer points. This corresponds to an annual material loss of around 6000 t of copper.
Assuming a copper price of around 10 000 US$/t, these losses add up to an economic loss of around 60 million US$/a. In addition to the pure material losses, additional costs are incurred for regular cleaning, maintenance, and repair work at the transfer points. These lead to unplanned downtime and cause downtime costs of around 200 000 US$/month.
The use of a contact-free sealing system such as AirScrape can almost completely eliminate these losses and the resulting costs. The contact-free operation drastically reduces dust emissions at conveyor belt transfers, keeping material in the process and eliminating sealing-related downtime. At the same time, wear on the belt and seal and the associated maintenance costs are minimized.
The economic benefit thus results both from the recovery of previously lost material and from the significant reduction in downtime and maintenance costs. In comparison, the investment costs for purchasing and installing the system are low and pay for themselves within a very short time, especially in the case of high-value bulk materials such as copper.
Ecological and occupational safety aspects
In addition to the economic advantages, ecological and occupational safety aspects are playing an increasingly important role. The significant reduction in dust emissions improves air quality in the workplace, reduces cleaning costs, and minimizes environmental impact. Legal limits and occupational safety regulations can be reliably complied with. Since the system is maintenance-free, the risk of accidents due to service and adjustment work during operation is also reduced.
Conclusion
Non-contact sealing systems such as AirScrape impressively demonstrate the potential of modern technologies for bulk material handling. They reduce dust, wear, and downtime while significantly increasing the usable output of the conveyor system. A comparison of different bulk materials in particular makes it clear that even small percentage losses of material can have a significant economic impact. The combination of higher availability, lower maintenance costs, and significant material recovery means that the investment pays for itself in a very short time, while also making an important contribution to occupational safety and sustainability.
Booth 4-A37A
