In mining industry, conveying applications, damage to conveyor belt poses a significant risk that can lead to production downtime, soaring costs, and substantial financial losses. The majority of unplanned conveyor belt failures are not caused by core failure, but rather by moisture penetration and material corrosion resulting from scratches, gouges, and cuts in the surface covering, which ultimately lead to wire rope corrosion or delamination of the fabric layers. In response to this, Conveyor belt Muti protection system - a multi-layered combination comprising CONTI® SurfaceProtect, CONTI RipProtect®, and CONTI TotalProtect, developed by industry-leading companies - have emerged.
Customer Value
Prevent High-Risk Unplanned Downtime: Every year in the global mining industry, longitudinal tears or steel cord corrosion that go undetected during routine inspections are the direct cause of massive accident claims amounting to millions of dollars. The protection system mitigates various hidden costs and losses.
Extended Conveyor Belt Lifespan: The combined detection capabilities of SurfaceProtect and MultiProtect cover all types of surface defects, preventing small and medium-sized cuts from expanding and causing premature belt failure. This maximizes the belt's service life and reduces total lifecycle costs.
Reduced Manual Inspection Workload: Eliminates high-risk on-site inspections by personnel. The cloud platform records damage trends and predicts when cleaning or repairs are needed.
Targeted Repairs: The system recommends repair priorities, avoiding the blind burning of frayed edges or unnecessary full-section belt replacements.
Quantifiable Return on Investment: After upgrading to ContiTotalProtect, a certain open-pit copper mine saved the cost of replacing an entire million-dollar conveyor belt and avoided over a month of lost power generation due to downtime, thanks to early warnings of steel cord breakage.
Applications and Industries
Mining Industry (Coal/Copper/Iron/Gold)
Used in underground main conveyor transfer systems, open-pit transport shafts, or processing and crushing transfer lines. SurfaceProtect is employed to address sudden high-impact damage caused by intermittent large, sharp rocks; RipProtect provides rapid protection against longitudinal tearing; and MultiProtect or TotalProtect monitor the real-time health status of steel wire ropes regarding fatigue and corrosion.
Cement/Building Materials Industry
Conveying limestone, sandstone, and high-hardness, heavy ores from coastal quarries can cause severe surface abrasion and premature exposure of internal steel cables. Combine the SurfaceProtect laser system with MultiProtect to track the impact-reserve area at high-drop material discharge points from buckets and monitor the condition of internal, concealed cables.
Thermal Power Plants
Conveyor belts must be equipped with rapid tear detection and surface wear/fatigue indicators as safety redundancies. Particularly on high-risk routes prone to ash and slag abrasion under furnaces, the introduction of RipProtect loop detection can minimize financial losses for power plants within seconds, thereby ensuring continuous power supply.
Metallurgical/Steel Mills
On conveyor lines handling red-hot sintered ore or scrap steel, surface protection devices can proactively detect defects such as sagging and bulging, as well as tendencies for transverse cable tears. This allows for the scheduling of splicing repairs as part of a centralized maintenance checklist, thereby reducing the likelihood of cascading shutdowns.
Ports/Terminals/Bulk Cargo Transshipment Stations
Mixed loads such as iron ore and coal pose significant threats to steel-cord layered conveyor belts. High-speed re-inspection by laser sensors and X-ray image analysis can assess steel-cord corrosion and external scratches.
FAQ
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