Flexco MXDP Extreme Duty Diagonal Plough Eliminates Return-Side Spillage and Protects Take-Up Area at Iron Ore Operation

Industry

Hard Rock

Application

Iron Ore

Product

MXDP Extreme Duty Diagonal Plough

Objective

•    Stop return-side spillage from reaching the gravity take-up area
•    Reduce overall pulley damage
•    Minimize conditions for belt failures

Conveyor Detail

•    Belt Width: 1500mm
•    Belt Material: Steel Cord Belt

Problem: 

A hard rock iron ore operation in Western Australia was experiencing significant maintenance costs, equipment damage, and production losses across two incline conveyors feeding the gravity take-up (GTU) area. These issues were driven by material spillage during wet conditions, as well as the impact of crash stops and repeated start-ups. 

Following a root cause analysis on a belt damage incident, the site team discovered that both conveyors were experiencing multiple surge events during operation in wet conditions. Those surges were pushing ore onto the return side of the belt, where the material then travelled back toward the main drive take-up area. Once the carryback reached the take-up, it began building up around the pulleys and creating severe damage to the belts and pulleys, also hazardous build-up around the platforms and walkways. The site was facing ongoing risk of belt damage, loss of production, and premature belt and pulley failure, along with a growing safety concern for personnel working near the take-up as loose rock spilled into the area. Before the RCA, no dedicated solution had been put in place to address return-side material on these lines.

Solution: 

After conducting an investigation and exploring all options to protect the conveyor belts and prevent carryback from reaching the take-up, the site selected the Flexco MXDP Extreme Duty Diagonal Plough. The MXDP is a curved plough engineered specifically to divert fugitive material away from critical components on the return run. Designed with an added high shield to help prevent material from bouncing over, it matched exactly what the operation needed. Two ploughs were installed on the return side of each affected conveyor. The first was positioned at the bottom of the incline to catch material early, before it could continue travelling down the return side. The second was installed on the lead into the take-up area, acting as a final line of defense for the most vulnerable zone on the conveyor. Together, the ploughs create layered protection that intercepts any ore finding its way onto the return side and clears it off well before it can reach the take-up.

Result:

The MXDP installation completely resolved the issues identified in the original RCA. Return-side spillage into the take-up area was stopped, further belt damage was prevented, and the lost production tied to repeated belt repairs was eliminated. Safety improved immediately, with rocks no longer spilling into the take-up area and personnel able to work in and around the zone with far less risk. Productivity gains followed close behind, as the reduced threat of belt repairs, inserts, and premature failure translated directly into fewer downtime events and more consistent throughput. Just as important, the site strengthened its own culture by addressing the issue at the root cause rather than treating symptoms, reinforcing a commitment to solving problems the right way.