Unearthing a New Approach to Mine Conveyor Maintenance

Published: 15/1

As the world’s leading copper producer, Chile relies heavily on conveyor systems in its vast open cast mines, which are essential for transporting materials between extraction and processing plants. One of the most notable sites in Chile is the El Abra mine, home to the longest and most robust conveyor belt system in the world, stretching more than 12 miles (20km). Maintaining these massive conveyors in peak condition is crucial to avoiding costly complications, including material build-up and the risk of fires caused by friction with the rollers. These issues can threaten safety, and force partial or complete production shutdowns, resulting in staggering costs.

Traditionally, cleaning under these conveyors has been a labor-intensive and hazardous task, requiring work with shovels and wheelbarrows or combustion-powered carriers. This inefficient and expensive approach can only be carried out during three to four scheduled downtimes a year, or in response to unexpected malfunctions.

 

A better idea

An innovative solution for cleaning conveyor belts combines Brokk’s Vacuum Excavation System with the Brokk 110 demolition robot. The radio controlled Brokk system allows precise cleaning under moving conveyors, ensuring operator safety and protecting infrastructure. In addition to enhanced safety, the Brokk system is said to have improved operational efficiency, significantly reducing the risk of costly stoppages by 80%.

The system’s design is also said to provide enhanced efficiency, maintaining the suction duct’s diameter to optimize vacuum truck performance. Cost reductions further extend beyond operational uptime. The system requires just two operators, instead of the eight workers previously needed for manual cleaning.

Further reducing maintenance costs is the fact that the electric motors require less frequent and simpler maintenance compared to combustion engines. This, combined with the fact that Brokk machines have more than triple the lifespan of their combustion-powered counterparts, significantly lowers long term expenses. According to Domingo Gonzalez, Mining Division manager for Chilian equipment distributor Socomaq, the Brokk system also supports decarbonization efforts by reducing silica exposure and eliminating musculoskeletal strain for operators—key objectives for mining companies. As a result, working conditions have improved dramatically.

“The response has been very positive, operators realize that they can learn to handle the Brokk well, making work easier, faster, and safer,” Gonzales explains. “Rather than being perceived as a threat to their jobs, the system allows them to be more competitive when it comes to renewing their company’s contract with the mining company.’’

 

A zero emissions future for mining

Sustainability is another crucial benefit. The system is electrically powered, which not only eliminates downtime for battery recharging or filter cleaning, but also completely removes emissions from the equation. This is particularly important in underground mining, where air quality is a critical concern, and helps mining companies meet their carbon footprint reduction targets. “Because we’ve achieved results in these cleaning performances never seen before, we’re rewriting the methodology for belt cleaning,” Gonzales says.

Brokk believes that its Vacuum Excavation System is revolutionizing mining operations in Chile and beyond by delivering unparalleled safety, efficiency, and sustainability, setting new industry standards.