High Angle Conveying,

Vital Link
to

IPCC Systems
(In-Pit Crushing and Conveying)

Joseph A. Dos Santos

Dos Santos International
Marietta, Georgia, USA

Sandwich Belt High-Angle

Conveyors
History
The Technology
Installations

From Research
To Reality

The DSI Snake Sandwich

High Angle Conveyor

Product
of Evolution

History
of
Sandwich Belt
High-Angle
Conveyors

Cover Belts of the 1950s

Cover Belt -Schematic

RUBBER TYRES PRESS COVER BELT

ONTO MATERIAL

1950s - First Sandwich Belt Model

= Conveying Angle
m = Coefficient of friction
for bulk material on bulk
material

b = Coefficient of friction
for bulk material on belt
N = Normal lineal hugging
load exerted by the top
belt
Wm = Lineal weight of
bulk material

Sandwich Belt Model #1

Loop Belts of the 1970s

Loop Belt -Schematic

Loop Belt Demonstration Unit

1970s
First use of Radial Pressure due to
Tension

T
Pr =
R

Dos Santos Sandwich Belts

of the 1980s
The Prophecy:
A Sandwich Belt High Angle Conveyor, rationalized in the
Conventional Conveyor Technology, will have the operating
characteristics of a conventional conveyor:

High Reliability and Availability

Low Operating and Maintenance Costs

S-Shape Sandwich Conveyor -Schematic

Snake Sandwich Conveyor -Schematic

First disclosure of Snake
Sandwich High Angle
Conveyor

Mechanically Presses Sandwich Conveyor -Schematic

First disclosure of
Mechanically Pressed
Sandwich High Angle
Conveyor

, m, b, N, Wm are as defined
for Sandwich Belt Model #1
Nm = That portion of N which
bears directly on the conveyed
material
Ne = That portion of N which
bears directly on the edges of the
bottom belt

e = Coefficient of friction at the

interface of the top and bottom
belts

Sandwich Belt Model #2

Snake Sandwich Conveyor Model

DSI Snake Sandwich

High Angle Conveyor

6
5

Sample Profile
and Details

3
1
2

6
5

4
1. Loading onto bottom belt between skirts

1
2

6
5

2. Top belt joins bottom belt to sandwich material

3
1

6
5

4
3. Curve 1, bottom belt hugs material
against top belt

1
2

6
5

4
4. Inflection 1 between curves 1 and 2

3
1
2

5
4
5. Inflection 2 between curves 2 and 3

3
1
2

6
5

4
6. Inflection 3 between curves 3 and 4

3
1
2

6
5

7. Material discharges from between belts

3
1
2

Snake Conveyor Profiles

Snake Conveyor Basic Profiles

Snake Conveyor Extended Profiles

Continuity of Hugging Principle

Material Hugging Pressure must be continuous and uniform. It must
hug all of the material always, without lapse even at the smallest scale
Radial pressure due to tension is the ideal way to apply hugging
pressure

Other Characteristics:
Capacity
Material Size
Belt Speed
Belt Width

Dos Santos Sandwich Belt

High Angle Conveyors
for

IPCC Systems
(In-Pit Crushing and Conveying)

The Most Common Concern:

Are Sandwich Belt High Angle Conveyors
suitable for in-pit mining applications?
Particularly:
Can they handle very high conveying rates?
Are they suitable for continuous operation 24/7?
Can they handle large, heavy, primary crushed ore and waste rock?

Subsequent installations will answer these questions

The most important concern:

Can they handle large, heavy, primary crushed
ore and waste rock?

Large belts can handle large lumps, small

belts cannot.

Dos Santos Sandwich Belt

High Angle Conveyors
Select Highest Rates, Coarsest Materials

Recommended Maximum Lump Size:

Predominantly Lumpy Material (> 10%)
Occassionaly Lumpy Material (< 10%)
DSSBI
DS 001
DS 002
DS 003
DS 004
DS 005
DS 011
DS 012
DS 022
DS 023
DS 024
DS 026
DS 027
DS 030
DS 036
DS 037
DS 038
DS 043
DS 051
DS 065
DS 077
DS 078
DS 079
UHAC

Belt Width
1524
1524
2000
1829
914
1372
914
1219
1829
1067
1524
1219
1524
1219
1372
1372
1067
1372
2134
2134
762
762
2600

0.1140 x Belt Width

0.1425 x Belt Width

Recc Max Lump Size

Design
Max Lump /
>10%Lumps >10%Lumps Lump Size
Belt Wdth
174
217
254
0.1667
174
217
154
0.1010
228
285
250
0.1250
209
261
154
0.0842
104
130
154
0.1685
156
196
203
0.1480
104
130
135
0.1477
139
174
100
0.0820
209
261
102
0.0558
122
152
152
0.1425
174
217
203
0.1332
139
174
203
0.1665
174
217
228
0.1496
139
174
250
0.2051
156
196
152
0.1108
156
196
203
0.1480
122
152
152
0.1425
156
196
152
0.1108
243
304
305
0.1429
243
304
152
0.0712
87
109
102
0.1339
87
109
100
0.1312
296
371
350
0.1346

BW/9
BW/7

DS 001

1524

174

217

254

0.1667

DS
001
Sandwich Conveyor Test & Demonstration
Materials
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Various, from light weight wood chips

to heavy course ores
- 0.27 to 2.4 t/cu-m (17 to 150 PCF)
- To 254 mm (10) minus
- To 2700 t/h (3000 STPH)
- Variable 30 to 60 degrees
- 1524 mm (60)
- Variable to 6.1 m/s (1200 FPM)
- Variable 7,900 to 19,50032 mm (26 to 64)
- 35,000 mm (115)
- 74.6 kW (100 HP)
- 111.8 kW (150 HP)

DS 002

1524

Sandwich Conveyor
for
Coal Mine, Western USA
Material
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Coal
- 2540 t/h (2800 STPH)
- 60 degrees
- 1524 mm (60)
- 5.33 m/s (1050 FPM)
- 32,900 mm (108)
- 35,000 mm (115)
- 149 kW (200 HP)
- 224 kW (300 HP)

174

DS
002

217

154

0.1010

DS 003

2000

228

DS
003

285

250

0.1250

Sandwich Conveyor
for
Copper Mine, Eastern Europe
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Drives
- Top Belt
- Bottom Belt

- Copper Ore
- 2.08 t/cu-m (130 PCF)
- To 250 mm (10) minus
- 4000 t/h (4409 STPH)
- 35.5 degrees
- 2000 mm (78.7)
- 2.85 m/s (561 FPM)
- 93,500 mm (307)
- 450 kW (600 HP)
- 2x450=900 kW (1200 HP)

DS 004

1829

209

DS
004
Sandwich Conveyor
for
Coal Mine, Western USA
Material
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Drives
- Top Belt
- Bottom Belt

- Coal
- 2903 t/h (3200 STPH)
- 35 degrees
- 1829 mm (72)
- 4.57 m/s (900 FPM)
- 29,000 mm (95)
- 149 kW (200 HP)
- 224 kW (300 HP)

261

154

0.0842

DS 005

914

104

130

DS
005

154

0.1685

Sandwich Conveyor
for
Metro Project, Los Angeles, CA, USA
Material
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Drives
- Top Belt
- Bottom Belt

- Excavated Earth
- 272 t/h (300 STPH)
- 90 degrees
- 914 mm (36)
- 1.6 m/s (315 FPM)
- 32,300 mm (106)
- 22.4 kW (30 HP)
- 22.4 kW (30 HP)

DS 011

1372

156

196

DS
011

203

0.1480

Sandwich Conveyor
for
Coal Mine, Western USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Raw Coal
- 0.961 t/cu-m (60 PCF)
- 203 mm (8) minus
- 1089 t/h (1200 STPH)
- 67 degrees
- 1372 mm (54)
- 3.56 m/s (700 FPM)
- 33,200 mm (109)
- 46,000 mm (151)
- 93.2 kW (125 HP)
- 93.2 kW (125 HP)

DS 012

914

104

Sandwich Conveyor
for
Coal Prep Plant, Eastern USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Refuse
- 1.28 t/cu-m (80 PCF)
- 135 mm (5.3) minus
- 454 t/h (500 STPH)
- To 41 degrees
- 914 mm (36)
- 2.34 m/s (460 FPM)
- 174,800 mm (574)
- 454,200 mm (1490)
- 186.5 kW (250 HP)
- 186.5 kW (250 HP)

130

DS
012

135

0.1477

DS 024

1067

122

152

DS
024

152

0.1425

Sandwich Conveyor
at
Underground Gypsum Mine, Eastern USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Gypsum Rock
- 1.70 t/cu-m (106 PCF)
- 152 mm (6) minus
- 363 t/h (400 STPH)
- 90 degrees
- 1067 mm (42)
- 1.52 m/s (300 FPM)
- 36,600 mm (120)
- 48,500 mm (159)
- 37.3 kW (50 HP)
- 37.3 kW (50 HP)

DS 026

1524

174

217

203
DS 027

0.1332
1219

139

174

203

0.1665

DS
026

DS
027

Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

Unit 026
- Raw Coal
- 0.88 t/cu-m (55 PCF)
- 203 mm (8) minus
- 1361 t/h (1500 STPH)
- 51 degrees
- 1524 mm (60)
- 3.56 m/s (700 FPM)
- 23,200 mm (76)
- 44,800 mm (147)
- 93.2 kW (125 HP)
- 93.2 kW (125 HP)

Sandwich Conveyors
for
Coal Mine, Western USA

Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drive
- Top Belt
- Bottom Belt

Unit 027
- Oversize Coal
- 1.04 t/cu-m (65 PCF)
- 2033X51mm (8x2)
- 272 t/h (300 STPH)
- 35 degrees
- 1219 mm (48)
- 1.27 m/s (250 FPM)
- 14,900 mm (49)
- 38,200 mm (125.5)
- 14.9 kW (20 HP)
- 14.9 kW (20 HP)

DS 036

1219

Sandwich Conveyor
for
Gold Mine, Western USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Gold Ore
- 1.6 t/cu-m (100 PCF)
- 250 mm (10) minus
- 689 t/h (760 STPH)
- 50 degrees
- 1219 mm (48)
- 1.65 m/s (325 FPM)
- 28,900 mm (95)
- 58,400 mm (191.5)

- 37.3 kW (50 HP)

- 56 kW (75 HP)

139
DS
036

174

250

0.2051

DS 037

1372

156

DS
037

196

152

0.1108

Sandwich Conveyor
at
Tunnel Excavation Project, Midwest USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- TBM Muck
- 1.1 to 1.3 t/cu-m (85 to 105 PCF)
- 152 mm (6) minus
- 1266 t/h (1395 STPH)
- 90 degrees
- 1372 mm (54)
- 3.56 m/s (700 FPM)
- 70,000 mm (230)
- 83,800 mm (275)
- 186 kW (250 HP)
- 186 kW (250 HP)

DS 051

1372

Sandwich Conveyor
at
Oil Refinery, Pet Coke Plant, Southern USA
Material
- Hot Petroleum Coke
- Density
- 0.85t/cu-m (53 PCF)
- Size
- 152 mm (6) minus
Conveying Rate - 635 t/h (700 STPH)
Conveying Angle
- 72.5 degrees
Belt Width
- 1372 mm (54)
Belt Speed
- 2.67 m/s (525 FPM)
Lift
- 26,200 mm (86)
Length
- 53,000 mm (173.9)
Drives
- Top Belt
- 56 kW (75 HP)
- Bottom Belt - 75 kW (100 HP)

156
DS
051

196

152

0.1108

DS 065

2134

243

Sandwich Conveyor
for
Self-Unloading Ship, Great Lakes USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Top Belt
- Bottom Belt

- Coal, Limestone, Iron Ore

- 0.8 to 2.16 t/cu-m (50 to 135 PCF)
- To 305 mm (12) minus
- To 3993 t/h (4400 STPH)
- 65 degrees
- 2134 mm (84)
- 3.5 m/s (700 FPM)
- 17,900 mm (59)
- 28,900 mm (95)
- 186 kW (250 HP)
- 186 kW (250 HP)

304
DS
065

305

0.1429

DS 077

2134

243

304

152

0.0712

Sandwich Conveyor
for
Self Unloading Ship, Great Lakes USA
Material
- Density
- Size
Conveying Rate
Conveying Angle
Belt Width
Belt Speed
Lift
Length
Drives
- Inner Belt
- Outer Belt

- Various
- 0.9 to 2.5 t/cu-m (55 to 155 PCF)
- 152 mm (6) minus
- To 4264 t/h (To 4700 STPH)
- 90 degrees
- 2134 mm (84)
- 5.0 m/s (1000 FPM)
- 18,300 mm (60.3)
- 166,000 mm (545)

DS
077
DISCHARGE

- 298 kW (400 HP)

- 298 kW (400 HP)
LOADING

Dos Santos Sandwich Belt High

Angle Conveyor in IPCC System
Majdanpek Copper Mine,
Serbia, Yugoslavia

Majdanpek Mine

Rock Belt Feeder

The Majdanpek IPCC System, first five years

performance 1992-1997:
Precluded tripling of the truck fleet (eliminated 10 trucks)
Precluded the need for 4 km of haulage ramps, 3.5 km of which would be
of constant ascent
Savings of US $12 million per year

UHAC
The vital link for a versatile IPCC System in
Western Australia

Are Sandwich Belt High Angle Conveyors

suitable for in-pit mining applications?
Yes!
The many installations presented demonstrate:
They can handle very high conveying rates
They are suitable for continuous operation 24/7
High tonnage requirements are handled by wide belts which can easily
handle large, primary crushed material
Conscientious design by DSI will ensure long life with minimal maintenance

Thank You