DSI High Angle Conveyors
Read more: how it works, downhill power regeneration, cost vs trucks and FAQ ↓
There are many ways to convey bulk materials, and no one knows that better than Dos Santos International. The system is based on the principle of sandwiching the bulk material between two smooth surfaced rubber belts and hugging the material continuously without lapse in order to develop its internal friction and preclude any tendency to slide back even at conveying angles up to 90 degrees (vertical).
Dos Santos International is the foremost authority on Sandwich Belt high angle conveyors and their 40 years of bulk materials handling has provided innovative solutions across the globe. They’ve proven both versatile and reliable in applications like ship loading, in-pit conveying, tunnelling and even for pulp, paper and biomass.
Present global warming is a challenge for the whole World. There is need to move towards green technology in future. DSI high angle conveyor transport in opencast mines shall be the green transport technology in the mine.
The main advantages of this system can be summarised as follows:
- i) Lowest cost/ ton for transport
- ii) Low operating cost with regard to energy, manpower, spares, maintenance etc.
- ii) Life exceeds 20 years, which is more than dumpers
- iv) Run with electric drive
- v) Carrying the material between two belts maintains a good environmental solutions
- vi) Can be made using a shiftable/ mobile design
How a Sandwich Belt High Angle Conveyor Works
A sandwich belt high angle conveyor holds the bulk material between two smooth rubber belts. The belts press the material continuously along the lift, so it is carried up a steep incline without rolling back or spilling. A conventional trough belt loses its grip on the material at a modest gradient, so it needs a long, shallow route. A sandwich belt can take the shortest path from the pit floor to the surface or to a transfer point.
Where High Angle Conveyors Are Used
- In-pit conveying in opencast mines: lifting coal, ore or overburden out of the pit on a short, steep route instead of long haul roads.
- Ship loading and unloading: raising material over a short horizontal distance.
- Tunnelling and underground mines: lifting muck on steep drifts and shafts.
- Downhill conveying: lowering material from high benches or plateaus on a steep incline, with the possibility of regenerating power.
- Plants and stockyards: steep feeds where plant footprint is limited.
Downhill Operation: Regenerative Power Saving
A sandwich belt high angle conveyor is not limited to lifting. It can also lower material down a steep incline, for example from a high bench or plateau to a plant or loading point at a lower level. In downhill operation the loaded belt drives the motors instead of the motors driving the belt. The drives then act as generators and can feed power back into the system, so the conveyor can regenerate energy rather than consume it. An uphill system has to supply power continuously for the whole lift, so a downhill system can save considerable power. The saving depends on the lift, throughput and drive arrangement of each project.
High Angle Conveyor vs Dump Trucks and Conventional Conveyors
As a pit deepens, haul roads get longer and diesel trucks carry material further for every tonne. A high angle conveyor shortens the lift path, which reduces the truck fleet needed on the ramp, fuel use and road maintenance. Compared with a conventional in-pit conveyor, it needs far less ground footprint because the incline is steeper.
Whether it is cheaper for your pit depends on lift height, throughput, material and life of mine. That is why Merchentus works out the cost per tonne for each case, side by side with truck haulage and conventional conveying, before a recommendation is made.
Why Work With Merchentus India
Merchentus India Exim International LLP is the technology partner and business representative of Dos Santos International (DSI), USA, in India. Our founder, Shyamal Kumar Bag, is a conveyor engineering consultant with decades of experience in belt conveyors, In-Pit Crushing and Conveying (IPCC) and high angle conveyors in Indian mining. We support mine owners and planners with techno-economic studies, system selection and engineering support.
Contact us for a techno-economic study of your pit, or see our engineering calculators and demos.
Frequently Asked Questions
What is a sandwich belt high angle conveyor?
It is a conveyor that carries bulk material between two rubber belts, so the material can be lifted at steep angles that a normal trough belt cannot handle.
Is a high angle conveyor cheaper than dump trucks?
It can be, particularly in deep pits with long haul roads, but the answer depends on your lift height, tonnage and mine life. We calculate the cost per tonne for your case.
What materials can it handle?
Coal, ores, overburden and other bulk materials, subject to lump size and material characteristics.
Can a sandwich belt conveyor be used downhill, and does it save power?
Yes. At steep downhill angles the loaded belt can drive the motors as generators, which can return power to the system. Unlike an uphill conveyor, which draws power for the whole lift, a downhill conveyor can reduce net power use. The amount depends on the lift, tonnage and drive design of your project.
Does it work with in-pit crushing and conveying (IPCC)?
Yes. A high angle conveyor is commonly paired with in-pit crushers and bench conveyors in an IPCC system to bring material out of the pit.
How do I get a study for my mine?
Send us your pit depth, annual tonnage and material details through our contact page.
MoU has been signed between Dos Santos International, US and Merchentus India Exim International LLP on 22nd March, 2023 DSI granting authority to Merchentus India for manufacturing of DSI Snake High Angle Conveyor in India and also to market their products in India and Australia.
This will re-define transportation of ore in mines both from opencast and deep underground as total pollution free, most energy efficient at the same time shall bring down the cost of transportation, which is the highest cost in mining. Such venture is for the first time by DSI in the World and perfect example of “Make in India” to indigenize the most advanced transport technology.