What sets BMG aside in bulk materials handling in the mining sector is the company’s ability to supply all components necessary for conveyor structures that handle a wide range of materials in harsh operating conditions. These products include belting, drives, bearings, couplings, motors and accessories, as well as gravity flow materials handling equipment.
“The mining sector’s operating efficiencies are currently under enormous pressure, which is why BMG has implemented a programme to provide specialist services to the mines that ensure optimum mechanical reliability of plant and machinery,” says Derek Clifton, materials handling sales manager, BMG – Bearing Man Group. “The company’s extensive range of energy efficient materials handling products – designed to facilitate reduced power consumption, low maintenance and extended service life – is enhanced by a technical solutions support service.
“This service encompasses the initial design concept, specification of components and quality control, as well as commissioning and maintenance of the materials handling equipment in use.”
BMG’s range of materials handling equipment, which is constantly extended to meet growing market demand, now includes the 4B series gravity flow materials handling products, designed for efficient handling of solids in arduous mining conditions.
The range of 4B series gravity flow materials handling equipment encompasses flap and rotary valves; hand, pneumatic and chain wheel slide gates, lump breakers and feeding tees, as well as safety silo valves.
Flap valves – also known as double dump valves – are a type of airlock valve, designed for bulk materials handling applications. These flap valves are primarily used to discharge powder or granular material from hoppers, bins and cyclones, operating under a pressure differential. Flap valve are often used to replace rotary valves, which can be jammed or damaged by fibrous or abrasive materials.
Flap valves are manufactured from hard wearing materials for extended service life in harsh operating conditions. Motor, pneumatic and gravity counter-weighted versions, which are available in standard and custom sizes, are enhanced by a wide range of sealing materials and stuffing box seals, to suit each application.
BMG’s 4B series of fabricated heavy duty slide gates are engineered as horizontal shut off gates in gravity flow applications, for dry materials, like powders, coals, granules and pellets. These gates are not suitable to seal in applications where a differential pressure exists.
These slide gates are available in hand and chain wheel, pneumatic and motor versions. A full range of standard sizes is available from BMG and custom units are manufactured to exact specifications.
Also in the 4B series are lump breakers which are easily integrated into an existing feeding system to break up material lumps that have compacted during transport or storage. A direct coupled drive with counter rotating dual shafts, breaks up compacted material between fingers and side combs, for improved product flow.
These compact lump breakers can process materials that include chemicals, salt, lime, kiln dust, sugar, cereals and fertilizers, but are not suitable for crushing hard rock.
Rotary valves and airlocks, which provide a constant volumetric feed rate, are recommended where there is limited space and where controlled feeding of powders and granular materials is required from silos, bins and hoppers.
This multi vane rotor provides accurate dosing and reduces leakage from cyclones and dust collectors into low and medium pressure pneumatic conveying lines. The same drop-through metering valve can be utilised into pneumatic conveying lines by the addition of a venturi feeding tee.
BMG’s highly efficient belt fastener system – the Super ScrewÔ – which was originally used as a temporary alternative to conventional hot and cold splicing, has proved to be totally reliable as a permanent splice for conveyor belt repairs, even in harsh mining environments.
This high strength splicing system is a flexible rubber splice using self tapping screws that enable Super Screw to be installed regardless of the configuration of the conveyor belt, ease of access and weather conditions.
Field tests prove this is the quickest method to repair a conveyor belt in any emergency situation, significantly reducing downtime. The mechanical joining technique is easy to complete, without the need for a skilled operator and heavy, costly equipment. With training from BMG, an in-house maintenance team can quickly and efficiently install this product, using a battery or pneumatic screw driver – there is no need for electrical power.
This leak proof system, with a high tensile strength, can be used for reliably joining a belt, repairing a longitudinal rip, or a puncture in a belt. The Super Screw splice is compatible with small pulley diameters, suitable for pipe conveyors and is conveyor scraper and V-plough friendly. This flexible splicing system can be used inserting new belting into old conveyor belt systems.
Super Screw, which can withstand service tensions to 2 000 kN/m, is available in various grades of rubber, to suit exact requirements.
The rubber material, containing tensile fabric used for the splices, is manufactured in rolls up to 25 m in lengths and in various strength ratings, from Class 315 to Class 2 000 conveyor belting. This system is also available in a ready to install option, with maximum pre-cut lengths of 3 meters and pre-installed assembly spacers.
These materials are abrasion, heat, fire or oil resistant and heat retardant, up to 200 °C. The non-magnetic system has metallic inserts made of stainless steel, with stainless steel screws.
Steel screws are screwed into an embedded nut inside the material, forming a sandwich effect of the top and bottom cover that clamps onto the belt carcass.
The surface of the splice is level with the two ends of the original belt, making the splice surface as even and as thick as the belt itself. It is fitted at the bias like regular splices to ensure optimal strength and flexibility around the pulleys.
In selecting the correct Super Screw fastener for each application, factors to be considered include the belt tension and strength of the belt, as well as the final belt thickness required. The rubber quality for each specific application is also important.
BMG’s field tests show that a conventional hot splice takes seven hours, a cold splice takes over eight hours (including curing) and the Super Screw takes less than one hour.
In addition, ambient conditions have to be considered before a cold splice can take place – if the humidity levels are too high, the adhesive may not be effective. An advantage of the Super Screw, is it is effective in all weather conditions. This conveyor belt repair system reduces total cost of ownership, while minimising risk.
BMG – specialist distributors of bearings, seals, power transmission components, electric and geared motors, as well as belting, fasteners, filtration, hydraulics and tooling – supplies many components and complete drive systems to the mines that are critical for efficient materials handling.