1/20/14 Examples of Good and Bad Chute Design

Examples of Good and Bad Chute Design Print

Jonathan Page B.Sc. (Mech Eng) GCC.

Ack nowle dge m e nts : The Bionic R e se arch Institute , C hute De sign C onfe re nce 1991

Anglo Am e rican C orporation have re vie we d the de sign of chute s handling hard m ate rials such as gold and
diam ond ore s.

This pape r provide s use r fe e dback . C urre nt chute de sign philosophy is e x plaine d, and e x am ple s of good
and bad chute de sign discusse d.

Jonathan Page is Divisional Me chanical Engine e r at Anglo Am e rican C orp. he ading up the m e chanical
de sign se ction. The se ction conce ntrate s on m ate rials handling, shaft conve yance s, and high pre ssure
piping and pum ping.

SYNOPSIS

This pape r give s fe e dback from the Anglo Am e rican C orporation on chute de sign for hard m ate rials
(diam ond and gold ore s). The curre nt de sign philosophy is e x plaine d and e x am ple s of good and bad
chute de signs are give n.

Gre at variability in the m ate rial characte ristics can com prom ise the final chute de sign. Be fore de sign it is
e sse ntial to te st the m ate rial characte ristics. W he re possible , final de signs should be te ste d and
optim ise d in pilot plants.

C urre nt practice s to com bat we ar proble m s are give n.

1. INTRODUCTION

The Anglo Am e rican C orporation of South Africa Lim ite d adm iniste rs various coal, diam ond and gold
m ine s.

The bulk m ate rials handling e quipm e nt that is com m on to all the m ine s include s be lt conve yors, hoppe rs,
silos, fe e de rs and chute s. C hute s are the link ing pie ce s in the m ate rials handling chain. The y are the
e sse ntial m e ans of guiding and dire cting m ate rials be twe e n the various storage , transport and proce ss
ite m s of e quipm e nt. Thus chute s have a com m on purpose .

The Me chanical Engine e ring De partm e nt has de ve lope d optim um chute de signs ove r the ye ars. Such
succe ssful de signs have e volve d on a trial-and-e rror basis, whe re site m odifications and the fe e dback of
ope rating e x pe rie nce have dire cte d the work .

This pape r will give practical e x am ple s of good and bad chute de signs for hard m ate rials (diam ond and
gold ore s).

2. PRINCIPLES OF CHUTE DESIGN

The re are five basic de sign obje ctive s:-

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to guide m ate rial on to a conve yor be lt, at the spe e d of the be lt, in the dire ction of be lt trave l.

to e lim inate m ate rial spillage .

to e nclose m ate rial dribble s.

to e nclose m ate rial from ope rating pe rsonne l.

to e lim inate dust libe ration.

3. CURRENT DESIGN PHILOSOPHY

C hute s are transfe r points in a m ate rials handling plant. The y ofte n de m and m ore atte ntion and can be
the source of m ore downtim e than the conve yors or e quipm e nt that pre ce de or follow the m . Ide ally the
chute s are de signe d first, and the n the plant e quipm e nt and structure s are place d around the m . This is
som e tim e s not possible due to othe r constraints. For e x am ple , such constraints are the pre se nce of critical
supporting ste e lwork , space re strictions unde rground and e x isting plant whe re m odifications are re quire d.
As a re sult, chute s m ay suffe r and the final de sign can be a com prom ise (Fig 1 shows how not to de sign a
chute ).

The nature and characte ristics of the e quipm e nt be fore and afte r the chute are cle arly de fine d. If a
conve yor be lt, what is the be lt width, be lt spe e d, loade d I m ate rial profile , m ate rial traje ctory? W hat is the
he ight through which the m ate rial m ust fall? Doe s the m ate rial have a single flow path, or are the re
alte rnative flow paths?

Fig 1: How not to

3.1 Material Characteristics

Although chute s have a com m on purpose , the y have to accom m odate a wide varie ty of m ate rial
characte ristics. Mine rals are found distribute d in m any diffe re nt ge ological are as. In addition, e ach
ge ological de posit ofte n contains m ate rials with diffe re nt prope rtie s.

The re are two type s of diam ond de posits: a volcanic pipe and an alluvial de posit (along rive r paths and
coastline s). In volcanic pipe s, m ate rial ne ar the surface is we athe re d and produce s a high proportion of
fine s. De e pe r unde rground, the m ate rial be com e s harde r and le ss we athe re d. Howe ve r, this m ate rial
we athe rs quick ly and produce s fine s due to crushing and proce ssing stage s towards the sm alle r size
range s.

Gold m ine s are usually at conside rable de pth. The rock is de nse , hard and abrasive . Howe ve r, the re are a
fe w ope n cast gold m ine s whe re the m ate rial characte ristics are significantly diffe re nt.

The re fore , the re is a variation in m ate rial characte ristics:

be twe e n diam ond and gold ore s

be twe e n ore s in diffe re nt de posits

be twe e n ore s during the life of a m ine .

Mate rial characte ristics can change from se ason to se ason, or e ve n day to day, on the sam e m ine .

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C hute s are de signe d for the worst possible conditions and m ate rial characte ristics. It is e sse ntial to de rive
by te sting the m ate rial characte ristics such as size distribution, m ax im um lum p size , m oisture conte nt,
angle of re pose e tc. For changing conditions, the spe ctrum of characte ristics is re quire d.

3.2 Pilot Plants

Pilot plants or sam ple plants are use ful, not only to the e x tractive m e tallurgist and plant ope rator, but
also to the chute de signe r. Such plants e nable chute de signs to be te ste d and optim ise d on the actual
m ate rial to be handle d.

C hute de sign som e tim e s ne e ds to be fine ly tune d to the m ate rial be ing transfe rre d. It is ofte n found that
only m inor site m odifications are re quire d to turn a proble m chute into a succe ssful one .

3.3 Operating Mines

It is e sse ntial to ge t fe e dback from ope rating m ine s on what doe s not work and what was done to re ctify
the proble m s. O the rwise , pre viously inade quate de sign drawings are copie d for future proje cts, thus
pe rpe tuating the proble m s.

3.4 Erection and Maintenance

Unde rground chute s are constructe d of bolte d pane ls in m anage able body pane l size s.

Surface chute s are fabricate d from longe r, we lde d, box se ctions. Howe ve r due atte ntion is paid to acce ss
to line rs and e re ction be twe e n floors of a building.

C hute s m ust be e asy to asse m ble and install. The y m ust be e ffe ctive in the ir job and re quire m inim al
m ainte nance . W e ar re sistant line rs m ust be cost e ffe ctive , strate gically place d and be e asily change d.

4. PA RA METERS OF CHUTE DESIGN

The following param e te rs are use d to diffe re ntiate be twe e n good and bad de signs. In the future , the aim
is to produce de sign guide line s for use as an office standard.

4.1 Chute A ngles

The angle of re pose for dry, run-of-m ine gold ore is ge ne rally tak e n to be 38. The optim um chute angle
in this case has be e n found to be 50-55. Angle s le ss than this are avoide d. The sam e angle is true for
dry, run-of-m ine diam ond ore , e .g. k im be rlite . Howe ve r, the inclusion of large am ounts of fine s, toge the r
with wate r, re nde rs the pre diction of re pose som e what difficult. In m ud-rush situations, the surcharge
angle can be 0. This is, howe ve r, an e x ce ptional condition and is not use d as a de sign case .

In diam ond plants, a chute angle of 45 is only acce ptable in final re cove ry and sort house are as whe re the
m ate rial is crushe d, washe d, size d and "guarante e d" to be dry .

C hute s with valle y angle ge om e trie s ne e d care ful atte ntion. In a chute with two adjace nt 55 plate s, the
valle y angle will be 45. He nce the re is the dange r of m ate rial build-up in the valle ys. The valle y angle is
incre ase d accordingly, or de signe d out, e .g. in a ve rtical side d chute .

In a chute e x te nde d to carry the fine s from be lt cle ane rs, angle s in e x ce ss of 700 are re quire d to pre ve nt
build-up of the ofte n stick y, we t, fine m ate rial that is re m ove d from the be lt. The fine s (or slim e s) that
stick to the be lt have e ffe ctive ly no angle of re pose -the y hang upside down. Thus if the re is any build-up
on the chute plate s, it will rapidly le ad to block age s or spillage (Fig 2) .

Fig 2: C hute angle s

4.2 Conveyor Head Chutes

The traje ctory of m ate rial flowing from the he ad pulle y of a conve yor be lt is pre dictable . Traje ctorie s are
se nsitive to be lt spe e d, m ate rial load profile , size distribution and m oisture conte nt. The traje ctory is
e stim ate d from the ce ntre of are a of the m ate rial profile . If the be lt line is tak e n, the discharge d m ate rial
will im pact the he ad chute hood highe r up than pre dicte d. O nce the traje ctory is de te rm ine d, the chute

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hood is de signe d around the m ate rial flow path (Fig 3).

C onve yor be lt capacitie s are ofte n subje ct to change in the life of a proce ss plant. C hanging throughput
re quire m e nts will m ost lik e ly produce changing be lt spe e ds. Traje ctorie s and the re sultant im pact zone s
will change . Thus the e ffe cts on he ad chute de sign are asse sse d (Fig 4).

Inspe ction acce ss cove rs are locate d out of the m ate rial im pact zone or flow path. C ove r plate s are size d
and hinge d so that a m an can e asily ope n the m . O nce ope ne d, the y m ust not fall back with the possibility
of injurie s (Fig 5) .

Fig 3: Incorre ct traje ctory

Fig 4: O ne m e thod to cate r for varying loading/spe e d

Fig 5: Location of inspe ction plate s

Effe ctive be lt cle aning is a "m ust" for any conve yor be lt. Howe ve r. The re m ove d m ate rial has to be
e fficie ntly transfe rre d away from the be lt cle ane r. In som e case s, a be lt cle ane r pe rform s the duty of a
se condary discharge de vice . Snub pulle ys be hind he ad pulle ys produce dribble s which should be suitably
handle d. Thus. not insignificant volum e s of m ate rial m ust be com bine d with the m ain stre am . Ste e pe r
chute angle s are im portant he re as m e ntione d e arlie r. Such be lt cle ane rs and dribble chute s are ofte n in a
m ost inacce ssible are a and the re fore te nd to be ne gle cte d. Sufficie nt acce ss is conside re d at the de sign
stage of a he ad chute . Alte rnative ly. the re m ove d m ate rial can be handle d se parate ly and not com bine d
with the m ain stre am .

O n a safe ty aspe ct, the side s of ahe ad chute e nclosing ahe ad and snub pulle y should be e x te nde d
back wards sufficie ntly to cove r all possible nip points on the be lt.

4.3 Chute Widths

C hute widths are usually de signe d to suit the pie ce of m e chanical e quipm e nt that follows the chute .
Ne ve rthe le ss, chute s are de signe d to a m inim um width of thre e tim e s the m ax im um e x pe cte d lum p size .
For e x am ple , for a 300 m m lum p size , the chute should be 900 m m -1 m square . Ide ally, facilitie s are
use d to re m ove rogue m ate rial from a m ate rials handling syste m as e arly as possible . In run-of-m ine
ore , such rogue m ate rial, consisting of outsize rock slabs, tram p iron, tim be r, e tc., would e asily chok e a
prope rly de signe d chute .

Anothe r im portant conside ration is the volum e tric flow rate of the m ate rial. O nce the chute is size d for the
large st lum ps, it is also size d for the volum e to be handle d.

4.4 Changes In Flow Direction

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W he re one conve yor transfe rs to anothe r conve yor, the e asie st configuration for the chute is whe n the
conve yors are in-line with e ach othe r. C onve yors at 900 to e ach othe r involve chute work that is m ore
com ple x but can be achie ve d without m any proble m s. A com m on rule of thum b is to provide twice the be lt
width as ve rtical he ight for in-line transfe rs, and 3,5 to 4 tim e s be lt width for 90 transfe rs. This ge ne rally
allows sufficie nt he ight to e nclose dribble s, e tc.

Most proble m s are e ncounte re d whe n conve yors are at a sm all acute angle . Such sm all change s of
dire ction involve awk ward chute ge om e trie s whe re the re could be re strictions to the flow of m ate rial and
proble m s of build up of m ate rial on shallow plate angle s. The capture of dribble s also be com e s difficult,
since the scraping are a is ge ne rally above ope n space (Fig 6) .

Fig 6: C onve yors at a sm all acute angle

As a ge ne ral conve yor de sign principle , the m ate rial should be in constant uniform m otion, not
inte rm itte nt loading. C hute s pe rform be tte r unde r uniform flow conditions.

4.5 Dead Boxes

De ad box e s have prove d be ne ficial in gold ore situations whe re the m ate rial is re lative ly dry .De ad box e s
are use d to tak e the dire ct im pact of m ate rial discharge d from a conve yor into ahe ad chute . O the r use ful
applications are in long chute s or high chute s whe re the m om e ntum of falling m ate rial m ust be brok e n
be fore re aching the lowe r conve yor be lt. C hange s of dire ction are also accom plishe d in this m anne r.. O nce
de ad box e s are fille d, the y form the ide al de fle ction plate or im pact we ar plate , whe re the "plate "
hardne ss is e qual to that of the fe e d m ate rial (Figs 7 and 8).

Fig 7: Typical de ad box

Fig 8: C ascade chute

In diam ond plants, de ad box e s are avoide d for run-of-m ine k im be rlite conditions be cause of the high clay
and m oisture conte nts. Howe ve r, the y m ay be use d late r in the plant whe re the m ate rial is size d and
washe d, and the n only with care ful conside ration in e ach de sign case .

In ge ne ral, de ad box e s are avoide d whe re the m ate rial is ve ry fine , we t or stick y. He re the de ad box e s
are not se lf cle aning, due to the abse nce of large particle s to give a scouring e ffe ct, and the fine m ate rial
will build up and cause block age s.

4.6 Conveyor Feed Chutes

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Fig 9: Typical Langlaagte chute dim e nsions

The Langlaagte chute is a we ll-k nown configuration throughout the South African m ining industry .This
chute was originally inte nde d for run-of-m ine ore situations to ge t the fine s to flow. Standard dim e nsions,
re late d to be lt width, have be e n de ve lope d as a guide (Fig 9) .W he re a num be r of Langlaagte chute s fe e d
a single conve yor be lt, e ve ry chute e x ce pt the first one is de signe d e ithe r highe r or pivote d up out of the
way whe n not in use .

The unde rside of the fe e d chute sk irts should rise , in the dire ction of be lt trave l, to a m ax im um of 50 m m
above the be lt. C hute s should be positione d at a m inim um distance in front of the tail pulle y of a
conve yor be lt. This is to avoid the transition distance whe re be lt troughing is not ide al (Fig 10).

Fig 10: Fe e d chute afte r transition distance

R adial doors are use d succe ssfully in chute s unde r ore passe s or silos. Apart from prim ary on/off fe e d
control, the y pe rform an e ffe ctive m ud-rush control function. (Langlaagte chute s are ine ffe ctive against
m ud-rushe s). R adial doors suffe r from the possibility of jam m ing whe n close d. The norm al air cylinde r
use d to ope n the door can be e nhance d by adding a k nock e r arm be twe e n the cylinde r rod and the door.
Thus the door can be close d with full force , ope ne d with re duce d force , or ham m e re d ope n (Fig 11) .

Figure 11: R adial door with k nock e r

4.7 Flapper Gates

Floppe r gate s are use d whe n one conve yor is re quire d to fe e d e ithe r of two discharge points. Thus a
bifurcating chute arrange m e nt is re quire d whe re e ach flow path m ust satisfy the ge ne ral chute de sign
guide line s. A critical are a is the hinge of the gate which should be place d above the ape x of the double
chute . Thus the gate is se lf cle aning and rock traps, which could jam the gate , are avoide d (Fig 12).

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Fig 12: Floppe r pivot above ape x

4.8 Construction

Unde rground chute s have to be transporte d in confine d shaft com partm e nts and narrow haulage s.
Installation site s are ofte n constricte d be cause of the low he adroom and the pre se nce of the conve yor
structure . He nce construction should be by m e ans of bolte d body pane ls of m anage able size s. Body
plate s are ge ne rally 6m m to 10 m m thick with 70 m m x 70 m m x 8 m m angle stiffe ne rs. Side plate s are
bolte d to the body by angle construction, with the conne ctions in she ar whe re possible . The top cove r is
e x te nde d ove r the side s and is bolte d down.

Surface chute s are m ade from longe r/talle r box se ctions we lde d toge the r, with due atte ntion to line r
acce ss and e re ction ne e ds.

The construction m ate rial is structural ste e l to SABS 1431 Grade 300W A.

Ade quate acce ss is re quire d by the ope rating and m ainte nance staff on the m ine . Acce ss is an im portant
conside ration in chute de sign and the associate d structural ste e lwork . Lifting be am s are de signe d for the
re place m e nt of line rs, and the re m oval of bolte d pane ls in m ainte nance ope rations. He nce inspe ction
acce ss and m ainte nance acce ss are im portant conside rations.

4.9 Lining Materials

Side line rs are ge ne rally 12 m m to 16 m m thick and e x te nd up to 3 tim e s the de pth of m ate rial flow to
cate r for surge s. Bottom line rs are up to 25 m m thick . Line r plate s are size d for a m ax im um m ass of 30
k g e ach, so that re place m e nt in confine d space s is e asie r. De ad box e s have lip line rs.

Q ue nche d and te m pe re d ste e l plate , with hardne sse s of BHN 400 or BHN 500, is incre asingly use d for line r
m ate rial. In high we ar applications, the se m ate rials are m ost cost e ffe ctive in te rm s of price and life , with
thinne r plate size s spe cifie d. Howe ve r, proje ct e ngine e rs m ay choose m ild ste e l for lowe r we ar
applications.

Fig 13: Across line rail m at AND Fig 14: In-line rail m at

In ce rtain circum stance s, rail m ats have be e n use d on the bottom chute plate s. Thus, horizontal rows of
rails are bolte d to the chute plate at 900 to the dire ction of flow, form ing a be d of de ad box e s.
Alte rnative ly the rails are se t in line with the flow to allow se lf cle aning (Figs 13 and 14).

Diam ond ore fine s and dribble s have be e n found to m ove m ore e ffe ctive ly on PTFE line rs such as
'ISO LIDUR " or "VESC O NITE", This type of line r is not e ffe ctive in high im pact are as.

4.10 De-Dusting

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Fig 15: Dust e x traction

For dry diam ond ore s e spe cially, transfe r chute s are de -duste d. He re , chute s are e nclose d with a dust
e x traction syste m applie d pre fe rably afte r the transfe r point to the be lt. C hute sk irt plate s have rubbe r
se als to stop too m uch false air e nte ring the chute . The rubbe r se al should not be m ade from old
conve yor be lting, as the re sultant se al is ine ffe ctive . The proportions of the chute and sk irts are ge ne rally
dictate d by the de -dusting re quire m e nts, such as air volum e and pick -up ve locity (Fig 15).

In ge ne ral, fe e d chute sk irt widths are two thirds of proje cte d be lt width, not two thirds of actual be lt width
as was com m on practice .

The sk irt se als are se e n as se als and not as a m e ans of containing the m ate rial on the be lt. The re are
case s whe re the sk irts are te rm inate d too high above the be lt, re sulting in long, floppy se als. The se ve ry
e asily flop ove r the e dge of the be lt, m ak ing e ffe ctive be lt training im possible . This is ge ne rally the case
whe n the sk irts are too wide as we ll. The long sk irts are also subje ct to m ate rial loading, which incre ase s
the re sistance to m otion of the conve yor, adding to powe r and te nsion, and acce le rating the conve yor be lt
top cove r we ar (Fig 16)

Fig 16: Sk irt se als

W he n de -dusting is not re quire d e .g. on gold m ine s with we t m ate rials, the re is no ne e d for rubbe r sk irt
se als. Unne ce ssary sk irt se als we ar out the be lt top cove r and add to frictional re sistance s. It is be tte r to
re de sign the sk irts the m se lve s in this instance .

5. CONCLUSIONS

O ptim um chute de signs have be e n de ve lope d ove r the ye ars. Such succe ssful de signs have e volve d on a
trial-and-e rror basis, whe re site m odifications and the fe e dback of ope rating e x pe rie nce have dire cte d the
work .

Gre at variability in the m ate rial characte ristics can com prom ise the final chute de sign. Be fore de sign it is
e sse ntial to te st the m ate rial characte ristics. W he re possible , final de signs should be te ste d and
optim ise d in pilot plants.

6. A CKNOWLEDGEMENTS

The author would lik e to thank the Anglo Am e rican C orporation of South Africa Lim ite d for pe rm ission to
publish this pape r. Thank s are also due to colle ague s in the Me chanical Engine e ring De partm e nt who have
contribute d to this pape r in m any ways.

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