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Positioning the cleaners far forward along the conveyor&#;s return run, keeping them out of the material flow, and minimizing any risk to the belt.
Far Forward
To minimize the release of carryback into the plant, belt cleaning should occur as close to the head pulley as possible. Typically, the primary cleaner is installed just below where material leaves the belt, ensuring carryback is promptly reintegrated into the material flow. This setup, with the cleaner tensioned against the belt and mounted securely on the head pulley's face, allows precise control of blade-to-belt pressure. By starting with a primary cleaner in this forward position, there's more room to add secondary and tertiary cleaners further along the belt, reducing the chances of carryback escaping and minimizing the need for additional recovery devices like dribble chutes or scavenger conveyors.
It's critical that cleaners are installed away from the material flow to prevent buildup on the blades or structure. Placing a cleaner in the material trajectory can lead to premature wear on its support frame and blade backs, necessitating blade changes before the edge wears out. Ideally, the primary cleaner should be positioned so that its blade tip is below the horizontal centerline of the pulley, ensuring effective cleaning without unnecessary wear.
Minimizing Risk to the Belt
Selecting a belt-cleaning device involves mitigating any potential damage to the belt or splices it's designed to protect. The cleaner's design should allow the blade to move away from the belt when encountering splices or damaged sections, preventing impact shock. This is particularly crucial for primary cleaners, which often operate at acute angles. Aggressive cleaners with high cleaning pressure can wear out the belt's top cover faster and increase the risk of snagging on protruding splices or belt flaps.
Care should be taken in choosing an appropriate material to put in contact with the belt. Material such as strips of used belting should never be applied as a belt-cleaning or sealing material, because they may include steel cables or abrasive fines. These embedded materials cause excessive wear of the belt&#;s top cover.
The conveyor belt is the workhorse of the load zone. It serves production goals with great endurance and resilience in moving tons of bulk material nonstop over long distances for extended periods.
As it continues performing within often demanding conditions, the conveyor belt will inevitably develop and encounter obstacles that can affect it as well as other system parts and areas.
To get greater service and life from the conveyor belt, operators need to be vigilant about keeping it clean. In particular, they must prevent carryback, the fugitive material that sticks to the belt beyond the discharge point and remains on the bottom side of the belt, rollers, or pulleys.
In addition to creating multiple health and safety risks, carryback can form a crown or raised portion on a pulley, making the belt misalign. As the mistracked belt keeps drifting, it will induce even more-serious spillage and dust. This will further increase hazards while demanding more company resources for housekeeping and maintenance.
Operators can avoid the problems of material build-up with a well-engineered conveyor belt cleaning system.
Different operations face different carryback challenges according to their applications. Steel, gold, aggregate, and fertilizer, to name but a few, will often require their own belt cleaning strategies.
Whatever the bulk material might be, well-engineered conveyor belt cleaners keep the belt as clean as possible by removing excess material that builds on and clings to it. An optimal conveyor belt cleaning system will usually include two conveyor belt scrapers: a primary belt cleaner and a secondary belt cleaner.
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BEP1 &#; Our best selling primary belt cleaner
Mounted to the head pulley below the material flow, the primary belt cleaner &#; also referred to as a pre-cleaner &#; scrapes excess material from the conveyor belt. In particular, it removes the larger pieces that constitute two-thirds of initial carryback.
Ideally, the primary belt cleaner will be made of a durable material such as urethane, which will act similarly to a metal blade&#;type scraper without metal&#;s risk of damage to the belt. The belt cleaner should offer adaptable mounting with a modular, compact design as well. Its profile will provide a varying attack angle to reduce blade-edge bull-nosing. A torsion tensioner also will self-adjust to maintain steady cleaning as the blade wears.
BES1 &#; Our best selling secondary belt cleaner
Located right past where the belt leaves the head pulley and anywhere else down the belt line, secondary belt cleaners scrape whatever material remains on the belt beyond the head pulley, especially fines.
Like the primary belt cleaner, the secondary blade can be made of material such as tungsten carbide or rubber. To avoid build-up, the correct secondary cleaner selection will depend on the conveyor belt&#;s characteristics.
With a secondary belt cleaner installed, the conveyor belt scrapers can achieve a cleaning efficiency of greater than 90%. By eliminating carryback and keeping belts clean, high-performing belt cleaners make conveyor systems both safer and more productive.
Belt cleaner blades (including replacement blades) can be customized to a bulk material handling system&#;s distinctive variables, including:
An effective conveyor belt cleaner system might also include specialty cleaners such as:
Bulk material handlers that are committed to a thorough, precisely engineered conveyor belt cleaning system reinforce their operational objectives in multiple ways:
As bulk material handling specialists, the engineers at Benetech understand what can stand in the way of safety and production at your specific facility. Our conveyor belt cleaning systems represent the best of our knowledge, experience and technology in resolving carryback problems. To learn more about how we can solve yours, contact us at +1(630) 844- to speak with a specialist.
Posted in Conveyor Belt Cleaners, Conveyor Belts, and Material Handling
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