Efficient Bulk Material Conveying System for Gypsum Handling

Case Study / By

Industry: Bulk Handling

Material Handled: Gypsum Rock, Crushed Rock, Screened Recycle Gypsum, Powders

Product Category: Belt Conveyor

Activity to be Mechanized/Automated:

  • Convey stored gypsum rock to the crusher.
  • Convey crushed gypsum and screened recycle gypsum to the mill silo at about 60 tons per hour intermittently, as needed.

An advanced conveyor system designed to efficiently handle abrasive gypsum materials, this solution minimizes spillage, dust generation, and downtime, while ensuring continuous, reliable operation across long distances and elevation changes.

Challenges vs Solutions

Challenges Solutions

To convey with minimum spillages, maximum throughput, operator safety, and negligible dust generation. >

Hopper Feed Belt Conveyors (up to 6.5 CubMtr front-end loader feed conveyors with belt feeding).

To transit a distance of almost 300 meters and an elevation difference of almost 30 meters.

Mill Silo Feed Troughed Long Distance Belt Conveyors (gantry mounted with both-side walkways and gravity-based automatic take-up).

To make the equipment extremely reliable and robust to suit seismic zone and wind load extreme parameters.

Crusher and Screen Feeder Conveyors (inclined feed belt conveyors).

Gypsum materials are abrasive and prone to capturing moisture, making control difficult.

Fully Sealed Belt Conveyors (reversible and/or sealed belts for powder handling).

Results / Benefits:

  • Cost Effective: Achieves lowest cost of ownership within a minimum 1-year ROI period.

  • Increased Efficiency: Reliable belt conveyor system reduces handling time, in-transit loss, and improves effectiveness.

  • Energy Saving: Uses IE3+ motors with energy and torque-efficient transmission systems.

  • Low Capital Investment: Low capital cost through the use of available, proven technologies.

  • 24x7x365 Running Capacity: Maintenance-friendly systems with low unplanned downtime.

  • High Productivity: Robust technology ensures reliability and stretched capacity utilization for enhanced productivity.