Overview
A major mining operation was experiencing inconsistent throughput visibility across several critical ore conveyors feeding downstream crushing and processing operations.
The facility had traditionally relied on mechanical belt scales to estimate material flow rates and production throughput. However, harsh operating conditions throughout the mine created ongoing reliability and maintenance challenges.
The Challenge
Harsh operating conditions throughout the mine created ongoing reliability and maintenance challenges, including:
- Heavy conveyor vibration
- Dust accumulation
- Changing belt tension
- Material buildup
- Shock loading from large ore
- Frequent recalibration requirements
As ore conditions and conveyor loading fluctuated throughout production, measurement accuracy became increasingly difficult to maintain. Operations teams lacked confidence in the conveyor throughput data being used for production balancing, inventory tracking, and process optimization.
The mine needed a more reliable and maintenance-friendly solution capable of delivering accurate, real-time bulk flow measurement in extreme operating conditions.
The Solution
The facility implemented Berthold Technologies radiometric bulk flow measurement technology across several key conveyor systems.
Using Berthold's non-contact radiometric measurement principle, the system continuously monitored conveyor loading and combined the measurement with conveyor speed signals to calculate precise real-time mass flow and totalized throughput.
Unlike conventional belt scales, the Berthold solution operates without moving parts or direct contact with the material being conveyed.
The system was specifically selected because measurement performance remains stable even under difficult mining conditions, including:
- Dust and dirt
- Conveyor vibration
- Variable loading conditions
- Wind exposure
- Changing belt tension
- Large particle size variations
Berthold's technology measures the attenuation of gamma radiation as material passes through the conveyor, allowing the system to continuously determine conveyor loading with high repeatability and long-term stability.
The mine implemented the DuoSeries LB 472 bulk flow measurement system, integrating the measurement directly into the facility's SCADA and process automation platform for centralized monitoring, alarming, and historical trending.
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The Results
Following implementation, the mining operation significantly improved conveyor throughput visibility while reducing maintenance requirements associated with traditional weighing systems.
Improved Throughput Visibility
Operations teams gained accurate, real-time insight into ore movement and conveyor loading throughout the process.
Reduced Maintenance Requirements
Because the Berthold system operates completely non-contact and contains no moving parts, maintenance demands were dramatically reduced.
Long-Term Measurement Stability
Unlike traditional belt scales that require ongoing recalibration, the radiometric measurement maintained stable long-term repeatability, even after years of operation.
Increased Reliability In Harsh Conditions
The measurement remained unaffected by dust, vibration, fluctuating belt tension, and varying ore properties, allowing operators to maintain reliable throughput monitoring under difficult process conditions.
Improved Production Coordination
More reliable bulk flow information helped balance crushing operations, downstream processing capacity, and inventory management.
Simplified Retrofit Installation
The system was installed directly onto existing conveyor infrastructure without major process modifications or extended downtime.
Why Radiometric Bulk Flow Measurement Continues To Grow In Mining
Mining environments are among the most difficult applications for conventional conveyor weighing systems. Dust, vibration, changing ore characteristics, and extreme operating conditions often impact measurement reliability and increase maintenance requirements.
Berthold's radiometric bulk flow technology provides mining operations with a highly robust alternative capable of delivering:
- Non-contact throughput measurement
- Continuous real-time tonnage monitoring
- Long-term repeatability
- Minimal maintenance requirements
- Reliable operation in extreme environments
- Easy retrofit installation on existing conveyors
With more than 2,000 installations worldwide, Berthold's bulk flow systems continue to help mining operations improve process visibility, production control, and operational efficiency across bulk material handling applications.
Looking To Improve Conveyor Throughput Visibility?
From radiometric bulk flow and density measurement to level, moisture, and process analytics, TechStar helps mining and mineral processing facilities implement reliable measurement technologies designed for the harshest operating environments.
