Bucyrus - Conveyor Belt Systems

Bucyrus has been manufacturing rugged conveyor systems for the mining industry for decades and has clients worldwide, providing the company with a wealth of experience and expertise in belt conveyor manufacture and design.

Rugged and reliable conveyor systems

The company offers rugged and reliable conveyor systems that are unsurpassed in performance and service life. Its standard and custom-designed solutions can handle the most demanding bulk material applications, both on the surface and underground.

The success of any belt conveyor system depends on innovative engineering, high-quality manufacturing, and the professional installation and start-up of all system elements. The ‘Belt Analyst’ computer program allows Bucyrus engineers to model belt conveyors, while CAD and finite element analysis allow them to design application-specific equipment.

Full conveyor belt system support

Bucyrus’ ‘five star service’ provides full life-cycle support for conveyor belts by qualified service engineers, including analysis of requirements, custom design, installation, commissioning and start-up, maintenance and support, and on-site training.

Belt starters

Belt starters are vital because it takes a great deal of power to start a loaded belt. Bucyrus offers belt starters for various drive technologies, including across-the-line starters for use with fluid couplings, CST clutches and reduced-voltage starter drives. DC-motor and AC variable-frequency motor controllers are also available.

Alignment-free drives

There is a growing trend toward alignment-free drives, which are easier to transport and quicker to install and relocate. They require less preventative maintenance than conventional drives and failures due to misalignment are virtually eliminated. With a narrower overall drive width, the drives feature a universal mounting, allowing left-hand or right-hand use. They also harness multiple drive technologies (fluid couplings, TPKL fill-controlled turbo couplings, AC drives and DC drives).

Belt conveyor take-up sections

To prevent fluctuations of load and torque, Bucyrus’ belt conveyor take-up sections apply accurate and highly responsive tension, ensuring the transmission of drive pulley torque and preventing belt sag between idlers. Bucyrus builds hydraulic cylinder, hydraulic wench and electrical wench take-ups.

Belt storage units

Bucyrus’ belt storage units automatically handle belt payout while advancing and belt storage when retreating. With capacities up to 2,000ft (610m), they are ‘smart’ devices that monitor and change belt tension quickly and accurately.

Belt conveyor transfer stations

Belt conveyor transfer stations allow steady, efficient transfer of extracted materials on to the belt conveyor. The most common types are in-line and right-angle. Bucyrus’ intermediate and tail loading sections are fabricated with impact-resistant idlers or impact slider beds made of EXALON® – Bucyrus’ proprietary high-molecular-weight polyethylene – and a structurally rigid, heavy-duty loading frame.

Models are available for receiving discharge from an extensive range of haulage equipment, including Un-A-Haulers® coal haulers, Un-A-Trac® scoops, feeder conveyors and shuttle cars.

Heavy-duty conveyor pulleys

Bucyrus’ engineered-class conveyor pulleys, Turbo-Disc and T-bottom, are heavy-duty and best-in-class. Both are designed to reliably drive conveyors with installed power in excess of 4,000hp (2,982kW). The high standard of engineering is reflected in Bucyrus’ standard three-year warranty, compared to the one year offered by competitors.

Steel conveyor rolls

Bucyrus’ steel rolls are available for roof-hung, floor-mounted or wire rope structures.

The design of the steel roll is the result of over two years of design and engineering effort and represents new technology in idler design. A new shaft-end configuration and a unique retrofit adaptor allow Bucyrus rolls to operate in virtually any competitor’s frame.

Three separate, metered grease inputs ensure that every roll has plenty of grease for a lifetime of trouble-free operation, and Idler PAL® ensures that the grease stays in the bearing where it is needed.

MSHA-approved conveyor rolls

EXALON® conveyor rolls are fully conductive and MSHA-approved for use in underground applications. EXALON rolls have been tested against leading bulk material handling steel conveyor rolls and are proven to last significantly longer, particularly in highly corrosive and/or highly abrasive environments. The benefits over conventional steel rolls include extended life, decreased belt damage, lower weight, sound dampening and less material accumulation.

About Bucyrus International

Bucyrus is a world leader in the design and manufacture of high productivity mining equipment for the surface and underground mining industries. Bucyrus' surface mining equipment is used for mining coal, copper, iron ore, oil sands and other minerals.

Bucyrus' underground mining equipment is used primarily for mining coal and is also used in mining minerals such as potash and trona. In addition to machine manufacturing, Bucyrus manufactures high quality OE parts and provides world-class support services for their machines. Bucyrus' corporate headquarters is located in South Milwaukee, Wisconsin, USA.