Chutes

http://www.saimh.co.za/education/course01/chutes.htm

Conveyor Belt Installations and Related Components

CHUTES.
Conveyor belts invariably discharge into a chute for gravitational transport of the ore
onto another conveyor belt or to the next stage in the ore dressing process. The ore is
discharged from the conveyor belt at considerable velocity, resulting in sever chute
wear and/or belt impact. The rate of ore flow impact can be broken by the installation
of a "dead box" in the chute as illustrated below. A layer of ore forms in the bottom of
the "dead box" and breaks the velocity of the flow. In addition, wear is rock on rock.
The chute can also be protected by liner plates.

Fig 1
2. PRINCIPLES OF CHUTE DESIGN
There are five basic design objectives:to guide material on to a conveyor belt, at the speed of the belt, in the direction
of belt travel.
to eliminate material spillage.
to enclose material dribbles.
to enclose material from operating personnel.
to eliminate dust liberation.
3. CURRENT DESIGN PHILOSOPHY
Chutes are transfer points in a materials handling plant. They often demand more
attention and can be the source of more downtime than the conveyors or equipment
that precede or follow them. Ideally the chutes are designed first, and then the plant
equipment and structures are placed around them. This is sometimes not possible due
to other constraints. For example, such constraints are the presence of critical
supporting steelwork, space restrictions underground and existing plant where
modifications are required. As a result, chutes may suffer and the final design can be a
compromise (Fig 2 shows how not to design a chute).
The nature and characteristics of the equipment before and after the chute are clearly
defined. If a conveyor belt, what is the belt width, belt speed, loaded I material profile,
material trajectory? What is the height through which the material must fall? Does the
material have a single flow path, or are there alternative flow paths?

1 dari 11

22/09/2015 12:36

Chutes

2 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

Fig 2: How not to

3.1 Material Characteristics
Although chutes have a common purpose, they have to accommodate a wide variety of
material characteristics. Minerals are found distributed in many different geological
areas. In addition, each geological deposit often contains materials with different
properties.
There are two types of diamond deposits: a volcanic pipe and an alluvial deposit (along
river paths and coastlines). In volcanic pipes, material near the surface is weathered
and produces a high proportion of fines. Deeper underground, the material becomes
harder and less weathered. However, this material weathers quickly and produces
fines due to crushing and processing stages towards the smaller size ranges.
Gold mines are usually at considerable depth. The rock is dense, hard and abrasive.
However, there are a few open cast gold mines where the material characteristics are
significantly different.
Therefore, there is a variation in material characteristics:
between diamond and gold ores
between ores in different deposits
between ores during the life of a mine.
Material characteristics can change from season to season, or even day to day, on the
same mine.
Chutes are designed for the worst possible conditions and material characteristics. It is
essential to derive by testing the material characteristics such as size distribution,
maximum lump size, moisture content, angle of repose etc. For changing conditions,
the spectrum of characteristics is required.
3.2 Pilot Plants
Pilot plants or sample plants are useful, not only to the extractive metallurgist and
plant operator, but also to the chute designer. Such plants enable chute designs to be
tested and optimised on the actual material to be handled.
Chute design sometimes needs to be finely tuned to the material being transferred. It
is often found that only minor site modifications are required to turn a problem chute
into a successful one.
3.3 Operating Mines
It is essential to get feedback from operating mines on what does not work and what
was done to rectify the problems. Otherwise, previously inadequate design drawings
are copied for future projects, thus perpetuating the problems.
3.4 Erection and Maintenance
Underground chutes are constructed of bolted panels in manageable body panel sizes.

22/09/2015 12:36

Chutes

3 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

Surface chutes are fabricated from longer, welded, box sections. However due
attention is paid to access to liners and erection between floors of a building.
Chutes must be easy to assemble and install. They must be effective in their job and
require minimal maintenance. Wear resistant liners must be cost effective, strategically
placed and be easily changed.
4. PARAMETERS OF CHUTE DESIGN
The following parameters are used to differentiate between good and bad designs. In
the future, the aim is to produce design guidelines for use as an office standard.
4.1 Chute Angles
The angle of repose for dry, run-of-mine gold ore is generally taken to be 38. The
optimum chute angle in this case has been found to be 50-55. Angles less than this are
avoided. The same angle is true for dry, run-of-mine diamond ore, e.g. kimberlite.
However, the inclusion of large amounts of fines, together with water, renders the
prediction of repose somewhat difficult. In mud-rush situations, the surcharge angle
can be 0. This is, however, an exceptional condition and is not used as a design case.
In diamond plants, a chute angle of 45 is only acceptable in final recovery and sort
house areas where the material is crushed, washed, sized and "guaranteed" to be dry .
Chutes with valley angle geometries need careful attention. In a chute with two
adjacent 55 plates, the valley angle will be 45. Hence there is the danger of material
build-up in the valleys. The valley angle is increased accordingly, or designed out, e.g.
in a vertical sided chute.
In a chute extended to carry the fines from belt cleaners, angles in excess of 700 are
required to prevent build-up of the often sticky, wet, fine material that is removed
from the belt. The fines (or slimes) that stick to the belt have effectively no angle of
repose - they hang upside down. Thus if there is any build-up on the chute plates, it
will rapidly lead to blockages or spillage (Fig 3) .

Fig 3: Chute angles

4.2 Conveyor Head Chutes
The trajectory of material flowing from the head pulley of a conveyor belt is
predictable. Trajectories are sensitive to belt speed, material load profile, size
distribution and moisture content. The trajectory is estimated from the centre of area
of the material profile. If the belt line is taken, the discharged material will impact the
head chute hood higher up than predicted. Once the trajectory is determined, the
chute hood is designed around the material flow path.
Conveyor belt capacities are often subject to change in the life of a process plant.
Changing throughput requirements will most likely produce changing belt speeds.
Trajectories and the resultant impact zones will change. Thus the effects on head chute
design are assessed.
Inspection access covers are located out of the material impact zone or flow path.
Cover plates are sized and hinged so that a man can easily open them. Once opened,
they must not fall back with the possibility of injuries.

22/09/2015 12:36

Chutes

4 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

Fig 4: Incorrect trajectory

Fig 5: One method to cater for varying loading/speed

Fig 6: Location of inspection plates

Effective belt cleaning is a "must" for any conveyor belt. However. The removed
material has to be efficiently transferred away from the belt cleaner. In some cases, a
belt cleaner performs the duty of a secondary discharge device. Snub pulleys behind
head pulleys produce dribbles which should be suitably handled. Thus. not insignificant
volumes of material must be combined with the main stream. Steeper chute angles are
important here as mentioned earlier. Such belt cleaners and dribble chutes are often in
a most inaccessible area and therefore tend to be neglected. Sufficient access is
considered at the design stage of a head chute. Alternatively. the removed material
can be handled separately and not combined with the main stream.
On a safety aspect, the sides of a head chute enclosing ahead and snub pulley should
be extended backwards sufficiently to cover all possible nip points on the belt.
4.3 Chute Widths
Chute widths are usually designed to suit the piece of mechanical equipment that
follows the chute. Nevertheless, chutes are designed to a minimum width of three
times the maximum expected lump size. For example, for a 300 mm lump size, the
chute should be 900 mm - 1 m square. Ideally, facilities are used to remove rogue
material from a materials handling system as early as possible. In run-of-mine ore,
such rogue material, consisting of outsize rock slabs, tramp iron, timber, etc., would
easily choke a properly designed chute.
Another important consideration is the volumetric flow rate of the material. Once the
chute is sized for the largest lumps, it is also sized for the volume to be handled.
4.4 Changes In Flow Direction
Where one conveyor transfers to another conveyor, the easiest configuration for the
chute is when the conveyors are in-line with each other. Conveyors at 900 to each
other involve chute work that is more complex but can be achieved without many
problems. A common rule of thumb is to provide twice the belt width as vertical height

22/09/2015 12:36

Chutes

5 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

for in-line transfers, and 3,5 to 4 times belt width for 90 transfers. This generally
allows sufficient height to enclose dribbles, etc.
Most problems are encountered when conveyors are at a small acute angle. Such small
changes of direction involve awkward chute geometries where there could be
restrictions to the flow of material and problems of build up of material on shallow
plate angles. The capture of dribbles also becomes difficult, since the scraping area is
generally above open space.

Fig 7: Conveyors at a small acute angle

As a general conveyor design principle, the material should be in constant uniform
motion, not intermittent loading. Chutes perform better under uniform flow conditions.
4.5 Dead Boxes
Dead boxes have proved beneficial in gold ore situations where the material is
relatively dry .Dead boxes are used to take the direct impact of material discharged
from a conveyor into ahead chute. Other useful applications are in long chutes or high
chutes where the momentum of falling material must be broken before reaching the
lower conveyor belt. Changes of direction are also accomplished in this manner.. Once
dead boxes are filled, they form the ideal deflection plate or impact wear plate, where
the "plate" hardness is equal to that of the feed material.

Fig 8: Typical dead box

Fig 9: Cascade chute

In diamond plants, dead boxes are avoided for run-of-mine kimberlite conditions
because of the high clay and moisture contents. However, they may be used later in
the plant where the material is sized and washed, and then only with careful
consideration in each design case.
In general, dead boxes are avoided where the material is very fine, wet or sticky. Here
the dead boxes are not self cleaning, due to the absence of large particles to give a
scouring effect, and the fine material will build up and cause blockages.

22/09/2015 12:36

Chutes

6 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

4.6 Conveyor Feed Chutes

Fig 10: Typical Langlaagte chute dimensions

The Langlaagte chute is a well-known configuration throughout the South African
mining industry .This chute was originally intended for run-of-mine ore situations to
get the fines to flow. Standard dimensions, related to belt width, have been developed
as a guide (Fig 10) .Where a number of Langlaagte chutes feed a single conveyor belt,
every chute except the first one is designed either higher or pivoted up out of the way
when not in use.
The underside of the feed chute skirts should rise, in the direction of belt travel, to a
maximum of 50 mm above the belt. Chutes should be positioned at a minimum
distance in front of the tail pulley of a conveyor belt. This is to avoid the transition
distance where belt troughing is not ideal.

Fig 11: Feed chute after transition distance

Radial Doors
Radial doors are used successfully in chutes under ore passes or silos. Apart from
primary on/off feed control, they perform an effective mud-rush control function.
(Langlaagte chutes are ineffective against mud-rushes). Radial doors suffer from the
possibility of jamming when closed. The normal air cylinder used to open the door can
be enhanced by adding a knocker arm between the cylinder rod and the door. Thus the
door can be closed with full force, opened with reduced force, or hammered open.

Figure 12: Radial door with knocker

4.7 Flopper Gates
Flopper gates are used when one conveyor is required to feed either of two discharge
points. Thus a bifurcating chute arrangement is required where each flow path must
satisfy the general chute design guidelines. A critical area is the hinge of the gate
which should be placed above the apex of the double chute. Thus the gate is self

22/09/2015 12:36

Chutes

7 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

cleaning and rock traps, which could jam the gate, are avoided.

Fig 13: Flopper pivot above apex

4.8 Construction
Underground chutes have to be transported in confined shaft compartments and
narrow haulages. Installation sites are often constricted because of the low headroom
and the presence of the conveyor structure. Hence construction should be by means of
bolted body panels of manageable sizes. Body plates are generally 6mm to 10 mm
thick with 70 mm x 70 mm x 8 mm angle stiffeners. Side plates are bolted to the body
by angle construction, with the connections in shear where possible. The top cover is
extended over the sides and is bolted down.
Surface chutes are made from longer/taller box sections welded together, with due
attention to liner access and erection needs.
The construction material is structural steel to SABS 1431 Grade 300WA.
Adequate access is required by the operating and maintenance staff on the mine.
Access is an important consideration in chute design and the associated structural
steelwork. Lifting beams are designed for the replacement of liners, and the removal of
bolted panels in maintenance operations. Hence inspection access and maintenance
access are important considerations.
4.9 Lining Materials
Side liners are generally 12 mm to 16 mm thick and extend up to 3 times the depth of
material flow to cater for surges. Bottom liners are up to 25 mm thick. Liner plates are
sized for a maximum mass of 30 kg each, so that replacement in confined spaces is
easier. Dead boxes have lip liners.
Quenched and tempered steel plate, with hardnesses of BHN 400 or BHN 500, is
increasingly used for liner material. In high wear applications, these materials are most
cost effective in terms of price and life, with thinner plate sizes specified. However,
project engineers may choose mild steel for lower wear applications.

Fig 14: Across line rail mat

In certain circumstances, rail mats have been used on the bottom chute plates. Thus,
horizontal rows of rails are bolted to the chute plate at 900 to the direction of flow,
forming a bed of dead boxes. Alternatively the rails are set in line with the flow to
allow self cleaning.
Diamond ore fines and dribbles have been found to move more effectively on PTFE
liners such as 'SOLIDUR" or "VESCONITE", This type of liner is not effective in high

22/09/2015 12:36

Chutes

8 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

impact areas.
4.10 De-Dusting

Fig 15: Dust extraction

For dry diamond ores especially, transfer chutes are de-dusted. Here, chutes are
enclosed with a dust extraction system applied preferably after the transfer point to
the belt. Chute skirt plates have rubber seals to stop too much false air entering the
chute. The rubber seal should not be made from old conveyor belting, as the resultant
seal is ineffective. The proportions of the chute and skirts are generally dictated by the
de-dusting requirements, such as air volume and pick-up velocity.
In general, feed chute skirt widths are two thirds of projected belt width, not two
thirds of actual belt width as was common practice.
The skirt seals are seen as seals and not as a means of containing the material on the
belt. There are cases where the skirts are terminated too high above the belt, resulting
in long, floppy seals. These very easily flop over the edge of the belt, making effective
belt training impossible. This is generally the case when the skirts are too wide as well.
The long skirts are also subject to material loading, which increases the resistance to
motion of the conveyor, adding to power and tension, and accelerating the conveyor
belt top cover wear.

Fig 16: Skirt seals

When de-dusting is not required e.g. on gold mines with wet materials, there is no
need for rubber skirt seals. Unnecessary skirt seals wear out the belt top cover and
add to frictional resistances. It is better to redesign the skirts themselves in this
instance.
CHUTE MAINTENANCE
The primary purposes of a chute are to:
1. Receive the 'burden" from the discharge point of a conveyor and direct it to the
required location.
2. Deposit the "burden" centrally and evenly on the receiving conveyor.
3. To "handle" the required quantity of "burden".
The secondary requirements are:(a) To resist abrasive wear.
(b) To resist burden build-up. To resist burden bridging.
(c) To reduce breakage of fragile "burden".
(d) To collect spillage & scrapings.

22/09/2015 12:36

Chutes

9 dari 11

http://www.saimh.co.za/education/course01/chutes.htm

(e) To minimize wear of belts.

(f) To prevent "burden" from escaping.
(g) To reduce the creation of dust.
(h) To resist corrosion.
Careful attention to chute lay-out and a certain amount of on site "tuning" of the chute
will be necessary before the conveyor system will reach peak efficiency.
While the burden being handled may be generally non-adhesive, fines particularly
when damp will build-up in corners of chutes. Non-adhesive (PTFE) or flexible surfaces
may be used to reduce the problem but ample access should be provided to allow for
manual cleaning.
Every designer will have his own ideas on the chute design and figures 17 to 23
indicate some basic lay-outs that may help to avoid pitfalls.
The burden being non-abrasive and free flowing it may be allowed to fall onto the
chute plate and have 'forward" velocity imparted to it to improve "loading" onto the
receiving belt.

Figure 17
For in-line transfer the burden should fall centrally onto the receiving belt.
The lower section of the chute may be turned for an angled transfer but the cross
angle of the impinging plate should be adjusted to facilitate central loading.
For abrasive burden it is better that impingement between burden and chute plates be
avoided as much as possible.

Figure 18
Similarly for adhesive burden contact with chute plates should be avoided for both the
main stream of burden and the scrapings.
Trajectories from high speed conveyors will make this type of chute too long.
For angled transfers baffles or rock-boxes will be necessary to centre the burden on
the receiving belt.
Where it is necessary for very abrasive free flowing burden to impinge against chute
linings or hard steel linings are often used.

22/09/2015 12:36

Chutes

http://www.saimh.co.za/education/course01/chutes.htm

Figure 19

Figure 20
Skega rubber wear bars give very good life provided that the burden strikes the rubber
surfaces at near 90. If the wear bar becomes dislodged it will not damage belting as
would a dislodged wear plate of steel.
With the type of chute shown in Figure 21 belt damage due to the impact of large
lumps is reduced by allowing the fines to fall through a grizzly onto the belt thus
forming a protective bed of fines on the belt for the lumps to fall onto.

Figure 21
If used for an angled transfer the grizzly bars should be in the same plan direction as
the receiving belt and some kind of baffling will be necessary to centre the load.
For high speed belts particularly with angled transfers it is necessary to destroy the
forward velocity in order to1. make the chute compact.
2. facilitate the collection of scrapings from the belt.
3. transfer the burden at run-up speeds as when starting a loaded belt.
Impact plates are usually made with a slightly concave surface to the burden, to
reduce sideways splash. They can be skewed to the oncoming burden and are
adjustable for position at top and bottom independently.

10 dari 11

22/09/2015 12:36

Chutes

http://www.saimh.co.za/education/course01/chutes.htm

Figure 22
When handling fragile burden impingements and changes of velocity should be
avoided.

Figure 23
For this purpose the chute should collect the burden at the point where the "trajectory"
leaves the pulley.
Over the top and centre section of the chute angles will be chosen to slightly
accelerate the burden while the lower part of the chute will retard the burden and lay it
onto the receiving belt at belt speed.
Angled transfers can be arranged by suitable banking the "slide" on the bend.
The slide plates must be inspected frequently for abrasive wear.
Back to Top

11 dari 11

22/09/2015 12:36