Why Iron Ore Is Particularly Demanding
Iron ore is among the most abrasive materials conveyed in mining. Magnetite and hematite ores have Abrasiveness Index (AI) values of 400—?00 g/t —?compared to coal at 30—?00 g/t. This means the same belt that would last 4 years on a coal conveyor may last only 8—?2 months on an iron ore conveyor if incorrectly specified. Cover grade selection is the most critical decision.
Iron Ore Abrasiveness by Type
| Ore Type | Abrasiveness Index | Relative Severity |
|---|---|---|
| Magnetite (fine, beneficiated) | 200—?00 g/t | High |
| Hematite (lump ore) | 400—?00 g/t | Very High |
| BIF (banded iron formation) | 500—?00 g/t | Extreme |
| Iron ore sinter | 300—?00 g/t + high temperature | Very High + Heat |
| DRI / pellets | 200—?00 g/t + high temperature | High + Heat |
Cover Specification by Application
| Application | Cover Grade | Top Cover | Bottom Cover |
|---|---|---|---|
| Primary crusher discharge (ROM) | W (—?0mm³) | 14—?0mm | 6—?mm |
| Secondary crusher discharge | W (—?0mm³) | 10—?4mm | 5—?mm |
| Fine ore / concentrate | W or M | 6—?mm | 3—?mm |
| Hot sinter conveying | T2/T3 + W properties | 8—?2mm | 4—?mm |
| Pellet conveying (hot) | T2 heat resistant | 6—?0mm | 3—?mm |
| Port / ship loading | W | 6—?mm | 3—?mm |
Carcass Selection
- Conveyors <800m: EP315/3 or EP400/3 with Grade W covers —?standard choice, easier splicing
- Conveyors 800—?000m: EP400/4 or EP500/4 —?higher tension rating needed
- Conveyors >2000m (overland): ST630–ST2000 steel cord belt —?low elongation essential for long conveyors
- Shaft conveyors: ST1600–ST3150 —?high tension, specialist design required
—?Lump Size Check for Iron Ore Conveyors
ROM iron ore from open pit blasting regularly contains lumps 400—?00mm. Minimum belt width = 2.5 × maximum lump size. For 500mm maximum lump: minimum belt width = 1,250mm —?select 1,400mm belt. Never try to convey oversized lumps —?they cause severe belt damage and idler destruction.
Loading Zone Requirements for Iron Ore
Iron ore loading zones require particularly robust design:
- UHMWPE or rubber impact bars across full loading length
- Chute walls lined with rubber (50mm NR for impact zone) or ceramic (for sliding zone)
- Rock box design to limit effective drop to <1.5m
- Heavy-duty skirting with spring-loaded design to accommodate belt deflection
- Magnetic tramp metal removal to prevent belt cutting from tramp iron
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