Global Leaders in

Conveyor Design & Technology

• Incorporate in 2004• Specializing in the design of conveyors

• Long overland conveyors• Horizontally curved conveyors • High tonnage conveyors• High lift conveyors• Totally enclosed pipe conveyors

• Static Analysis with Proprietary Rheological Model (Sidewinder)

• Dynamic Analysis (Verified by Field Measurements)

• Discrete Element Modeling with Proprietary Model (Newton)

• Finite Element Analysis: Pulleys, Idler Junction, Turnovers, Transitions, etc.

• Laboratory Testing: Rubber Rheology, Idler Testing, Materials Testing

• Forensic Engineering and Field Measurements

Advanced Conveyor TechnologiesCompany Overview

❖ExpertiseStatic & Dynamic Analysis of Overland Conveyors

Field Measurements of Conveyor Systems

Finite Element Analysis

Discrete Element Modeling

Software Design (Sidewinder, Newton, PAX)

❖Work ExperienceProject Engineer - Conveyor Dynamics Inc (1993-2004)

President - AC-Tek (2004-2019)

❖EducationB.S. Mechanical Engineering, University of Idaho

M.S. Mechanical Engineering, University of Idaho

Ryan LemmonPresident

❖ExpertiseStatic & Dynamic Analysis of Overland Conveyors

Field Measurements of Conveyor Systems

Rubber Rheology

Discrete Element Modeling

Software Design (Sidewinder, Newton, PAX)

❖Work ExperienceProject Engineer - Conveyor Dynamics Inc. (1995-2004)

Vice-President - AC-Tek (2004-2019)

❖EducationB.S. Engineering Mechanics, University of Wisconsin

M.S. Aerospace Engineering, University of Washington

David KruseVice President

Advanced Conveyor TechnologiesExecutive Personal

Engineering DesignOverland Conveyors

Control System Design

Transfer Chutes

System ValidationField Measurements

Site Commissioning

New IdeasDesign Innovations and

Technology Advancements

Laboratory TestingRubber Technology

Idler & Component Testing

Material Characterization

Software DevelopmentStatic & Dynamic Analysis (Sidewinder)

Finite Element Analysis (PAX)

Discrete Element Analysis (Newton)

Custom Software Development

Advanced Conveyor TechnologiesEngineering Design Circle

• Static Analysis: Proprietary model uses rubber rheology to accurately predict the power consumption.

• Dynamic Analysis: Calculates the dynamic behavior of during starting, stopping, and emergency/failure conditions.

• Verified by field measurements on a range of conveyors around the world.

Software TechnologyKey Components

Newton (DEM)• Discrete element modeling software specialized

for efficient modeling of transfer chutes.

Pulley Analysis (PAX)• 3D finite element Analysis (FEA) software for

the design and analysis of pulleys and shafts.

Sidewinder

Rubber indention losses and material flexure can consume 50-70% of the power consumption

on a long overland conveyor.

Standard calculation methodologies such as CEMA and DIN can not accurately predict the

power and belt tensions for these systems.

AC-Tek has developed a proprietary rolling resistance model which takes into account the belt’s

bottom cover rubber properties.

This effect is a function of belt speed, temperate, and strain (material loading).

Belt Tension & Power PredictionRubber Rheology Testing

Belt Velocity

Take-up Position

Torque – High Speed Shaft Torque – Low Speed

Field Measurements & Forensic EngineeringVerification of Theoretical Models

Horizontal Curve

Displacements

Turnover

Displacements

▪ Sasol Shondoni, South Africa: 20.6 km, 2400 t/h of coal, horizontal curves

▪ VALE S11D, Brazil: 3 Overland conveyors, 21,000 t/h of iron ore

▪ KPC, Indonesia: 2 Overland conveyors, 12.6 km and 9.2 km, horizontal curves

▪ Obajana Cement, Nigeria: 7 km, 2400 t/h, horizontal curves

▪ Twistdraai Colliery, South Africa: 12.5 km, 2400 t/h, horizontal curves

▪ Aitek, Sweden: 3 km, 8000 t/h, Artic temperatures

▪ VALE S11D, Brazil: Downhill conveyors (385 m drop), 9500 t/h iron ore

▪ ….and many many more

Field Measurements Verification of Static and Dynamic analysis

Worldwide Experience & InstallationsGlobal Locations

• U.S.A. & Canada

• Finland, Sweden, Netherlands, Armenia

• South Africa, Zambia, Ghana, Nigeria

• Brazil, Columbia, Columbia

• Chile, Peru

• Australia

• India

• Indonesia

• China

• Mongolia

• Russia

Sasol (Shondoni), South Africa (2014) 20.5 km single flight overland conveyor with multiple horizontal curves2,400 t/h of Coal - 1200 mm – ST-2500 N/mm - 6.5 m/sWorld’s longest conveyor without an intermediate drive station!

Obajana Cement, Nigeria (2008)7.0 km Elevated Overland Conveyor with multiple horizontal curves2,400 t/h of Limestone - 1200 mm - ST-1250 N/mm - 5.0 m/s, 3 x 500 kW

Kaltim Prima Coal, Indonesia (2014)9.2 km overland conveyor with multiple horizontal curves. 4,500 t/h of Coal - 1400 mm - ST-2000 N/mm - 7.25 m/s

Kaltim Prima Coal, Indonesia (2012)12.6 km Overland Conveyor4,500 t/h of Coal - 1100 mm - ST-2250 N/mm - 8.5 m/s - 2 x 2250 kW

Twistdraai Colliery, South Africa (2011) Three overland conveyors ranging from 1.3 km to 12.4 km. 2400 t/h of Coal - 1200 mm - 5.0 m/s12.4 km overland has both head & tail drives as well as multiple horizontal curves.

Solomon Overland Conveyor Project, Australia (2013): Ten (10) overland conveyors with a total system length of 36 km.Conveyors transport 7400 t/h to 2600 t/h of iron ore. Longest conveyor is 7 km.

Morenci, Arizona (2015) Design of a 1.4 km overland with a 1,800 m horizontal curve5,100 t/h of Copper Ore

VALE S11D, Brazil (2014) Three downhill conveyors ranging from 1.6 km to 4.5 km19,200 t/h of Iron Ore - 2200 mm - ST-8000 N/mm - 5.0 m/s Longest conveyor has 5 x 1500 kW motors & brake sizes of 3 x 350 kN + 4 x 640 kN

VALE S11D – Waste Conveyors, Brazil (2016) 2 Downhill conveyors with 385 m of drop9,500 t/h of Iron Ore - ST-8000 N/mm - 1800 mmConveyors have 8800 kW of power and 2,800 kN-m brake torque.

VALE S11D – Bench Connection, Brazil (2016) 12 conveyors ranging from 1.0 km to 4.0 km. Conveyors transport 9,500 t/h of iron ore 1800 mm wide belt.

Optimum Colley, South Africa (2011)Existing 4.0 km horizontally curved overland conveyor was split into two conveyors. A new 5.1 km conveyor from Boshmanspoort feeds the second half of the existing conveyor at the new transfer point.

Robinson Run, USA (2008)Three overland conveyors (3.5, 3.3, and 1.7 km). 2500 t/h of Coal - 1600 mm - 4.0 m/sDynamic Analysis & Field Measurements

Black Thunder Mine, Wyoming (2009)Design, commissioning and data acquisition 10,900 ft (3.3 km) overland conveyor7000 t/h of Coal - 72” belt (1830 mm) - 1135 fpm (5.8 m/s)

Bluewater Power, Australia (2009): 3.1 km overland conveyor with multiple horizontal curves. 800 t/h of Coal – 800 mm - 5.25 m/s

Gold Fields, Ghana (2009) Design of multiple in-plant conveyors A new 2,600 t/h stockpile feed & reclaim conveyor system. Chutes designed using DEM

Aitik, Sweden (2010)Design of eleven conveyors ranging from 50 m to 3,000 m8,000 t/h of Copper OreLargest conveyor has 192 m of lift - 2000 mm - ST-6000 N/mm - 9,200 kW

El Abra, Chile (2010)Design of 4.5 km downhill conveyor8550 t/h of Copper Ore - 1600 mm - ST-3150 N/mm 3 x 900 kW Power, 3 x 150 kN-m Brakes

Baily Crabapple, USA (2010) Three conveyor totaling 22,034 ft (6,700 m)4600 tph (4175 t/h) of coal. Total installed power of 9,000 hp (6700 kW)

Endako, Canada (2010)Design audit, field measurements, and a design upgrade on a 2.3 km incline conveyor. 3,650 t/h of molybdenum ore - 54” (1372 mm) - ST-4800 N/mm - 4.8 m/s4 x 930 kW installed power

Bayovar, Peru (2010) Two overland conveyors (4.1 km and 2.0 km)2,250 t/h of Phosphate - 1600 mm - ST-1800 N/mm - 4.6 m/s

Boschmanspoort, South Africa (2011)5.1 km overland conveyor 1400 t/h of Coal - 1050 mm - ST-2000 N/mm - 4.5 m/s

CSN – Porto de Sepetiba, Brazil (2011)Field Measurements, Design Audit, and Design Upgrade Analysis of 7 conveyors. 17,600 t/h of Iron Ore - Longest conveyor is 2,000 m

Negzi, Zambia (2011)5.8 km overland with multiple horizontal curves (2,100 m and 3,500 m)1,400 t/h Platinum Ore - 900 mm - ST-2000 N/mm - 4.0 m/s

Antamina, Peru (2011) Field Measurements and Design Upgrade of 3.2 km Conveyor7,500 t/h of Copper Ore - 1600 mm - ST-6000 N/mm - 4.0 m/.s

Oyu Tolgoi, Mongolia (2012) Design of 11 conveyors. Longest conveyor is 2.7 km long. 7,200 t/h of copper ore - 1800 mm - ST-1800 N/m - 3.8 m/s

Aditya Birla Group Dahej, India (2012)Field Measurements on multiple pipe conveyors. 1,100 t/h of coal - 1600 mm - ST-800 N/mm

Porto do Itaqui, Brazil (2016)Field Measurements on a 5.0 km and 1.3 km Pipe conveyor1,000 t/h of Coal - 1460 mm Multiple 300 m horizontal and vertical curves.

Enlow Fork, West Virginia USA (2012)Six overland conveyors and two slope conveyors. 84” Slope conveyor transports 10,000 tph of coal up 235 m - ST-6000 N/mmLongest overland is 12,700 ft (3.8 km) and transports 4,600 tph coal

VALE Projecto Executivo, Brazil (2012)Four port conveyors – Longest is a 2 km overland feeding a ship loading tripper20,000 t/h of Iron Ore - 2200 mm - ST-4500 N/mm70 m belt turnovers installed to prevent spillage of material into the bay

Simplot, Utah (2014)Design of 800 m overland conveyor with a 850 m horizontal curve2,000 t/h of Phosphate Ore

Collahuasi, Chile (2015) Field measurements on two overland conveyors with a 5000 m horizontal curve10,000 t/h of Copper Ore

Lumwana Copper, Zambia (2008)Six conveyors including a 4.3 km overland conveyor4066 t/h of Copper Ore - 5.2 m/s - 4 x 560 kW