A series of custom-engineered chute solutions that address complex material flow challenges and reduce equipment wear have helped improve performance, maintenance efficiency and operational reliability at a zinc mining operation in the Northern Cape.

Weba Chute Systems has partnered with Vedanta International Zinc’s Gamsberg mine to introduce innovations such as swing doors and modified impact beds to enhance chute performance.

To simplify and speed up liner replacement during shutdowns, the company redesigned the liner pattern on the spout, explains Weba Chute Systems regional manager: Northern Cape Arnold Archer. The company also introduced a standby spout system that could be swapped out through a simple bolt-off, bolt-on procedure, to enable maintenance to be done outside of scheduled shutdowns.

“As we demonstrated our expertise and added value, the mine invited us to assess other transfer points where they were experiencing operational challenges,” Archer explains. “These included the jaw crusher feed chute and the apron feeder discharge chute, both of which handle large run-of-mine ore lumps from up to 800 mm to 1 200 mm.”

Material arriving at the jaw crusher was moving at high velocity, leading to excessive wear and damage. After analysing the application, Weba Chute Systems proposed a solution.

“We replaced the existing jaw crusher feed chute with one of our custom-engineered designs incorporating swing doors to absorb the energy of incoming material, reducing impact and wear,” says Archer. “We later implemented the same swing door concept in the apron feeder discharge chute. Today, swing doors are also installed on the vibrating grizzly feeder and directly above the crusher – all effectively controlling flow and reducing wear.”

The company also modified the impact bed on the grizzly feeder – by raising the impact bed, incoming material begins to slow down before reaching the first swing door.

“These innovations made a significant difference, particularly in managing the impact from oversized lumps,” he notes. “We also fine-tuned door weights to optimise material flow, prevent build-up and reduce the risk of blockages.”

In addition, the mine commissioned Weba Chute Systems to install a semiautogenous grinding mill discharge chute, which accommodates a 4 m transfer height, tapering from a 2.4-m-wide screen opening to a 600-mm-wide conveyor belt.