Process flow challenges impact plant performance in the mining industry and typically arise when new or existing screens, crushers or feeders underperform as a result of inefficient material transfer between stages in the processing circuit, says Weba Chute Systems.

The company explains that transfer chutes linking different units of process equipment can become the source of bottlenecks, leading to problems such as uncontrolled material velocity, excessive impact, spillage, uneven feed distribution or accelerated wear. The result is often premature failure of liners or vibrating equipment, increased downtime and overall loss of plant efficiency.

Weba Chute Systems MD Mark Baller says that original-equipment manufacturers, engineering, procurement and construction management contractors and mine operators are increasingly calling on the company to assist in resolving process flow issues that impact plant performance.

“In many cases, the mine or project team initially focuses on the mechanical or structural performance of the upstream equipment,” Baller explains. “However, when the problem persists, closer inspection often reveals that the root cause lies in the uncontrolled manner in which the material is being transferred from one point to another.”

He emphasises that even small deviations in material flow trajectory, velocity or impact angle can have a significant influence on how effectively downstream equipment performs.

The company asserts that its extensive experience across a range of commodities - from iron-ore, coal and manganese to platinum, gold and copper - and across almost every part of the process flow sheet enables its engineers to quickly identify where transfer conditions are contributing to a problem and to propose targeted solutions.

“Through [discrete element modelling] simulations,” Baller explains, “our team is able to visualise material trajectories, particle interactions and wear patterns to pinpoint exactly where problems occur - whether this involves excessive material build-up, misalignment or uncontrolled impact. This scientific approach ensures that any redesign is not based on trial and error but on quantifiable evidence.”

Baller notes that the company’s approach is holistic, adding that it does not tackle transfer point problems in isolation but rather aims to stabilise the entire system - ensuring that equipment such as screens, feeders and mills are protected and operate within their design parameters.

Weba Chute Systems asserts that its designs are engineered for every application – from primary crushing and screening to secondary milling, flotation and concentrate handling.