As mining operations in the Democratic Republic of Congo (DRC) scale up and push for higher throughputs, custom engineered chutes are starting to make a vital difference to transfer point efficiency.

The drive for production has meant that traditional chute designs are increasingly being found wanting, reports Weba Chute Systems Africa business development manager Edward Cruickshank.

Many mines in the region are handling material that is abrasive, fine and often sticky, he explains, adding that these properties can vary significantly, depending on moisture content and seasonal rainfall.

“This is a high rainfall region and that variability makes bulk materials handling particularly challenging.

“High tonnages, abrasive ore and fluctuating moisture content all accelerate wear and increase the risk of blockages. If a transfer point fails, the impact on downstream processes and production can be enormous,” notes Cruickshank.

It is precisely these conditions that are driving demand for engineered application-specific chute solutions. Mines are recognising that chutes cannot be treated as generic steel boxes, he says.

“Chutes are critical process flow components,” says Cruickshank, adding that if they are not designed properly to manage material flow, reduce impact velocities and control wear, they become a bottleneck and a maintenance headache.

Growing in the DRC

Weba Chute Systems has been steadily strengthening its presence in the DRC, designing and manufacturing chute solutions for some of the region’s most demanding copper and cobalt mining operations.

With multiple installations already operating successfully and new projects in the pipeline, the company sees the DRC as a strategic growth market.

Mines are focusing more sharply on uptime, safety and the long-term cost of ownership of their materials handling infrastructure, notes Cruickshank.

“Over the past few years, we have seen steady growth in our installed base, driven by both brownfield expansions and new copper and cobalt developments,” he says.

A current project at an openpit copper and cobalt mine in the DRC illustrates both the challenges and the value of Weba Chute Systems’ approach.

The company is designing and manufacturing a specialised ball mill feed chute – a seemingly modest component but one that plays a pivotal role in overall plant performance.

“Ball mill feed chutes are the interface between the conveying system and the grinding circuit, and their design has a direct influence on mill performance and liner life,” explains Cruickshank.

For this project, he says Weba Chute Systems is focusing on controlling the material trajectory, ensuring that the feed distribution into the mill is even and accommodates high throughput rates, while managing extreme wear conditions.

In highlighting the far-reaching consequences that he has witnessed from poorly designed feed chutes in mining operations, Cruickshank says that, for instance, if the feed is uneven or uncontrolled the result is increased liner wear, unstable mill operation and reduced milling efficiency.

“By engineering the chute specifically around the ore characteristics, operating parameters and spatial constraints of this plant, we help customers achieve more stable operation and better downstream efficiency,” says Cruickshank.

Each chute is engineered with the assistance of discrete element modelling to predict material flow and wear patterns before anything is built, he outlines, adding that this allows Weba Chute Systems to optimise the design and target wear areas properly.

Delivering its high level of performance in the DRC also requires Weba Chute Systems to pay close attention to reliability and maintainability, given the logistical and operational challenges of working in remote locations.

The company’s design philosophy is built around these realities, states Cruickshank.

“We combine advanced chute design methodologies with robust materials selection and a strong focus on maintenance accessibility,” he says, adding that this enables mines to reduce the frequency and complexity of interventions.

“Our approach is therefore about extending service life and making the inevitable maintenance work as straightforward and safe as possible.”

In parallel, Cruickshank says Weba Chute Systems works closely with partners in the region to ensure that mines are supported by a strong local presence – a collaborative approach that provides customers with on-the-ground technical backup, inspection support and maintenance capability, which is critical in remote and logistically complex operating environments like the DRC.