Coal Age

APR 2016

Coal Age Magazine - For more than 100 years, Coal Age has been the magazine that readers can trust for guidance and insight on this important industry.

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Victaulic's Refuse-to-Fuse system was designed to quickly join 2- to 8-in. high- density polyethylene (HDPE) pipe and eliminate the need for fusing. Ordinarily, HDPE pipe is joined using a butt fusion or by using fused flanges. This system joins pipe just like the convention Victaulic cou- pler, using a groove that is cut from the outside diameter (circumference) near the ends. According to Victaulic, the system allows miners to quickly join HDPE pipe, and the joint that is created is much stronger than the pipe itself. The fusion process can be temperamental. Pipe can- not be fused in the rain and the curing time per join can be as long as an hour depend- ing on the size of the joint. On a 4-in. joint, Victaulic claims to have a 10:1 advantage on installation times, which can also be performed in the rain and snow. The fusion process requires a fusing machine. There are capital costs associated with the machine and there are expenses related to operations and maintenance. The Victaulic system can be installed with a socket wrench. If the miners have access to an impact wrench, the installation time increases substantially. Victaulic has also developed a variety of components for the Refuse-to-Fuse sys- tem, such as a transition for connecting HDPE to steel pipe and a spigot adaptor for slurry lines that might require an outlet. www.victaulic.com Composite Rollers The Sandvik HR185, the latest generation, all-composite roller, is a low-weight, low- noise innovation that answers the miners' needs for a superior conveyor component. The new composite rollers deliver signifi- cantly more value than competing steel rollers, from lower cost to corrosion resis- tance in wet and high-salt environments. They're safer, quieter and more economical. The composite shell material used in the HR185 rollers is up to 70% lighter than the shell used on traditional steel rollers and up to 40% lighter than other plastic shell materials on the market. This significantly lower weight enables safer, easier handling and helps reduce the risk of injuries that can occur while installing new rollers or replacing failed rollers during maintenance. In addi- tion, should a roller reach the end of its service life and stop rotating, there is no steel end cap to damage the belt, reducing the risk of belt damage. The HR185s are also ideal for noise- sensitive applications, including export terminals and conveying installations near populated areas. They generate more than 50% less noise than traditional steel rollers. The natural dampening effect of the com- posite means the rollers minimize noise impact on the surrounding environment. "In addition to improving safety and increasing productivity, these composite rollers can reduce total cost of ownership by up to 20%", said Chris Mitchell, global product line manager for Sandvik Mining. They require less time and manpower to install and maintain, and their reduced power demand due to a lower rotating iner- tia means savings in electricity costs. A large, non-rotating end cap covers up to 90% of the roller face and helps to limit damage to seals and bearings from dirt, rocks and other material buildup at the roller face, further extending the roller life and reducing costs." The 185 composite conveyor rollers fea- ture a composite tube and molded compos- ite end caps, which hold the bearings and seals. Unlike other plastic rollers that rely on the physical properties of a single primary shell material to deliver both strength and abrasion resistance, the shells of Sandvik HR185 rollers are formed by advanced pro- cesses to deliver a two-part composite tube that can handle all the running loads of a steel roller at a significantly reduced weight. Despite their light weight, the new Sandvik HR185 composite rollers deliver durability in demanding medium- to heavy- duty conveying applications. Suitable for high speeds and large tonnages, the rollers are available in diameters from 152 mm to 44 www.coalage.com April 2016 p r o d u c t n e w s HDPE Pipe Joining System Eliminates the Fusion Hassles The Victaulic system has a 10:1 advantage over the fusion process.

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