ENGINEERED DESIGN

The WEBA design philosophy is simple:

To provide you with a total solution for problems traditionally associated with transfer points.

There is no doubt that the transfer chute is one of the most overlooked components in any bulk materials handling installation, especially since this relatively low-cost item can be the source of a number of major problems.

Armed with information gathered from flow studies, on-site investigations and extensive operational experience, the WEBA team set about designing a transfer chute which would eliminate the problems associated with conventional types of transfer chutes. This led to the birth of the award-winning patented WEBA transfer chute system.

Design Criteria for WEBA Chutes

The design criteria for bulk solids transfer chutes are based largely on steel chutes which may be fitted with steel alloys, ceramic or rubber linings to reduce wear and costs and facilitate maintenance.

Assuming material characteristics are known, the design of chutes depends on the following factors:

  1. Material trajectory into the chute
  2. Material flow from the initial impact area​​​​​
  3. Material flow through the chute​​​​​
  4. Material flows through the discharge area​​​​​

Structure of WEBA Chutes

Visual evidence including video photography indicates that material flows through the WEBA chutes in a flow pattern referred to as “the supertube”. This flow structure results in the elimination of a number of problems experienced in steel-lined chutes.

Figure 1 General Layout of a Reverse Flow Weba Chute

Advantages of WEBA Chute Engineered Design

Based on the operational experience of a large number of WEBA chutes worldwide, it can be concluded that retrofit and new projects can benefit from integrating the WEBA chute design into their transfer systems.

These advantages include:

  1. Frictional effects are less effective in WEBA chutes compared to normal steel chutes.In conventional steel chutes material slides in contact with the liners, while in WEBA chutes material flows in the form of a “supertube” and is not continuously in contact with stationary material
  2. Due to material essentially flowing on material, wear of steel liner components is significantly reduced, resulting in much reduced maintenance and the associated downtime and costs
  3. Due to the action of material impacting on material and material moving over like material, the degradation of the material is reduced compared to conventional chutes as is the generation of dust
  4. The ability to control the velocity, flow direction and cross-sectional area at the discharge ensures a flow which is similar to what is required for example, in feeding belt conveyors. The result is lower belt wear, degradation of material, and spillage problems at the discharge.
  5. A number of factors which require design in conventional chutes are eliminated.These include the necessity of determining frictional factors which are dependent on bed depth, and the calculation of the effects of drop or free fall heights in the chute
  6. The material collected between the wear plates reduces and absorbs sound, reducing the external noise levels of WEBA chutes

With WEBA Chute you will be provided with a clear and trusted material handling system suitable for all kinds of mines. For many new to the industry, the term materials handling conjures up a number of ideas, not all of them correct. It can seem like a vague term, but it’s actually quite easy to understand.

Material handling includes the process (and all that it entails) of moving, controlling and protecting materials, as they are manufactured, stored, used, disposed of or distributed both into and out of the mine. The process is done in such a way that the profitability and the productivity of the mine are improved.

The WEBA Chute can quickly and easily become the material handling system of choice, regardless of the materials that a mine is excavating. Material handling equipment is an absolute necessity for any mine. It keeps the production process going and reduces any possible downtime due to material movement issues. When investing in any mining equipment, making sure that you have the best of the best is the only way to guarantee that the mine continues to function as it should. Inferior mining chutes can lead to costly downtime as well as pricy maintenance and repairs.

The design of the WEBA Chute transfer system is done in such a way that the chute continues to function optimally, with downtime never being a worrying issue. Our option of 2 reliable chutes, will quickly have a mine functioning optimally.

One of the many reasons why you will find greater use and efficiency when you have our chute system has to do with the following:

Let us begin with a maintenance matter covered before in IM but very well worth repeating as it is so important. Mark Baller, Managing Director of transfer chute experts Weba Chute Systems believes that transfer points should be accorded the same importance as other minerals processing machinery. In particular, the effect of the chute’s performance on the life of conveyor belts which can account for up to 60% of the capital cost of a bulk materials handling plant deserves attention.

“The cost of replacing a conveyor belt not to mention the downtime associated with belt maintenance and replacement makes it worth looking more closely at any measures that will extend the conveyor’s life,” says Baller. “Typically, conveyors like feeders, crushers, hoppers and screens are selected to match certain operational requirements; however, there is little emphasis on the design of the chutes transferring materials between elements.” This is a mistake, he argues, as chutes are essential elements in a bulk solids handling plant, and are also subject to operational characteristics and physical constraints. “Among the most common problems on transfer chutes are spillage, blockages and high levels of wear on the receiving belt due to major differences between the material velocity and the belt velocity,” he says. “There is also misalignment of the receiving conveyor belt which is caused by uneven loading from the transfer chute.”

Key to solving these challenges is good design, he emphasises. While conventional chute design often allows the uncontrolled discharge of bulk materials, Baller considers that a holistic design is necessary focusing not only on the entry and exit points, but also controlling the flow, volume and velocity of the material being transferred. “Each transfer point therefore needs to be custom designed, to control the direction, flow and velocity of the material,” he says. “Weba Chute Systems bases its designs on the supertube’ effect which often employs a cascade lining system allowing 95% of material to run on other material at all times. This may also be achieved using conventional lining systems.” He emphasises that one of the designer’s aims must be to achieve controlled transfer of material onto the conveyor belt, reducing wear and tear on belts while also minimising the impact that creates dust. The results are cost saving for customers and better occupational health and safety compliance, “The ‘super flow effect’ is designed into our products using sound engineering principles and sophisticated 3D software,” says Baller. “We also use Discrete Element Method (DEM) simulation as a verification tool.”

 

Although the transfer of a  material handling system has a long lifespan, there might come a time when maintenance becomes a necessity. At WEBA we have the perfect solution for all belt maintenance requirements. Years of design, innovation and gaining invaluable field experience, means that we know exactly what needs to be done when the time comes to carry out maintenance..

WEBA Chute System Benefits

You can, without a doubt, look forward to numerous benefits when you’ve made the smart choice of investing in a proper, well-designed transfer chute. Material handling PDF’s, along with this site, will provide you with all of the information you need. Here are a handful of the great benefits of the overall chute system that you can look forward to:

  1. A cost-effective material transfer solution

With each WEBA Chute System, we manufacture, we aim to use the most affordable technology and materials, along with using our years of exceptional experience, to solve your material transfer problems. We never cut back on quality, so you can always expect a superior product.

  1. High Safety Standards

We also place emphasis on accident prevention, environmental protection, and workplace safety, to prevent injuries on site which could harm employees and set back productivity.

For more information about how you can change the way that your mine functions, contact us.