Discharge Conveyor Replacement

The project involved the replacement of Discharge Conveyor 2, originally installed in 1975.
The conveyor was exhibiting advanced internal and external component deterioration and was considered uneconomical to continue repairing.
Its existing length and arrangement were also no longer suitable for the current process configuration.
DMD developed the coordinated design required to replace the conveyor while reconnecting the numerous existing product chutes, aspiration ducts and supporting infrastructure.

The replacement conveyor had to be integrated into an existing operational plant with limited space and numerous fixed interfaces.
A total of 13 tie-in points were required across the existing product chutes and aspiration ductwork.
The original conveyor had not been installed square to the surrounding building structure, creating significant alignment, orientation and dimensional challenges.
The replacement arrangement needed to accommodate the existing process connections while improving access, maintainability and suitability for the current operating requirements.
Installation planning also had to minimise modification work and disruption to the surrounding plant.

A detailed laser scan and manual verification survey were completed to accurately establish the position, orientation and condition of the existing installation.
Particular attention was given to confirming the 13 existing tie-in points and the non-orthogonal alignment of the conveyor relative to the building.
Detailed chute and aspiration-duct development studies were undertaken to connect the replacement conveyor into the existing process arrangement.
Conveyor, structural and ductwork designs were coordinated within a single 3D environment.
Potential clashes, access restrictions and fabrication issues were identified and resolved before construction.
Installation, lifting, maintenance and future component-replacement requirements were considered throughout the design.
The final arrangement was developed to minimise site modification and simplify installation within the available shutdown period.