Case Study: Resisting Corrosion with HDPE Conveyor Rollers
For any mining operation, conveyor systems are critical, especially when it comes to handling materials in corrosive environments. In Louisiana, one of our longstanding customers operates an underground conveyor system that conveys salt—a material that is exceptionally harsh on traditional steel rollers due to its corrosive properties. Seeking an alternative to the high-maintenance, corrosion-prone steel rollers, the customer turned to HDPE (high-density polyethylene) conveyor rollers. This case study explores the challenges our client faced with using steel rollers on their underground conveyor and the impact that switching to HDPE rollers had on their operation.
The Problem
Operating in a high-moisture, salt-laden environment is demanding for any conveyor system, but for steel rollers, it’s particularly challenging. Salt’s corrosive nature can cause steel rollers to rust and seize up, potentially causing the rollers to become non-functional and inflict damage to the conveyor. This customer’s steel rollers suffered heavy corrosion, requiring frequent maintenance to keep the rollers operational. The customer needed a solution that could resist corrosion, reduce maintenance costs, and operate reliably in a harsh underground setting.
The Solution
West River Conveyors suggested switching to HDPE conveyor rollers. Known for their inherent resistance to corrosion, rust, and chemical damage, HDPE rollers offer several advantages over steel in corrosive environments. Key benefits of HDPE rollers include:
- Corrosion Resistance: Unlike steel, HDPE doesn’t rust or corrode, making it an ideal choice for environments with high moisture or corrosive substances like salt.
- Lightweight: HDPE rollers are significantly lighter than steel, simplifying handling and installation and reducing the overall load on the conveyor system.
- Low Noise Operation: HDPE’s material properties help dampen operational noise, contributing to a quieter, more comfortable work environment.
- Reduced Wear on Conveyor Belts: The smooth surface of HDPE rollers minimizes friction, extending the lifespan of conveyor belts.
For the Louisiana salt mining operation, these characteristics aligned well with their needs. Though HDPE rollers generally support lighter loads compared to steel, the customer’s salt conveyor system was well within HDPE’s load-bearing range, making this solution a good fit for their application.
The Results
The HDPE rollers met and exceeded the customer’s expectations in the underground salt environment. Since installation, the customer reported:
- Minimal Corrosion: While the steel rollers quickly corroded and seized in the salt-rich conditions, the HDPE rollers remained free from corrosion, maintaining smooth, consistent operation.
- Improved Longevity: With no rust or corrosion buildup, the HDPE rollers continue to operate efficiently with minimal need for maintenance.
- Enhanced Work Environment: The lightweight, low-noise HDPE rollers contributed to easier handling and a quieter operation, enhancing worker comfort in the underground setting.
With reduced maintenance and improved reliability, the HDPE rollers have proven to be an effective, cost-efficient solution for the customer’s needs. This case shows how HDPE can be a valuable alternative in harsh, corrosive environments where steel might struggle.
Enhance Your Conveyance with WRC
West River Conveyors’ customer in Louisiana successfully implemented HDPE rollers on their salt conveyor, achieving notable improvements in corrosion resistance, maintenance reduction, and operational noise. For any industry dealing with corrosive materials, HDPE rollers can offer a practical alternative to steel. If you’re considering ways to improve your conveyor system’s performance in challenging environments, contact West River Conveyors today. Our team is here to help you find the ideal conveying solution for your unique application.