This article examines belt mistracking in coal handling systems and evaluates the field performance of the REMATRACK TTX solution in maintaining alignment and operational continuity.
Belt mistracking as an operational risk
Conveyor systems are essential for continuous production in mining and energy operations. However, mistracking can lead to efficiency loss and structural damage.
At a coal-fired power plant in New South Wales, a 1.75 km conveyor system carrying over 3,500 tonnes per hour experienced severe mistracking due to a non-conforming belt section.
With no available downtime for replacement, the issue was already causing production loss.
On-site solution
REMA TIP TOP installed four REMATRACK TTX units along the beltline, enabling immediate intervention without stopping operations.
The system’s one-step casting design eliminates joints, reducing wear, while polyurethane lagging provides high durability.
Results
Belt alignment was restored immediately, stopping production loss.
Installed across a 600-meter section, the system maintained stable performance for over 24 months.
Key outcomes:
- Elimination of production loss
- Reduced structural risk
- Delayed need for belt replacement
Assessment
This case highlights the importance of rapid engineering intervention in maintaining conveyor system reliability.
