Big Roller™, energy efficient overland conveying with negative marginal cost of abatement energy efficient overland conveyor development

The Challenge 

Pilbara iron ore mines face growing pressure to cut carbon emissions as diesel haulage becomes more energy intensive. With practical electrification of the haulage fleet years away, a significant opportunity exists through the potential of larger-diameter conveyor rollers to deliver immediate energy efficiency improvements.

Proposed Solution 

Testing confirmed increasing idler roller diameter from current standard dimensions of 152 mm to 508 mm reduces energy-wasting indentation rolling resistance by 68% for steel rollers and 57% for lightweight nylon composite rollers.

A commercial batch of 50 nylon rollers weighing under 25 kg was manufactured, establishing the potential for supplying rollers suitable for safe. practical field handling.

Relocatable conveyor ground modules incorporating larger-diameter rollers were independently validated to Australian structural standards.

Proposed Benefits to WA

Installation of the Big RollerTM conveyor technology solution could support approximately 25 skilled WA jobs per project, and the technology creates significant IP export potential. The demonstrated efficiency gains from the system could cut up to 1.5 MW of installed power demand or 12,500 tonnes of CO₂ annually per 13.5 km conveyor installed – providing the potential for rapid emissions savings.

Report DOI

DOI: 10.71342/622919254936