1. Underground Coal Mining
Conveyor chains are critical in underground coal mining due to the cramped and challenging environment.
Face Conveyor (AFC): Face Conveyor is perhaps the most important application in longwall coal mining. AFC uses multiple heavy-duty round link or die-forged face chains to move coal directly from the shearer (cutter) along the coal seam to the coal face. They operate under tremendous pressure and abrasive conditions to move large quantities of coal to the next level of the conveying system.
Beam Loader (BSL): The BSL is located at the end of the AFC and utilizes a similarly rugged chain system to move coal from the AFC to the main entrance and exit conveyor belts, maintaining a continuous flow of coal.
Face Conveyor/Drag Chain Conveyor: Widely used in underground mines to transport coal and other excavated materials along tunnels, lanes and galleries. These chains are equipped with scrapers to drag the material through the conveyor trough. Their enclosed design helps control dust and enables them to operate in tight spaces.
Continuous miners and roadheaders: While these powerful excavators are primarily used as coal cutters, some models use a rugged internal chain system to move cut coal from the face to a shuttle car or other conveyor.
2. Open-pit coal mining and processing plants
While large open-pit operations often use belt conveyors for long-distance conveying, chains are essential for specific high-stress applications.
Feeder-breakers: These primary crushers are often equipped with heavy-duty chain conveyors (such as swaged flight chains) to feed and break up large pieces of coal or overburden before they enter the primary processing flow.
Deep tray conveyors (deep tray conveyors): While conveying pure coal is less common than other heavy mineral conveyors, deep tray conveyors with rugged chains can be used to transport large pieces, lumps, or hot coal when the coal is mixed with large pieces of rock or needs to be handled at extremely high temperatures (for example, after a drying process).
Coal Washer Chains/Jigger Chains: Specialized chains are used in coal preparation plants, in coal washers and jiggers to separate coal from impurities such as rock and slate by density separation. These chains are designed to resist corrosion and wear in wet, abrasive slurries.
Reclaiming Systems: Chains may be part of a system to recover coal from a pile and send it to other conveyors for onward transport.
Ash Handling Systems: In coal-fired power plants (often co-located with mines), heavy-duty chains are used in conveyors to move the abrasive and often hot ash.
