Going Downhill Can Move Your Operations Up

We usually think of “going downhill” as a bad thing—but in bulk material handling, it can be a major advantage.

When the terrain allows it, downhill conveyors are among the most energy-efficient systems available for mines and processing plants. These conveyors harness the natural force of gravity, using the weight of the bulk material to generate power rather than consume it.

At DSI, we’ve seen firsthand how Sandwich Belt high angle conveyors can do more than just move material—they can become a source of energy and even facilitate energy storage.

In one notable case, a DSI-designed overland conveyor system was able to regenerate power and feed it directly back into the mine’s grid—all by leveraging the simple, reliable pull of gravity on a downhill slope.

This month’s newsletter explores how “going downhill” can actually drive your operations upward—and why it’s a smart consideration for your bulk material handling strategy.

Two Options for Downhill Conveying at Mexican Gold Mine

The mine originally contracted DSI for a Sandwich Belt high angle conveyor, which saved space and created a direct haulage path over the mountain. It also offered free energy – 200kW – into the mine grid when operating at the design rate. The Sandwich Belt order was cancelled due to geology concerns, so DSI instead developed a net regenerative overland conveyor system that exploited horizontal curves to reduce the number of conveyor flights saving the client money.

DOWNHILL POWER PRODUCTION

At a Venezuelan phosphate mine, a six-flight overland conveyor system was developed to transport material downhill to their port facilities.

Geotechnical investigations showed that the site was unsuitable for supporting the foundation and storage pile loads, so the storage barn had to be moved. The steep, downhill transport path was easily accomplished by a downhill HAC.

The concept for the DSI Mega Battery was inspired because of the proven capability to generate power with a downhill Sandwich Belt high angle conveyor. Utilizing two, parallel Sandwich Belt conveyors, during times of low power demand, the Sandwich Belt conveyor would elevate heavy steel balls to a higher potential energy state. During high power demand, a lowering unit lowers the heavy steel balls back to grade, generating power back to the grid.

C E L B R A T I N G T W E N T Y – E I G H T Y E A R S

On July 7, Dos Santos International proudly celebrated 28 years in business. This achievement wouldn’t be possible without the continued trust and support of our valued customers and representatives.

Your confidence has fueled our growth and inspired us to keep pushing the boundaries of bulk material handling innovation. We are truly grateful and look forward to many more years of collaboration and success together.

Here’s to the journey ahead—thank you for being a part of it!

SERVICE CORNER

UPCOMING EVENTS

COPPER 2025

Amy Duncan will be presenting on “The Vital and Missing Link in High Angle Conveying” at the upcoming 12th International Copper Conference in Phoenix, Arizona. This event is part of the Extraction 2025 initiative and will focus on key topics with mining, mineral processing and pyrometallurgy.