Solving Cleaning Challenges in Restricted Spaces to Optimize the Sulfur Conveyor Line
| Product application | Belt Cleaner C1R4、SAC2 |
| Width of belt | 1200mm |
| Industry | Petrochemical Industry |
| Material | sulfur |
Challenges
Due to the extremely restricted space near the shuttle drive pulley, the existing single-stage cleaner was ineffective. Consequently, a significant amount of sulfur failed to discharge into the chute and was instead carried back by the return belt, ultimately accumulating as waste. Statistics reveal that each ship loading operation generated 7 to 8 bags of sulfur waste.
This not only represented a direct loss of raw material but also created a heavy demand for manual cleanup. More critically, clearing this carryback and adjusting the cleaning equipment required an average of 6 hours of downtime per shipment. During tight shipping schedules, this posed a risk of vessel delays, exposing the client to substantial demurrage charges.
Solution
To address the pain point of limited space, we implemented the C1R4 Primary Belt Cleaner as the first line of defense. Featuring a one-piece molded PU blade designed specifically for chemical environments, its compact structure and torsion pressure adjustment mechanism perfectly overcame the installation constraints. Additionally, we configured the SAC2 Secondary Belt Cleaner as the second line of defense. Utilizing tungsten carbide blades combined with rubber vulcanization technology, it offers superior wear resistance and scraping power. It is specifically designed to remove fine materials missed by the primary cleaner, ensuring the belt surface is thoroughly clean.
(1) Primary Belt Cleaner (C1R4) : Features a one-piece molded PU blade with a torque pressure adjustment device. It is designed for chemical environments and is suitable for confined spaces.（Left）
(2) Secondary Belt Cleaner (SAC2) : Features tungsten carbide blades with vulcanized rubber. It offers high wear resistance, long lifespan, and quick replacement capabilities, making it suitable for diverse materials.（Rught）![]()
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Improvements
Upon implementing JIMWAY’s dual cleaning system, the improvements were immediate. The conveyor belt surface was restored to a pristine condition, effectively solving the persistent headaches of waste accumulation and frequent downtime. The following comparison highlights the specific data before and after the improvement.
Comparison
Metric | Before | After | Benefits |
Cleanliness | Significant sulfur adhesion | Approx. 90%, belt is clean | Significant reduction in carryback |
Waste Volume | Approx. 7–8 bags / ship shift | < 1 bag / ship shift | Reduced material waste |
Downtime | Approx. 6h / ship shift | Adjusted only once before ship arrival | Maximized production capacity |
Blade Lifespan | Approx. 2 months | > 1 year | Substantial reduction in maintenance costs |
Manual Cleaning | Required multiple workers | Almost not needed | Reduced labor costs |
Conclusion
Through this upgrade, JIMWAY not only resolved the immediate cleaning challenge but also created long-term economic value by extending equipment lifespan and restoring production capacity. As evidenced by the data, the doubling of consumable life and the elimination of downtime have directly reduced total operating costs. The client has highly affirmed these results and plans to replicate this successful model across other conveyor lines in the plant to comprehensively enhance production efficiency.