Abstract: Apron feeders, having a material hopper and chain conveyors with outboard chain driven pans, are under significant stress and at risk of premature failure at the material-control wings. Herein, embodiments of pan are provided fit with mechanically-fastened wings to mitigate stress risers. Each pan has an upper plate with overhanging portions forming left and a right outboard chain connection. At a high stress location, between the hopper walls and the chain connections, the wings are mechanical secured to an upper plate of the pan. In embodiments, the wings are formed of an L-shaped wing, such as a bent plate, having a base portion for parallel and mechanical connection to the upper plate. The wing's base portion can be fastened with one or more of the bolt holes and bolts that also secure the pan to the chain conveyors.

Abstract: Apron feeders, having a material hopper and chain conveyors with outboard chain driven pans, are under significant stress and at risk of premature failure at the material-control wings. Herein, embodiments of pan are provided fit with mechanically-fastened wings to mitigate stress risers. Each pan has an upper plate with overhanging portions forming left and a right outboard chain connection. At a high stress location, between the hopper walls and the chain connections, the wings are mechanical secured to an upper plate of the pan. In embodiments, the wings are formed of an L-shaped wing, such as a bent plate, having a base portion for parallel and mechanical connection to the upper plate. The wing's base portion can be fastened with one or more of the bolt holes and bolts that also secure the pan to the chain conveyors.

Abstract: A double roll crusher is provided for mined oil sands feed, even in the winter season. Each roll has a driveline driven by a high efficiency motor controlled by a variable frequency drive (VFD). Through removal of the prior, yet ubiquitous fluid coupling and related failure-prone components, a shorter, streamlined, lower inertia driveline results. The VFDs and a system controller adapt to the processing of difficult oil sand feed, anticipating high current events, adjusting roll speed on-the-fly, adjusting feeder rate or both to minimizing the high cost of process interruptions. Maximum startup torque and on-the-fly modification of roll and feeder speeds is provided to manage feed, environment and process variations and in instances of a stall, immediate recovery therefrom for reduced downtime, reduced wear and increased efficiency.