ZOOMRY
HuaXia JianLong Group – 2,600 t/h Curved belt conveyor System
Project Location: Hebei, China
Year Completed: 2014
Client: HuaXia JianLong Group
Capacity: 2,600 tons per hour
Conveyor Lengths: 2,300 m + 780 m (two flights)
Curve Angle: 45° horizontal turn
Curve Radius: 500 m
Material: Iron ore, aggregates
Project Background
HuaXia JianLong Group is a large-scale mining and steel conglomerate in Hebei Province. With the expansion of its iron ore processing plant, the existing truck transport between the mine pit and the crushing station became a bottleneck. The mountainous terrain required a long-distance conveyor that could navigate a sharp 45° horizontal curve with a radius of only 500 meters. The client needed a reliable, high-capacity solution to replace trucks, reduce dust emissions, and lower operating costs.
Project Requirements
The client requested a two-flight belt conveyor system with the following specifications:
- Total length: 2,300 m (main flight) + 780 m (secondary flight)
- Horizontal curve: 45° bend with a radius of 500 m (no transfer station)
- Capacity: ≥ 2,600 t/h (continuous)
- Material: Iron ore (particle size 0–200 mm, density 2.5 t/m³, highly abrasive)
- Terrain: Mountainous with elevation changes up to 80 m
- Environmental compliance: Dust emission ≤ 10 mg/m³
- Reliability: 24/7 operation with easy maintenance
ZOOMRY's Customized Solution
Core Equipment – Curved Belt Conveyor System
ZOOMRY designed and supplied a two-flight curved belt conveyor system (2,300 m + 780 m) with a 45° horizontal turn (radius 500 m). Key features:
- Belt width: 1,600 mm (heavy-duty, suitable for high‑capacity iron ore flow)
- Belt speed: 3.15 m/s
- Drive system: Main flight: 2 × 500 kW motors (total 1,000 kW); secondary flight: 1 × 315 kW motor
- Curve technology: Special friction self-aligning idlers and gradual tension control to prevent belt deviation on the 45° curve (radius 500 m)
- Idler sets: Heavy-duty type (diameter 159 mm) with labyrinth seals, rotational resistance ≤ 2.5 N
- impact beds: Installed at feed points to absorb heavy iron ore impact
- Belt Cleaners: Dual tungsten-tipped scrapers at head and tail (cleaning efficiency ≥ 96%)
- Full enclosure: Steel covers along both conveyors to suppress dust
Dust Control System
Sealed covers and dust extraction points at transfer chutes reduced dust emissions from an estimated 25 mg/m³ to below 8 mg/m³, meeting local environmental standards and avoiding penalties.
Adaptation to Sharp Curves
The 45° horizontal curve with a 500 m radius was the most challenging part. ZOOMRY applied its patented “curved belt conveyor technology” with hexagon idler sets and force‑guided belt tracking, ensuring stable operation without the need for an intermediate transfer station.
Implementation Process
Design & Manufacturing
ZOOMRY’s engineering team conducted a detailed topographic survey and simulated the curve dynamics using finite element analysis. All components were manufactured at ZOOMRY’s ISO 9001-certified factory and pre‑assembled in sections.
Installation & Commissioning
A 15-person installation team completed the assembly in 70 days using a modular approach. After a 72‑hour load test, the system achieved a stable capacity of 2,650 t/h, exceeding the requirement.
Training & After‑Sales
ZOOMRY provided 12 days of on‑site training for 20 mine maintenance personnel, covering daily inspection, belt tracking, and emergency procedures. A local spare parts warehouse ensures critical components (idlers, scrapers, belts) are available within 7 days.
Project Outcomes
- Throughput increase: The system now handles 2,650 t/h, a 40% improvement over the previous truck‑based transport, eliminating 60 truck trips per day.
- Environmental compliance: Dust emissions decreased to 7.5 mg/m³, well below the national standard.
- Reliability: After 9 years of operation, the system availability remains above 99%, with no major component failure.
- Cost savings: Energy consumption per ton reduced by 45% compared to trucks, and annual maintenance costs cut by 50%.
Client Testimonial
“The 45° curved conveyor from ZOOMRY solved our terrain challenge perfectly. The system runs smoothly without belt deviation, and the dust control is excellent. We are very satisfied with their installation speed and after‑sales support.” – Project Manager, HuaXia JianLong Group
Why Choose ZOOMRY for Curved Belt Conveyors
- Proven curve technology: Successfully delivered conveyors with turning radii as small as 300 m and angles up to 90°.
- Heavy‑duty design: Conveyors tailored to high‑abrasion ores, with reinforced idlers and wear‑resistant liners.
- Full EPC service: Survey, design, manufacturing, installation, training, and after‑sales support.
- Local spare parts: Rapid response (≤ 7 days) for critical components.
