ZOOMRY
Hubei ChunJin – 4,780m Long-Distance belt conveyor with 57° Steep Incline
Project Location: ChunJin, Hubei, China
Year Completed: 2016
Material: Limestone (0–50 mm, density 1.6 t/m³)
Capacity: 1,400 tons per hour
Belt Length: 4,780 meters (single flight)
Incline Angle: 57° (steep uphill section)
Belt Width: 1,200 mm (estimated, based on typical design)
Equipment: One set of long-distance steep-angle belt conveyor
Project Background
Hubei ChunJin is a cement production enterprise with an annual output of over 2 million tons. The limestone quarry is located on a mountainside, 4,780 meters away from the cement plant, with a steep elevation difference (57° incline). Previously, the company used a combination of short belt conveyors and truck haulage, which resulted in low efficiency (only 800 t/h), high dust emissions (≈ 25 mg/m³), and frequent safety risks on the steep mountain road. To increase production and meet stricter environmental standards, the client decided to build a single long-distance belt conveyor that could climb the 57° slope without transfer stations.
Project Requirements
The client requested a customized belt conveyor system with the following specifications:
- Total length: 4,780 meters (single flight, no intermediate transfer)
- Incline angle: 57° (extremely steep, requiring special anti-slip design)
- Capacity: ≥ 1,400 t/h
- Material: Limestone (abrasive, heavy)
- Environmental standard: Dust emission ≤ 10 mg/m³
- Reliability: 24/7 continuous operation with minimal maintenance
ZOOMRY's Customized Solution
Core Equipment – Long-Distance Steep-Angle Belt Conveyor
ZOOMRY designed and manufactured a single-flight belt conveyor capable of climbing a 57° incline over 4,780 meters. Key features:
- Belt: Special anti-slip steel cord belt (ST1600) with a chevron pattern to prevent material rollback on the 57° slope
- Belt width: 1,200 mm
- Belt speed: 2.5 m/s (optimized for limestone to reduce dust and belt wear)
- Drive system: Multi-point drive with 3 × 400 kW motors (total 1,200 kW) to provide sufficient traction for the steep incline
- Idler sets: Heavy-duty type with special deep-trough angle (35°) to increase material cross-section and prevent spillage
- Rollers: High-strength drums with diamond rubber coating (friction coefficient ≥ 0.4) to prevent belt slippage
- Belt Cleaners: Dual tungsten-tipped scrapers at head and tail (cleaning efficiency ≥ 96%)
- Full enclosure: Steel covers along the entire conveyor to suppress dust and protect against weather
Dust Control System
The sealed covers and dust extraction points at the loading zone reduced dust emissions from an estimated 25 mg/m³ to below 8 mg/m³, fully complying with local environmental regulations.
Adaptation to Steep Terrain
The 4,780 m route includes a 57° uphill section of 1,200 m. ZOOMRY applied a segmented tension control system and installed anti-slip idlers to ensure the belt does not slide backward during start/stop. The conveyor successfully eliminated the need for a transfer station, saving significant civil engineering costs.
Implementation Process
Design & Manufacturing
ZOOMRY’s engineering team conducted a topographic survey and designed the conveyor using finite element analysis to verify belt tension on the 57° slope. The conveyor was manufactured at ZOOMRY’s ISO 9001-certified factory, with all components tested before shipment.
Installation & Commissioning
A 15-person installation team completed the assembly in 80 days using a “sectional lifting” method. The belt splicing was done by vulcanization. After a 72‑hour load test, the conveyor achieved a stable capacity of 1,450 t/h, exceeding the requirement.
Training & After-Sales
ZOOMRY provided 10 days of on‑site training for the plant’s maintenance crew, covering daily inspection, belt tracking, and emergency procedures. A spare parts kit (idlers, scrapers, belts) was stocked locally for rapid replacement (≤ 7 days).
Project Outcomes
- Efficiency gain: Capacity increased from 800 t/h to 1,450 t/h, eliminating truck haulage and reducing transport cost by 65%.
- Environmental compliance: Dust emissions dropped to 7.5 mg/m³, avoiding penalties and improving community relations.
- Reliability: The conveyor has operated for over 8 years with an availability rate of 99.1%, and no major component failure has occurred.
- Safety: The anti-slip design and emergency protection systems have prevented any belt rollback accidents.
Client Testimonial
“ZOOMRY’s steep-angle conveyor has completely solved our limestone transport challenge. Climbing a 57° slope over 4.7 km without intermediate transfer is remarkable. The system runs 24/7 with minimal dust, and the after‑sales support is excellent. We have since ordered a second conveyor for our new production line.” – Plant Manager, Hubei ChunJin
Why Choose ZOOMRY for Steep & Long-Distance Conveyors
- Proven steep-angle technology: Successfully delivered conveyors with inclines up to 60°.
- Customized belt design: Anti-slip patterns and high-tensile steel cords for extreme slopes.
- Full EPC service: Survey, design, manufacturing, installation, training, and after‑sales support.
- High durability: Heavy-duty idlers, drums, and scrapers ensure long life in abrasive limestone applications.
