Project Background

In Huanggang City, Hubei Province, an open-pit factory specializes in limestone mining and processing, with limestone as its core material (particle size: 5-30mm, moisture content: 6%-9%, featuring high hardness and easy dust generation). It is necessary to build an exclusive conveying line from the mine crushing area to the factory raw material silo, connecting the entire process chain of "mining - crushing - conveying - storage". Previously, the factory adopted a hybrid mode of "conventional belt conveyors + truck transshipment". However, under the open-air environment and topographic conditions in Huanggang, multiple bottlenecks have gradually emerged.

Along the 3,200-meter conveying route that passes through 3 natural bends, conventional belt conveyors require 2 transshipment stations, increasing equipment investment and causing a limestone loss rate of 4.5%. The single-unit capacity of only 1,800 TPH cannot match the crushing capacity of 2,200 TPH, resulting in frequent limestone backlogs during peak periods. The open design causes dust emissions to reach 25mg/m³, far exceeding the 10mg/m³ limit specified in the Integrated Emission Standard of Air Pollutants, leading to constant complaints. Additionally, due to Huanggang's rainy climate, conventional conveyors cannot adapt to a 12-meter lifting height, requiring costly slope platforms prone to rainwater scouring. More critically, core components rely on foreign procurement, with spare parts response exceeding 30 days and annual downtime over 80 hours.

ZOOMRY Heavy Industry, based on on-site survey data (topographic curve distribution, limestone properties, local meteorological records), designed a full-chain solution centered on long-distance curved belt conveyors, combined with wheeled truck unloaders and hopper feeders, forming a closed-loop system perfectly adapted to Huanggang's open-air conditions.

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Core Project Requirements and Objectives

Combining the climatic characteristics of Huanggang City, the factory's production scale and industry standards, the project clarifies requirements around four dimensions: parameter matching — cover the entire 3,200-meter distance, capacity ≥ 2,200 TPH, belt width 1,200mm, adapt to 3 horizontal curves (turning radius ≥ 600m, maximum turning angle ≤ 60°), 12-meter lifting height with sealed dust-proof function; scenario adaptation — withstand 40℃ summer highs, -8℃ winter lows and Huanggang's rainy environment, with core component protection ≥ IP55; compliance — dust emissions ≤ 10mg/m³, comply with CEMA standards and domestic environmental regulations; operation and maintenance — core component service life ≥ 50,000 hours, spare parts response ≤ 7 days via local service outlets, with multilingual training.

Based on the above requirements, the project sets four core objectives:

1. Efficiency breakthrough: Realize 3,200-meter full-distance conveying without transshipment, stable capacity ≥ 2,200 TPH, completely replacing truck transshipment;
2. Environmental compliance: Reduce dust emissions below 8mg/m³, control limestone loss rate within 1%, meeting Huanggang's environmental requirements;
3. Topographic adaptation: Adapt to 3 bends and 12-meter lifting without topographic modification, withstand rainy and large temperature difference climate;
4. Operation and maintenance optimization: Control annual failure rate ≤ 0.6%, reduce downtime through localized O&M, cut maintenance costs by 30%.

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Customized Solution

Based on the 3D topographic survey data of the Huanggang factory and limestone property analysis, ZOOMRY adopts a design concept of "precision selection by function + full-process collaborative matching", organically integrating core conveying equipment with supporting systems.

Core Equipment

To meet the requirements of the 3,200-meter curved route, 2,200 TPH capacity and 12-meter lifting height, ZOOMRY custom-produces one set of long-distance curved belt conveyors, focusing on three dimensions:

• Dual adaptation for curves and lifting: For the 3 horizontal curves (turning radius: 600m, maximum turning angle: 57°), self-aligning Conveyor idlers (133mm diameter, suitable for 1,200mm belt width) are configured, with radial runout ≤ 0.4mm and water intake ≤ 95g in 72-hour immersion test. For the 12-meter lifting height, a gradual slope design (average 0.375%) with ST2500 steel cord Conveyor Belt (tensile strength ≥ 2,500N/mm, 12mm wear-resistant layer) ensures reliable heavy-load lifting.
• Power system adapted for heavy load: "Three-drive at the head" design with 3×220kW variable-frequency motors (total 660kW, IP55), matched with hardened gear reducers (≥96% efficiency). Belt speed set to 3.5m/s, ensuring stable 2,200 TPH feeding through PLC linkage. Drive pulleys made of 40Cr forged material (500mm diameter) with diamond rubber coating, ultrasonic flaw detection, and 50,000+ hour service life.
• Enhancement of open-air durability: Conveyor frame with hot-dip galvanizing (Zn12 grade per GB/T 13912-2002); detachable transparent PC Rain Cover for inspection and weather shielding; hydraulic tensioning device with oil temperature control, stable in -8℃~40℃ temperature difference.

Auxiliary Equipment

To realize seamless limestone flow from transport vehicles to the raw material silo, ZOOMRY configures two types of independently developed supporting equipment:

• ZRLS-TU1400 wheeled truck unloader: Installed in the limestone receiving area, belt width 1,400mm, capacity 200-1,000 TPH, suitable for 40-ton dump trucks. Equipped with 2 hydraulically adjustable ramps (6.7° slope), double-layer rubber sealed skirt, and vibrating feeding device adjusting unloading speed in real time.
• ZR series hopper feeder: Installed between unloader and conveyor, 10m³ standard receiving hopper, 18.5kW variable-frequency motor enabling 1,800-2,200 TPH feeding adjustment. Inner wall paved with 12mm wear-resistant ceramic liners; dust cover and rain edge on top prevent dust scattering and rainwater ingress.

Core Components

All key components are independently produced by ZOOMRY, with performance surpassing national and CEMA standards:

• Idlers and rollers: Mute idlers (133mm) in straight sections with rotational resistance ≤ 2N, noise ≤ 45dB, water intake ≤ 95g, adapting to Huanggang's rainy environment. Direction-changing rollers made of 40Cr seamless steel pipe (400mm), thermal spraying wear-resistant treatment improving wear resistance by 50%, ovality < 1.5mm.
• Cleaning and safety components: PU Belt Cleaners at head and tail (≥98% fitting degree), belt deviation switches (alarm at 5mm deviation), emergency rope break system (0.01s shutdown), and non-powered dust removal chute at discharge end.

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Full-Process Project Implementation

Preliminary Survey

ZOOMRY dispatched a 6-person technical team to Huanggang City, completing three key tasks within 12 days: conducting 3D topographic survey using total stations and UAVs, accurately marking the center positions of 3 curves, turning radii and slope distribution of the 12-meter lifting section, optimizing frame installation height; collecting limestone samples to determine idler spacing (1.2m) and belt tension (18kN); formulating an open-air protection plan referencing 5-year meteorological data (temperature extremes, rainy season distribution).

Production and Manufacturing

All equipment produced in ZOOMRY's Hebei factory under ISO 9001 and ISO 14001 systems: drive rollers pass 24-hour static load test at 1.2× rated load; idlers undergo 1,000-hour no-load test; ST2500 belt completes tensile, wear and bending tests. Factory representatives conducted on-site acceptance; open-air durability tests (high-low temperature cycle, rain test) achieved excellent results.

Installation and Commissioning

A 10-person installation team adopted "modular splicing + phased commissioning": the 3,200-meter conveyor divided into 16 sections (200m each), pre-assembled in factory, requiring only bolt connection and belt vulcanization on-site — installation cycle of only 30 days (industry average: 45 days). Temporary rain shelters protected equipment during rain. Commissioning proceeded in three steps: individual equipment no-load tests, system linkage tests, and 72-hour full-load trial run simulating Huanggang's high-temperature and rainy conditions, optimizing the PLC program to achieve stable 2,250 TPH.

Operation and Maintenance Training

15-day special training for 8 O&M personnel covering daily inspection (idler rotation, hydraulic oil level, rain cover tightness), common fault handling (belt deviation, motor overload), and regular maintenance. Additional courses on "rainy season drainage inspection" and "winter hydraulic system preheating" tailored to Huanggang's climate. Local service outlets ensure spare parts response ≤ 7 days; 24-hour multilingual technical hotline provides timely support.

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Project Results

After operation, the equipment has performed stably in Huanggang's open-air environment, with all indicators exceeding expectations. In efficiency: 3,200-meter full-distance conveying without transshipment achieved stable 2,250 TPH, fully matching the 2,200 TPH crushing capacity; conveying cycle shortened from 5 hours to 1.4 hours, reducing annual downtime by 45 hours; smooth adaptation to 3 bends saved investment and maintenance costs of 2 transshipment stations.

In environmental protection: full-system sealed design reduced dust emissions from 25mg/m³ to 7.2mg/m³, with zero complaints since operation; limestone loss rate reduced from 4.5% to 0.8% — based on 18 million tons annual volume, annual loss reduced by approximately 666,000 tons; rain cover and sealed belt reduced rainy season agglomeration rate from 12% to 1.5%, eliminating additional crushing processes.

In reliability: core components have operated 35,000+ hours without major replacement; annual maintenance frequency reduced from 10 to 3 times, costs down 40%; annual failure rate only 0.4% (target: 0.6%), no major failures from extreme weather. For the second-phase upgrade, only motor power and PLC fine-tuning is needed to reach 2,500 TPH, demonstrating excellent expandability.

The project manager stated: "We were most worried about the 3 bends and Huanggang's rainy weather. ZOOMRY's equipment not only handles curves smoothly but also withstands summer heavy rains and winter low temperatures. Technical engineers provide remote guidance when needed — no production delays at all. For our new limestone processing line, we will definitely choose ZOOMRY again."

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Core Advantages of ZOOMRY

1. Scenario-based customization capability: Targeting Huanggang's topographic and climatic characteristics, ZOOMRY completed full solution customization in only 2.5 months, perfectly adapting to 3 bends and rainy environment — significantly shorter than international brands' 6+ month design cycle.
2. Full-chain equipment synergy: From unloaders, feeders to curved conveyors, all independently developed with seamless parameter matching, avoiding compatibility issues. Core components independently produced, with performance surpassing national and CEMA standards.
3. Localized operation and maintenance services: Domestic service outlets and spare parts warehouses enable ≤7-day response time; 24-hour multilingual hotline resolves issues quickly, completely eliminating dependence on imported spare parts.

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