ZOOMRY
Chengde Iron Ore – 3,300m Long-Distance Curved belt conveyor
Project Location: Chengde, Hebei Province, China
Year Completed: 2018
Material: Iron ore (abrasive, high density)
Capacity: 2,000 tons per hour
Conveyor Length: 3,300 meters (single flight)
Belt Width: 1,400 mm
Horizontal Curves: 3 curves, each with radius 1,200 m
Lifting Height: 140 meters (undulating mountainous terrain)
Drive System: 4 × 63 kW motors (total 252 kW)
Belt Type: ST3150/1400 steel cord Conveyor Belt (tensile strength ≥ 3,150 N/mm)
Project Background
The iron ore mine in Chengde, Hebei Province, is located in a mountainous area with undulating terrain. The client previously relied on truck transport from the pit to the processing plant, which faced severe challenges: the 3.3 km route with steep slopes and sharp turns caused high fuel consumption, dust pollution (≈ 25 mg/m³), and frequent accidents. To increase capacity to 2,000 t/h and meet stricter environmental regulations, the client decided to replace trucks with a long-distance curved belt conveyor that could navigate the mountainous terrain without intermediate transfer stations.
Project Requirements
The client required a single-flight curved belt conveyor system with the following specifications:
- Total length: 3,300 meters (no transfer stations)
- Capacity: ≥ 2,000 t/h (continuous)
- Belt width: 1,400 mm
- Horizontal curves: 3 curves, each with a radius of 1,200 m
- Elevation change: 140 m net lift (with multiple undulations)
- Material: Iron ore (0–200 mm, highly abrasive, density 2.5 t/m³)
- Environmental standard: Dust emission ≤ 10 mg/m³
- Durability: Heavy-duty components to withstand abrasion
ZOOMRY's Customized Solution
Core Equipment – Long-Distance Curved Belt Conveyor
ZOOMRY designed and supplied a single-flight curved belt conveyor (3,300 m) capable of negotiating three horizontal curves (radius 1,200 m each) and a 140 m elevation change. Key features:
- Belt: ST3150/1400 steel cord belt (tensile strength ≥ 3,150 N/mm) to handle heavy load and long distance
- Belt speed: 2.5 m/s (optimized for iron ore to reduce dust and wear)
- Drive system: 4 × 63 kW motors (total 252 kW) with soft start, distributed along the route for balanced tension
- Curve technology: Special friction self-aligning idlers and gradual tension control to prevent belt deviation on each 1,200 m radius curve
- 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 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 Mountainous Terrain
The 3,300 m route includes three horizontal curves (each radius 1,200 m) and a 140 m net lift with multiple undulations. ZOOMRY’s curved belt conveyor technology eliminated the need for three intermediate transfer stations, saving significant civil works and reducing material degradation.
Implementation Process
Design & Manufacturing
ZOOMRY’s engineering team conducted a UAV topographic survey and simulated the curve dynamics using finite element analysis. The conveyor was manufactured at ZOOMRY’s ISO 9001-certified factory, with all components pre‑assembled and tested before shipment.
Installation & Commissioning
A 12-person installation team completed the assembly in 80 days using a modular approach. The belt splicing was done by vulcanization. After a 72‑hour load test, the conveyor achieved a stable capacity of 2,050 t/h, exceeding the requirement.
Training & After-Sales
ZOOMRY provided 10 days of on‑site training for 15 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 2,050 t/h, a 30% improvement over the previous truck transport, eliminating 50 truck trips per day.
- Environmental compliance: Dust emissions decreased from 25 mg/m³ to 7.5 mg/m³, well below the national standard.
- Reliability: After 5+ years of operation, the system availability remains above 99%, with no major component failure.
- Cost savings: Energy consumption per ton reduced by 40% compared to trucks, and annual maintenance costs cut by 50%.
Client Testimonial
“The curved belt conveyor from ZOOMRY has transformed our mine’s logistics. Navigating three horizontal curves over 3.3 km without a single transfer station is a game-changer. The dust control is excellent, and the system has run reliably for over 5 years with minimal maintenance.” – Operations Manager, Chengde Iron Ore Mine
Why Choose ZOOMRY for Curved & Long-Distance Conveyors
- Proven curve technology: Successfully delivered conveyors with multiple horizontal curves and radii as small as 300 m.
- Heavy‑duty design: ST3150 steel cord belts and reinforced idlers for high‑abrasion iron ore.
- Full EPC service: Survey, design, manufacturing, installation, training, and after‑sales support.
- Local spare parts: Rapid response (≤ 7 days) for critical components.
