Project Background

An ironworks in Chengde, Hebei Province specializes in iron ore smelting and processing. Its core raw material is iron ore (particle size: 8-50mm, moisture content: 3%-6%, high hardness, strong abrasiveness, and easy dust generation). Previously, the ironworks had no dedicated long-distance iron ore conveying equipment. Transportation from the mine crushing area to the plant's raw material warehouse relied entirely on heavy trucks, with no fixed conveying lines. As production capacity expanded, the drawbacks of pure truck transportation became increasingly prominent.

The 3,300-meter transportation distance required frequent round trips, with a single trip taking over 40 minutes, and trucks had to detour mountain roads to avoid natural turns, resulting in low actual efficiency. Open-air truck transportation led to dust emissions of 25mg/m³, far exceeding the 10mg/m³ limit specified in the Comprehensive Emission Standard for Air Pollutants, prompting repeated rectification demands from the local environmental protection department. Due to the high hardness of iron ore, the material loss rate during loading and unloading reached 5.3%, with an annual loss exceeding 750,000 tons. The 140-meter mountain elevation difference made it difficult for trucks to climb slopes, with vehicle failures occurring frequently during heavy-load transport and annual downtime exceeding 90 hours.

To completely solve these problems, the ironworks decided to build an exclusive long-distance iron ore conveying line, requiring suppliers to provide full-process new construction services from scheme design to commissioning and O&M. In response to the mountainous terrain of Chengde, the new construction needs, and the characteristics of iron ore, ZOOMRY designed a new construction scheme of "core conveying equipment + supporting pretreatment equipment + independent components", ensuring every link is fully customized without reusing any old equipment.

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Project Overview

Core Requirements

Based on the ironworks building from scratch, the requirements focus on four dimensions:

• Basic parameter requirements: The newly-built conveying line shall cover 3,300 meters, with a belt width of 1,400mm and capacity ≥ 2,000 TPH. It shall adapt to 3 horizontal curves (turning radius of 1,200 meters) and achieve a 140-meter lifting height, with a multi-point drive design for heavy loads in mountainous areas.
• Scenario adaptation requirements: The equipment shall withstand 40℃ summer highs, -12℃ winter lows, and rainy weather. It shall have dust-proof and rain-proof functions to prevent iron ore from caking due to moisture, while adapting to high abrasiveness.
• Full-process service requirements: Due to the lack of existing equipment and O&M experience, ZOOMRY shall be responsible for the entire new construction process — from line planning and equipment production to on-site installation — without modifying or reusing any old equipment.
• Compliance and O&M requirements: Dust emission ≤ 10mg/m³, equipment compliant with CEMA standards and domestic environmental regulations. Core component service life ≥ 50,000 hours. Relying on domestic service outlets, spare parts response ≤ 7 days, with special training for O&M personnel.

Core Objectives

1. New construction compliance: After completion, capacity shall be stably ≥ 2,000 TPH, with no transshipment throughout the entire 3,300-meter process, completely replacing truck transportation.
2. Environmental protection compliance: Dust emission controlled within 8mg/m³, iron ore loss rate reduced to below 1%, meeting local environmental requirements.
3. Operation & maintenance control: Annual equipment failure rate ≤ 0.6%. O&M team able to operate independently after training, spare part response cycle ≤ 7 days.

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Long-Distance Iron Ore Conveying Project Scheme for Chengde, Hebei

Core Equipment

To adapt to the 3 horizontal curves and 140-meter lifting height, ZOOMRY has fully customized one set of long-distance curved belt conveyor, completely produced according to project requirements with no old components:

• Multi-curve technology: "Multi-section curve coordinated tension control technology" is adopted. For the 3 horizontal curves with a 1,200-meter radius, ZOOMRY's independently developed friction self-aligning Conveyor idler sets (159mm diameter, adapted to 1,400mm belt width) are configured, with radial runout ≤ 0.4mm and water inflow ≤ 95g in 72-hour immersion test. For the 140-meter lifting height, a "segmented gradual slope" design (max slope ≤ 15°) is adopted, combined with an ST3150/1400 steel cord Conveyor Belt (tensile strength ≥ 3,150N/mm, 18mm wear-resistant layer), with a 130mm overlap sealing structure further blocking dust.
• Multi-point drive: A "distributed multi-point drive" with 4×63kW variable-frequency motors (total 252kW, IP55) is adopted. Motors are evenly distributed across the 3,300-meter line, with enhanced power in the lifting section to avoid excessive belt tension from single-point drive. Belt speed set to 3.2m/s, with PLC-linked feeding ensuring stable 2,000 TPH. Drive pulleys made of 40Cr forged steel (500mm diameter) with diamond rubber coating (friction coefficient ≥ 0.45), ultrasonic flaw detection, and 50,000+ hour service life.
• Strong open-air durability: Conveyor frame with hot-dip galvanizing (Zn12 grade per GB/T 13912-2002), increasing rain erosion resistance by 60%. Detachable transparent PC Rain Cover (18° inclination) for inspection and weather shielding. Hydraulic tensioning device with oil temperature control, stable in -12℃~40℃ temperature differences, automatically compensating for belt thermal expansion and contraction.

Supporting Pretreatment Equipment

To realize seamless connection from trucks to conveyors, two types of supporting equipment are newly built:

• ZRLS-TU1400 Wheeled Truck Unloader: Installed in the newly-built receiving area, belt width 1,400mm, capacity 200-1,000 TPH, adapting to 50-ton dump trucks. Equipped with 2 hydraulically adjustable ramps (6.7° slope), double-layer rubber sealing skirt, and high-frequency vibrating feeding device adjusting unloading speed according to conveyor status.
• ZR Series Hopper Feeder: Installed on the new transfer platform, 10m³ standard receiving hopper, 18.5kW variable-frequency motor adjusting feeding amount (1,800-2,000 TPH). Inner wall with 15mm wear-resistant ceramic liners; dust cover and rain edge on top prevent dust dispersion and rainwater entry.

Core Components

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

• Idlers and drums: High-wear-resistant idlers in straight and lifting sections, rotational resistance ≤ 2N, noise ≤ 45dB. Direction-changing drums made of 40Cr seamless steel pipe, surface thermally sprayed with tungsten carbide, increasing wear resistance by 80%, ovality < 1.5mm.
• Cleaning and safety components: PU Belt Cleaners at head and tail (≥98% fitting degree), belt deviation switches (alarm at 5mm), emergency rope break system (0.01s shutdown), and overload protection devices, complying with international safety standards.

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Project Implementation

Preliminary Survey and New Construction Planning

ZOOMRY dispatched a 6-person technical team to Chengde, completing the basic planning within 15 days: constructing a 3D topographic model of the 3,300-meter route via UAV aerial photography and total station surveying, accurately marking curve centers, turning radii, and the 140-meter lifting section slope; determining installation height and foundation positions of the new conveyor frame to avoid rainy season waterlogged areas; collecting iron ore samples to confirm idler spacing (1.3m) and belt tension (25kN); formulating an open-air protection plan based on meteorological data.

Production and Manufacturing

All equipment and components were newly produced at ZOOMRY's Hebei factory under ISO 9001 and ISO 14001 systems: drive drums passed 24-hour static load test at 1.2× rated load; idlers underwent 1,200-hour no-load test run; ST3150/1400 belt completed tension and wear tests. The ironworks sent representatives for factory acceptance; all new equipment met technical requirements with excellent open-air durability test results.

On-Site Installation

A 10-person installation team adopted "modular splicing" mode: the 3,300-meter conveyor divided into 17 sections (190-200m each), pre-assembled in factory, requiring only bolt connection and belt vulcanization on-site — completed in 35 days (industry average: 50 days). Commissioning proceeded in three steps: individual equipment no-load test, system linkage test, and 72-hour full-load trial run, with PLC optimization achieving stable 2,050 TPH.

Operation & Maintenance Training

An 18-day special training was provided for 8 O&M personnel, covering daily inspection of new equipment (idler rotation, hydraulic oil level, rain cover sealing) and common fault handling (belt deviation, motor overload). Additional training on "rainy season drainage inspection" and "winter hydraulic preheating" addressed Chengde's mountainous characteristics. Bilingual operation manuals and fault case videos were provided.

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Project Results

After completion, the iron ore conveying line achieved a breakthrough from scratch, with all indicators exceeding expectations. In efficiency: the newly-built 3,300-meter line realizes no transfer throughout, with actual capacity stably maintained at 2,050 TPH. Compared with truck transportation, the conveying cycle was shortened from 8 hours to 1.6 hours, reducing annual downtime by approximately 50 hours. The line accurately adapts to the 3 natural turns in Chengde's mountainous area without additional detours or transfer stations, reducing the iron ore loss rate during loading and unloading from 5.3% to 0.8% — based on annual conveying volume, annual iron ore loss reduced by 795,000 tons.

In environmental protection: the full-system sealed structure controls dust emission at 7.5mg/m³, fully complying with local requirements. The ironworks has received no further environmental complaints. The rainproof design and sealed belt reduced rainy season iron ore caking rate from 10% to 1.5%, eliminating additional crushing investment and energy consumption.

In O&M cost optimization: core components (idlers, drums) have operated 40,000+ hours without major replacement. Annual maintenance frequency decreased from 12 times to 3 times, costs reduced by 40%. Spare parts response controlled within 7 days via ZOOMRY's service outlets, reducing annual downtime from 90 hours to 22 hours.

The project manager stated: "Before building this conveyor line from scratch, we were most worried about mountain turns and the 140-meter lifting height. ZOOMRY not only completed the 3-kilometer line quickly, but the equipment stably withstands severe winter and rainy seasons. We no longer rely on trucks — efficiency improved and environmental standards are met. For future expansion, we will definitely prioritize ZOOMRY."

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Core Advantages of ZOOMRY

1. Project Customization Capability: In response to complex mountainous terrain and new construction needs, relying on curve tension control technology and segmented drive design, the full scheme was customized in 2.5 months — 50% shorter than the industry average — accurately adapting to newly-built line parameters and scenario requirements.
2. Full-Process Services: Full-process EPC services from survey planning, equipment production to installation and commissioning. All equipment and components are newly produced without reusing any old components, ensuring reliability and consistency of the new line.
3. Operation & Maintenance Guarantee: Relying on domestic service outlets and spare part warehouses, common spare parts response within 7 days. 24-hour technical hotline quickly resolves on-site problems, completely eliminating dependence on imported spare parts.

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