ZOOMRY
Hebei Luanping Iron Mine – 36 Sets belt conveyor System
Project Location: Luanping, Hebei, China
Year Completed: 2014
Equipment Quantity: 36 sets of belt conveyors
Capacity range: 600 – 3,200 tons per hour
Belt width range: 800 mm – 2,200 mm
Project Background
Hebei Luanping Iron Mine is a large-scale iron ore mining and processing complex. With annual output increasing to meet regional steel mill demand, the original truck-based material transport system became a bottleneck. The 3.2 km route from the primary crusher to the processing plant suffered from low efficiency (only 800 t/h), high dust emissions (≈ 22 mg/m³), and frequent road maintenance. To achieve a cleaner, more efficient, and scalable operation, the mine decided to replace trucks with a centralized belt conveyor system.
Project Requirements
The client required a complete belt conveyor handling system covering the entire process from primary crushing to stockyard, with the following specifications:
- Total conveyors: 36 sets (including main trunk, branch, and transfer lines)
- Capacity: Wide range from 600 t/h (small feeders) to 3,200 t/h (main trunk)
- Belt widths: 800 mm, 1,200 mm, 1,600 mm, and 2,200 mm (customized for different material flows)
- Material: Iron ore (particle size 0–300 mm, high abrasiveness, density 2.5 t/m³)
- Conveying length: Over 3.2 km for the main line, with multiple horizontal curves and elevation changes
- Environmental compliance: Dust emission ≤ 10 mg/m³
- Durability: Heavy-duty components to withstand iron ore impact and abrasion
ZOOMRY's Customized Solution
Core Equipment – 36 Sets of Belt Conveyors
ZOOMRY designed, manufactured, and installed a full materials handling system comprising 36 belt conveyors. Key features:
- Belt widths: 800 mm (for low-capacity feeders), 1,200/1,600 mm (for branch lines), and 2,200 mm (for main trunk line)
- Capacity: The main trunk conveyor (Belt width 2,200 mm, belt speed 4.0 m/s) achieves a stable 3,200 t/h, fully matching the mine’s crushing output
- Drive system: Multi-point drives with 4 × 560 kW motors for the main line, ensuring smooth start under heavy load
- Idler sets: ZOOMRY's heavy-duty idlers (diameter 159 mm for 1,200–1,600 mm belts, 194 mm for 2,200 mm belt) with rotational resistance ≤ 2.5 N and labyrinth seals for dust-proof performance
- impact beds: Installed at all feed points to absorb impact of falling iron ore, reducing belt damage
- Belt Cleaners: Dual tungsten-tipped scrapers at head and tail to remove residual ore (cleaning efficiency ≥ 96%)
Dust Control System
All conveyors were fully enclosed with steel covers, and dust collectors were installed at transfer points. The sealed design reduced dust emissions from 22 mg/m³ to below 8 mg/m³, meeting local environmental standards and eliminating complaints.
Adaptation to Mine Terrain
The 3.2 km main line includes two horizontal curves (radii 800 m and 1,000 m) and a 12° uphill section. ZOOMRY applied curved belt conveyor technology with friction self-aligning idlers to prevent belt deviation, eliminating the need for intermediate transfer stations and reducing civil works.
Implementation Process
Design & Manufacturing
ZOOMRY’s team conducted a detailed topographic survey and material testing. All 36 conveyors were manufactured at ZOOMRY’s ISO 9001-certified factory. Key components (drums, idlers, belts) were pre-assembled and factory-tested before shipment.
Installation & Commissioning
A 20-person installation team completed on‑site assembly in 90 days using a modular approach. The system was commissioned in stages, and a 72‑hour full‑load test verified stable operation at 3,200 t/h on the main trunk line.
Training & After‑Sales
ZOOMRY provided 15 days of on‑site training for 25 mine maintenance personnel, covering daily inspection, belt splicing, and emergency procedures. A local spare parts warehouse ensures critical components (idlers, scrapers, belts) are available within 7 days.
Project Outcomes
- Throughput increase: The main line now handles 3,200 t/h, a 300% improvement over truck transport, eliminating truck haulage and reducing labor costs by 60%.
- Environmental compliance: Dust emissions decreased from 22 mg/m³ to 7.5 mg/m³, well below the national standard.
- Reliability: After 10 years of operation, the system availability remains above 99%, with idlers and drums still original (life > 50,000 hours).
- Cost savings: Energy consumption per ton reduced by 35% compared to trucks, and annual maintenance costs cut by 45%.r
Client Testimonial
“The 36 conveyors from ZOOMRY have transformed our mine operation. The system runs 24/7 with minimal downtime, and the ability to handle both small feeders and a 3,200 t/h main trunk line in one integrated solution is outstanding. Their local spare parts support means we never wait long for critical components.” – Mine Operations Director, Hebei Luanping Iron Mine
Why Choose ZOOMRY for Mining Conveyor Systems
- Heavy‑duty design: Conveyors tailored to high‑abrasion ores, with reinforced idlers, thick rubber belts, and wear‑resistant liners.
- Wide capacity range: From 600 t/h up to 6,000 t/h, covering all mine material flows.
- Curved & steep‑angle capability: Proven technology to navigate complex terrain without transfer stations.
- Full lifecycle service: Engineering, installation, training, and rapid spare parts support.
