Project Background

Wuxue Southeast Mining operates a large-scale sand and aggregate production base in Wuxue City, Hubei Province, Central China. The mining area is located in a complex terrain zone characterized by rolling hills, deep gullies, and existing road networks. To connect the primary crushing station to the processing plant, a long-distance overland conveying system was required — one capable of traversing 8.6 kilometers of challenging topography while maintaining high-capacity throughput.

The project demanded a single-flight curved belt conveyor system spanning 8,617 meters with 9 horizontal curves — the sharpest reaching 36°. This level of multi-curve complexity is among the most demanding in the industry. Conventional straight conveyors would have required multiple transfer towers, significantly increasing civil costs, dust emissions, and material degradation. Furthermore, the client sought not just equipment supply but a comprehensive EPC + 8-year custody operation and maintenance (EPC+M+O) contract, entrusting ZOOMRY with full lifecycle responsibility from design and construction through daily operations and preventive maintenance.

ZOOMRY was selected based on its proven track record in long-distance curved conveying systems and its ability to deliver turnkey solutions with integrated long-term O&M services. The project has since become a benchmark for large-scale aggregate conveying in China.

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Project Requirements

The Wuxue Southeast Mining project imposed exceptionally demanding technical and operational requirements, reflecting both the terrain complexity and the client's commitment to long-term operational excellence:

1. Capacity and Specifications: Conveying capacity of 2,500 t/h on a 1,200mm wide belt, handling abrasive sand and aggregate with particle sizes of 0–31.5mm, over a total length of 8,617 meters in a single flight.
2. Multi-Curve Navigation: The route incorporates 9 horizontal curves with a maximum turning angle of 36°, requiring specialized idler arrangements, anti-deviation systems, and dynamic belt tension control to ensure stable operation across all curve segments.
3. Terrain Adaptation: The conveyor must cross hills, gullies, and existing roads with minimal civil works, utilizing curved sections to follow natural terrain contours and eliminate the need for multiple transfer stations.
4. Dust and Environmental Control: Dust emissions must be maintained below 8 mg/m³ along the entire route, with fully enclosed conveyor covers and dust suppression systems at transfer and discharge points.
5. EPC+M+O Lifecycle Model: The contract encompasses full turnkey delivery (Engineering, Procurement, Construction) plus 8 years of custody operation and maintenance, including daily operation, wear parts replacement, performance optimization, and preventive maintenance.
6. Intelligent Monitoring: Real-time condition monitoring system covering belt rip detection, pulley bearing temperature and vibration, idler rotation status, and centralized SCADA for predictive maintenance and remote diagnostics.

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ZOOMRY's Customized Solution

To meet the project's demanding requirements, ZOOMRY deployed a comprehensive technical solution integrating advanced curved conveyor design, specialized components for abrasive materials, and intelligent control systems — all wrapped within an EPC+M+O delivery model.

Optimized Spatial Curve Design

The 8,617-meter route incorporates 9 horizontal curves with a maximum angle of 36° — a configuration requiring precise dynamic analysis. ZOOMRY's engineering team employed finite element method (FEM) dynamic simulation to model belt behavior across every curve segment, determining optimal forced guiding idler configurations, transition geometry, and belt tension distribution. Self-aligning idler sets were strategically positioned at each curve entry and exit, with radial runout ≤ 0.4mm to ensure smooth belt tracking even under varying load conditions.

The belt selected was a high-abrasion-resistant steel cord Conveyor Belt with tensile strength exceeding ST3150, specifically engineered for the abrasive sand and aggregate material. A 12mm-thick wear-resistant top cover extends service life under continuous 2,500 t/h operation.

Anti-Deviation and Spillage Control

With 9 curve segments, preventing belt deviation was paramount. ZOOMRY equipped the system with special five-roll troughing idler sets in curve sections, combined with centralizing guide devices and an automatic belt tracking system. Conveyor guide rollers with IP66 sealing provide continuous alignment correction, while real-time deviation sensors trigger automatic adjustments to maintain belt position within ±5mm tolerance. The entire conveyor route is enclosed with Rain Covers to prevent dust dispersion and protect material from wind and rain.

Long-Distance Drive Configuration

To manage the 8,617-meter length efficiently, ZOOMRY designed a multi-drive distributed power system with intermediate drive stations positioned at optimal intervals. Each station employs soft-start couplings and power balancing control to reduce peak belt tension and lower overall energy consumption. High-efficiency drive pulleys made of 40Cr forged steel (diameter 500mm) with diamond-pattern rubber lagging (friction coefficient ≥ 0.4) ensure reliable power transmission. The distributed configuration reduces maximum belt tension by approximately 25% compared to a single head-drive design, extending belt service life.

Real-Time Condition Monitoring

The entire system is equipped with a comprehensive intelligent monitoring platform:

• Belt Rip Detection: Inductive loop sensors embedded along the conveyor length detect longitudinal belt tearing in real time, triggering immediate shutdown within 0.2 seconds to prevent catastrophic damage.
• Pulley and Idler Monitoring: Temperature sensors and vibration accelerometers on all drive and bend pulleys, plus wireless idler rotation monitoring at critical curve sections, feeding data to the centralized SCADA system.
• Belt arrestor safety system: Mechanical + hydraulic dual-trigger technology with 0.2-0.3s response time, full-belt bidirectional capture, providing graded braking force for the steep incline sections along the route.
• Predictive Maintenance: Machine learning algorithms analyze historical data trends to predict component wear, enabling planned maintenance interventions and minimizing unplanned downtime.

EPC + 8-Year Custody Operation & Maintenance

This project represents ZOOMRY's most comprehensive service model: a full EPC+M+O contract encompassing every phase of the asset lifecycle:

• Engineering & Design: Complete 3D route survey using UAV and total station, FEM dynamic conveyor analysis, civil and structural design for all terrain crossings.
• Procurement & Manufacturing: All core equipment and components produced in ZOOMRY's ISO 9001-certified factory, including idlers, pulleys, belts, drive systems, and steel structures.
• Construction & Installation: Modular assembly approach dividing the 8,617m route into manageable sections, with on-site bolt connection and belt vulcanization — completed ahead of schedule.
• 8-Year O&M: A dedicated on-site team of 15+ operations and maintenance professionals manages daily operations, preventive maintenance, wear parts inventory, and performance optimization, ensuring the conveyor consistently meets or exceeds the 2,500 t/h target.

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Project Results

Since commissioning, the Wuxue Southeast Mining conveyor system has operated continuously with exceptional performance, validating ZOOMRY's design and O&M capabilities:

• Stable High-Capacity Throughput: The system consistently delivers 2,500 t/h, eliminating the bottleneck between the crushing station and processing plant. Over 15 million tons of sand and aggregate are conveyed annually, with an operational availability rate exceeding 99%.
• Seamless Multi-Curve Operation: All 9 horizontal curves — including the 36° maximum angle segment — operate without belt deviation incidents. The anti-deviation system and automatic tracking ensure stable belt positioning across varying load and weather conditions.
• Environmental Compliance: Dust emissions are maintained at 7.8 mg/m³ (well below the 8 mg/m³ target), with fully enclosed covers preventing material spillage and protecting the surrounding environment from dust pollution.
• Reduced Total Cost of Ownership: The EPC+M+O model has reduced the client's total cost per ton conveyed by over 30% compared to traditional truck haulage, with the added benefit of predictable maintenance expenditure and zero unplanned capital replacement costs over the 8-year O&M period.
• Benchmark Status: This project is now recognized as one of the longest single-flight curved belt conveyor systems with integrated O&M in China, serving as a reference for large-scale aggregate and mining conveying projects nationwide.

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Core Advantages of ZOOMRY

1. Advanced Curve Conveyor Engineering: ZOOMRY's FEM dynamic analysis and specialized idler design for multi-curve, large-angle routes ensure reliable operation even under the most demanding terrain conditions — a capability proven by the 9-curve, 36° maximum angle success at Wuxue Southeast Mining.
2. Full Lifecycle EPC+M+O Delivery: From initial survey and design through construction, commissioning, and 8+ years of daily operation and maintenance, ZOOMRY offers the industry's most comprehensive service model, ensuring performance guarantees and predictable total cost of ownership.
3. Self-Manufactured Core Components: All critical components — idlers, pulleys, belts, drive systems — are produced in-house under ISO 9001 quality management, ensuring full traceability, rapid spare parts supply, and consistent quality across the entire conveyor system.

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