ZOOMRY
Yunnan Yuntian Chemical Group, as a leading domestic phosphate chemical enterprise, has recently initiated the expansion project for its phosphate powder refining production line, requiring the construction of a dedicated bulk material conveyor line from the phosphate crushing station to the production workshop. The core material is phosphate powder (moisture content 12%-15%, particle size 0.1-5 mm). At that time, the traditional trough belt conveyor system adopted by the enterprise had three core pain points, directly constraining capacity release and environmental compliance:
First, severe dust pollution. The open design of the traditional trough belt conveyor during phosphate powder transportation resulted in dust emissions as high as 30 mg/m³, far exceeding the 15 mg/m³ limit in the national "Comprehensive Standard for Air Pollutant Emissions" (GB16297-1996), leading to frequent complaints from surrounding areas of the plant. Moreover, phosphate powder easily forms clumps when exposed to rain, causing soil pollution upon dispersion, which contradicted Yunnan's development requirements emphasizing ecological protection. Second, poor terrain adaptability. The conveyor route spanned 719 m, passing through two gentle slopes (maximum gradient 8°) and one river bend (turning angle 95°). Ordinary belt conveyors required three transfer stations to achieve turning and climbing, not only increasing equipment investment costs (cost per transfer station exceeding 500,000 yuan) but also causing conveyor efficiency losses (approximately 15% loss at transfer points). Third, insufficient capacity matching. The new production line required a stable phosphate powder conveyor capacity of 350 t/h, but the traditional belt conveyor, affected by transfer links, only achieved an actual efficiency of 280 t/h, failing to meet production load demands and causing frequent "material-waiting shutdowns" on the production line.
To address Yunnan Yuntian Chemical's demand for a "sealed, environmentally friendly, terrain-adaptable, capacity-compliant" belt conveyor system solution, ZOOMRY assembled a specialized technical team. Combining site survey data from the enterprise's plant (terrain, existing facility layout, phosphate powder characteristics) with its own tubular belt conveyor technology standards, after two rounds of scheme iteration, the final determination was an integrated solution of "core tubular belt conveyor + complementary feeding/unloading equipment + proprietary components," fully leveraging the belt conveyor's advantages in "sealed transportation, curve adaptation, long-distance without transfer" to precisely match project parameters and the scenario needs of Yunnan's chemical industry.
Yunnan Yuntian Chemical Belt Conveyor System Requirements
Core Requirements
Yunnan Yuntian Chemical's requirements for the belt conveyor system focus on the three dimensions of "parameter matching, scenario compatibility, compliance and reliability": In terms of parameters, it explicitly requires a total conveyor capacity of the belt conveyor system ≥350 t/h, with the core equipment adopting a tubular belt conveyor (a type of belt conveyor), tube diameter 350 mm (adapted to phosphate powder particle size), belt length 719 m, needing to achieve 95° bend conveyance without transfer; in terms of scenarios, the equipment must adapt to Yunnan's mountainous 8° gentle slopes and rainy season (annual precipitation over 1000 mm) high-humidity environment, and installation must avoid existing pipelines in the plant; in terms of compliance, dust emissions ≤10 mg/m³, the equipment must pass ISO 9001 quality certification and local environmental acceptance, while providing Chinese operation training and after-sales support.
Core Objectives
Based on customer needs and the production and environmental requirements of Yunnan's chemical industry, the project sets four core objectives: first, environmental compliance, controlling belt conveyor system dust emissions within 8 mg/m³; second, efficiency matching, achieving 350 t/h continuous stable conveyance without transfer losses to meet full-load production line demands; third, terrain adaptation, ensuring stable operation of the equipment on 8° gentle slopes and 95° bends without material slippage or deviation; fourth, long-term reliability, with core components of the belt conveyor system (rollers, drums) having a service life ≥50,000 hours and annual failure rate ≤1%.
ZOOMRY Belt Conveyor System Solution
Core Equipment
For the project parameters, ZOOMRY custom-designed the tubular belt conveyor with multiple features:
- Sealed and environmental design: Adopting a "hexagonal roller group structure (6 rollers arranged in a regular hexagon)" to fold the belt into a 350 mm diameter tube (belt overlap ≥120 mm), achieving fully sealed phosphate powder conveyance, combined with a non-powered dust collection chute at the discharge end, dust emissions are ultimately controlled at 7.2 mg/m³; aligning with the core advantage of the tubular belt conveyor for "sealed material handling and acute bend adaptation," its maximum turning angle reaches 110°, easily meeting the project's 95° bend requirement without transfer stations.
- Terrain and capacity adaptation: The belt conveyor drive unit selects two SEW gear motors (total power 75 kW), paired with anti-slip belt (friction coefficient ≥0.35), ensuring stable climbing under heavy load on 8° gentle slopes without material slippage risk; belt speed set at 2.5 m/s, belt width 1200 mm, through PLC-linked feeding regulation, achieving 350 t/h continuous conveyance, 719 m belt length without transfer, completely eliminating transfer losses of traditional belt conveyors.
- Quality assurance, the belt conveyor core components use 40Cr forged drums (diameter 219 mm), processed by CNC four-roller rolling (ellipticity <1.5 mm), and passing ultrasonic flaw detection, meeting the belt conveyor "above-national-standard quality" requirements, ensuring long-term reliable operation.
Complementary Equipment
To build a complete conveyor chain, the system complements two types of core auxiliary equipment, all independently developed by ZOOMRY and compliant with technical specifications: first, the ZR120D hopper feeder, installed at the belt conveyor feed end, hopper capacity 5 m³, using a variable frequency motor (power 15 kW), which can adjust feeding volume in real-time based on belt conveyor operation status, ensuring stable 350 t/h feeding and avoiding material accumulation blockages (phosphate powder transportation in Yunnan mostly uses 25-ton dump trucks, the feeder needs to adapt to intermittent unloading rhythm); the hopper inner wall is lined with wear-resistant plates (thickness 12 mm) to cope with phosphate powder abrasiveness, extending equipment life. Second, the ZRLS-TU1400 truck unloader, for raw material reception, equipped with a hydraulically adjustable ramp (slope 6.7°), adapted to Yuntianhua's common 25-ton dump trucks, unloading efficiency up to 400 t/h, meeting raw material supply needs for full-load belt conveyor operation; the ramp base is fitted with rubber skirts to reduce dust dispersion during unloading, forming an environmental closed loop with the belt conveyor sealing.
Core Components
All system components are independently produced by ZOOMRY, with performance superior to national standards: rollers select silent rollers (diameter 133 mm), radial runout ≤0.4 mm (national standard ≤0.5 mm), 72-hour immersion test water ingress ≤95 g (national standard ≤150 g), operating noise ≤42 dB, reducing plant noise pollution; roller service life ≥50,000 hours, low replacement frequency in later maintenance, reducing spare parts procurement and replacement costs. Cleaning scrapers use PU material, fitting degree with belt ≥95%, effectively removing residual phosphate powder from belt surface, avoiding belt deviation due to material adhesion; the tail scraper is equipped with automatic compensation device, automatically adjusting spacing after wear, without frequent manual maintenance (Yuntianhua plant areas are mostly suburban, with limited maintenance personnel). Conveyor Belt uses PVC whole-core flame-retardant conveyor belt (thickness 15 mm), tensile strength ≥18 MPa, complying with chemical industry flame-retardant safety standards, with temperature resistance range -5°C~35°C, adapting to Yunnan's climate, ensuring year-round stable operation.
Project Implementation and Assurance
ZOOMRY, leveraging experience and qualifications in belt conveyor field, assures project landing throughout from production to after-sales, fully demonstrating professionalism and credibility:
In production and quality control, all belt conveyor system equipment is produced at ZOOMRY's Hebei factory, fully incorporated into ISO 9001 quality management system and ISO 14001 environmental management system, core components (drums, rollers) must pass material testing in chemical laboratory and mechanical performance testing before leaving the factory; Yunnan Yuntianhua sent representatives for factory acceptance, all parameters meeting contract requirements.
In on-site installation and commissioning, ZOOMRY dispatched an 8-person engineer team to Yuntianhua plant, using "modular splicing" mode for belt conveyor installation: dividing the 719 m belt conveyor into 12 pre-assembled units, on-site only requiring bolt connections and belt vulcanization, installation cycle only 28 days (industry average 45 days); during commissioning, 72-hour continuous full-load trial operation was conducted, simulating enterprise production conditions, optimizing belt conveyor PLC program parameters, ensuring conveyor efficiency stable at 355 t/h, exceeding demand; the installation team also resolved the "bend roller spacing deviation" issue discovered during installation, adjusting roller positions on-site to ensure no belt deviation.
In training and after-sales, ZOOMRY provided 10-day specialized training for 5 maintenance personnel of Yuntianhua, covering belt conveyor daily inspections (roller rotation status, belt tension), common fault handling (motor overload, belt deviation) and spare parts replacement, providing Chinese operation manual; simultaneously offering "5-year warranty + lifetime technical support", establishing spare parts warehouse in Yunnan, common components (rollers, scrapers) response time ≤48 hours, complying with the "spare parts supply and technical guidance" service promise in the brochure.
Project Achievements
The belt conveyor system has operated stably since commissioning, with all indicators exceeding expectations, not only solving the core pain points of bulk material transportation for Yunnan Yuntianhua but also providing a benchmark scheme for phosphate powder transportation in Yunnan's chemical industry, creating significant economic and environmental value:
In environmental compliance, the belt conveyor full-sealed conveyance reduced plant dust emissions from 30 mg/m³ to 7.2 mg/m³, far exceeding national standards, Yuntianhua no longer received environmental complaints, and avoided environmental penalty risks (Yunnan has strong penalties for chemical enterprises, single penalty amount can reach millions of yuan level); phosphate powder loss rate from 6% to 0.8%, based on annual conveyance of 2.5 million tons, annual loss reduction of 20,500 tons, increasing revenue by over 1.64 million yuan.
In efficiency and capacity, the belt conveyor achieves 719 m continuous conveyance without transfer, actual efficiency stable at 355 t/h, meeting production line full-load demand, compared to traditional belt conveyor + transfer station scheme, conveyance cycle shortened from 4 hours to 2.1 hours, annual reduction in material-waiting shutdown time about 30 hours, indirectly creating capacity value over 5 million yuan (calculated at 200 yuan profit per ton of fertilizer); meanwhile, no-transfer design reduces 3 transfer station investments and labor costs, project initial investment reduced by 22%.
In reliability and maintenance, the belt conveyor system has run for 12 months with failure rate only 0.6% (far below 1% target), core components no large-scale replacement, only regular belt and scraper replacement, maintenance cost controlled within 80,000 yuan annually; at the end of 2024, during Yuntianhua production line expansion, the belt conveyor through simple drive unit upgrade (power increased to 90 kW) can meet 400 t/h new capacity demand, demonstrating system scalability, aligning with the "equipment upgrade service" concept in the brochure.
Why Choose ZOOMRY Belt Conveyor System
Compared to same-industry brands, ZOOMRY belt conveyor system's core advantages are reflected in three aspects: first, stronger customization capability, can optimize belt conveyor parameters for Yunnan terrain and Yuntianhua phosphate powder characteristics (such as bend design, sealing upgrade), while international brands mostly provide standardized products with long adaptation cycles; second, higher cost-performance, independent production of core components (rollers, drums) reduces costs, belt conveyor system overall investment 25% lower than imported brands, and quality complies with ISO and CEMA standards; third, faster service response, localized spare parts warehouse and Chinese training solve maintenance pain points, avoiding international brands' "long spare parts cycle, language barriers" issues.
The success of the Yunnan Yuntianhua belt conveyor system project validates ZOOMRY's technical strength and EPC service capability in the belt conveyor field. In the future, ZOOMRY will continue to focus on chemical and mining sectors, with the concept of "creating conveyor masterpieces, building a century-old foundation", providing more customized belt conveyor solutions for enterprises, practicing the brand promise of "We Move The World!".
