Project Background

In the bulk material processing sector in Vietnam, a company has been deeply engaged in the transshipment and processing of coal and ore (including iron concentrate, limestone, etc.) for many years. With the continuous expansion of its production capacity, it urgently needs to independently build an exclusive long-distance bulk material conveying line to connect the raw material receiving area and the processing plant. Prior to this, the company relied entirely on third-party trucking services and had never established an independently controllable professional conveying system.

For the 5,537-meter transportation route, trucks needed to go through 4 temporary loading and unloading points for transshipment, increasing comprehensive investment by approximately 35% and leading to a coal loss rate as high as 6% and an ore loss rate of 4%. The route naturally contains 2 right-angle (90°) bends and 1 gentle slope (15°), requiring additional terrain modification costs. Dust emission from open-top transportation reached 28mg/m³, far exceeding the 10mg/m³ limit in EU IED and China's GB16297 standards. The actual transportation capacity of 1,500 TPH was seriously out of line with the dynamic production demand of 1,800-4,200 TPH. If imported equipment were selected, the spare parts supply cycle would be as long as 45 days with annual downtime exceeding 100 hours.

Leveraging its years of experience in R&D of bulk material conveying equipment, integrated capabilities of full product lines, and international certifications, ZOOMRY successfully undertook this project. Through the system design of "multiple terrain-adapted belt conveyors + mobile stacking equipment at process nodes + core components", ZOOMRY built a closed-loop conveying system covering "receiving - conveying - stacking".

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Core Project Requirements

Combining the company's actual working conditions and global industry standards, the project established a demand system around four dimensions: parameter matching — cover the entire 5,537-meter route, main line capacity ≥ 4,200 TPH, branch line ≥ 1,800 TPH, belt widths adapted to three specifications (1,200mm, 1,400mm, 1,600mm), meeting terrain adaptation for long-distance, steep angle, and curved conveying; scenario adaptation — compatible with material characteristics (coal prone to dust, ore causing high wear), stable operation in Vietnam's extreme environments (40℃ highs, -10℃ lows); compliance — dust ≤ 10mg/m³, CE and EAC certified, multi-language operation interface; O&M support — core component service life ≥ 50,000 hours, global spare parts response ≤ 7 days, 1-year technical support.

Based on the above requirements, the project set four core objectives:

1. Efficiency Breakthrough: Realize transshipment-free conveying for the entire 5,537-meter route, ensure main and branch line capacities stably meet standards, completely replace truck transshipment.
2. Environmental Compliance: Reduce dust emission to below 8mg/m³, control material loss rates to within 1% (coal) and 0.8% (ore).
3. Terrain Adaptation: Adapt to bends and gentle slopes without terrain modification, ensure equipment's environmental tolerance meets Vietnam's climatic characteristics.
4. Cost Optimization: Keep annual failure rate below 0.5%, reduce comprehensive costs through cost-effective equipment and rapid O&M.

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Long Distance Conveying Solution for Coal and Ore

Based on on-site 3D topographic survey data and material characteristic analysis, ZOOMRY adopted a design concept of "precision equipment selection by road section + full-process collaborative matching", organically integrating conveying equipment and supporting systems.

Core Conveying Equipment

In response to three typical working conditions along the 5,537-meter route, ZOOMRY customized three types of differentiated belt conveyors.

The long-distance belt conveyor for the straight section is designed with a 1,600mm belt width, 4,200 TPH capacity, and 4.0m/s belt speed. It adopts a multi-drive system with three 315kW variable-frequency motors (total 945kW) and hardened gear reducers (≥96% efficiency). The 159mm silent idlers have radial runout ≤ 0.4mm and water intake ≤ 95g in 72-hour immersion test. The ST2500 steel cord belt has tensile strength ≥ 2,500N/mm with a 15mm wear-resistant layer and 130mm overlap sealing structure.

The Steep angle belt conveyor for the gentle slope section has a 1,400mm belt width and 2,800 TPH capacity. A combined structure of "35° trough idler group + corrugated sidewall belt" is designed for the 15° slope, climbing directly without transshipment and shortening the route by 200 meters. The 200mm-high sidewalls and 1.5m-spaced partitions prevent ore rolling and coal adhesion. The hydraulic tensioning device automatically compensates for belt thermal expansion and contraction.

The curved belt conveyor for the bend section has a 1,200mm belt width and 1,800 TPH capacity. It adopts "self-aligning idler group + flexible turning technology", compressing the turning radius to 30m — far below the 80m minimum of conventional equipment — adapting to 90° bends without felling vegetation or leveling ground. The HDPE corrosion-resistant idlers have 40% improved wear resistance, with real-time tension control dynamically adjusting belt tension according to bend operating status.

Process Node Equipment

To realize smooth material flow from receiving to stacking, ZOOMRY configured three types of independently developed supporting equipment:

The ZRLS-TU1800 Wheel-Type Truck Unloader in the receiving area has an 1,800mm belt width, 600-1,800 TPH capacity, equipped with two 6.7° hydraulically adjustable ramps, rubber sealing skirts, and vibrating feeding device adjusting unloading speed in real time.

A ZR series Hopper Feeder is installed between the unloader and conveyor, with a standard 10m³ hopper, 18.5kW variable-frequency motor enabling 1,800-2,800 TPH flow adjustment. The inner wall is paved with wear-resistant lining, and the dust cover combines with a dehumidification device to reduce dust and prevent coal caking in Vietnam's humid climate.

The ZR160SF Radial Telescopic Stacker in the plant stacking area has a 1,600mm belt width, 3,000m³/h capacity, 20-meter stacking height, and 10-22-meter telescopic stroke. It supports PLC-controlled automatic stacking modes, with a lattice-type carbon steel chassis and hydraulic winch system locking within 0.01 seconds after power failure.

Core Components

All key components are independently produced by ZOOMRY, surpassing national and CEMA standards. Silent conveyor rollers (133mm diameter) have rotational resistance ≤ 2N and noise ≤ 43dB. Drive pulleys are made of 40Cr forged material with 219mm diameter, 12mm diamond rubber coating, and 50,000+ hour wear life. The cleaning system features 3 sets of PU Belt Cleaners with 98% fitting degree, combined with passive dust-collecting chutes and deviation alarm devices.

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Project Implementation Process

ZOOMRY adopted a "modular implementation + full-cycle management and control" model, completing installation and commissioning in only 45 days — 25% shorter than the industry average.

In the early survey stage, an 8-person technical team spent 15 days completing 3D topographic surveying via drones and total stations, marking gentle slopes, bends, and drainage points, and optimizing the conveyor route. Material samples were tested for fluidity and wear resistance. The multi-language operation interface and Southeast Asian spare parts allocation plan were planned in advance.

Production and manufacturing fully complied with ISO 9001 and ISO 14001 systems. Pulleys passed 24-hour static load tests at 1.2× rated load. Idlers completed 2,000-hour no-load test operation. Steel cord belts were delivered only after tensile and wear tests. The company participated in acceptance throughout, with all equipment passing CE and EAC certification.

Installation and commissioning adopted "factory pre-assembly + on-site splicing" mode, dividing the 5,537-meter conveyor into 25 modular units requiring only bolt connection. Commissioning proceeded in three steps: individual equipment no-load test, system linkage test, and 72-hour full-load trial simulating coal and ore conveying scenarios and extreme temperature conditions.

20 days of multi-language training were provided to 15 employees, covering daily maintenance (idler inspection, hydraulic oil level monitoring) and fault handling (belt deviation, motor overload). Special courses on "motor heat dissipation in high-temperature environment" and "equipment moisture protection in rainy season" addressed Vietnam's climate. ZOOMRY's 24-hour global technical hotline and regional spare parts warehouses ensure delivery within 7 days.

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Project Results

After commissioning, the system has operated stably with all indicators exceeding expectations. In efficiency: transshipment-free conveying for the entire 5,537-meter route ensures main line capacity stably at 4,250 TPH and branch line at 1,850 TPH. The conveying cycle is shortened from 8 hours to 2.5 hours, reducing annual downtime by approximately 60 hours.

In environmental protection: the fully sealed design reduces dust emission to 7.5mg/m³, fully complying with international standards and eliminating export compliance risks. Coal loss rate reduced to 0.9%, ore loss rate to 0.7% — annual material loss reduced by over 120,000 tons.

In reliability and cost: core components have operated 30,000+ hours without major replacement. Annual maintenance frequency reduced from 15 to 5 times, costs down 40%. Compared with imported equipment, initial investment has significant advantages with a 2.5-year payback period.

In terrain adaptation: equipment successfully adapts to the 15° gentle slope and 90° bends, saving substantial civil engineering costs. In -10℃~40℃, annual failure rate is only 0.4%, with no major failures from extreme weather. The project manager commented: "ZOOMRY's solution not only solves long-distance conveying, but also eliminates our worries with rapid O&M response. We will prioritize cooperation with ZOOMRY for future expansion."

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Core Competitiveness of ZOOMRY

1. In-depth Scenario Adaptation Capability: In response to Vietnam's complex terrain and climate, ZOOMRY completed full solution customization in only 3 months — shortening the design cycle by 50% — through special designs such as corrugated sidewalls and flexible turning.
2. Full-Chain Equipment Synergy Advantage: The full range of equipment from unloaders to stackers is independently developed, with seamless parameter connection. Core components are independently produced, with better quality controllability and adaptability than outsourced components.
3. International Compliance and Service System: Equipment has obtained multiple international certifications, meeting global compliance requirements. Multi-regional spare parts warehouses and multi-language technical teams realize 7-day spare parts response and 24-hour technical support.

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