Curved Overland Conveying System Transforms Long-Distance Bulk Material Handling

Modernising Bulk Material Transport for Sustainability and Efficiency

Jinfeng Cement Group, the biggest private cement manufacturer in Jiangsu Province, China, faced a significant challenge at their large cement plant which is equipped with nine clinker production lines along with an aggregate plant that produces 25 million metric tons of finished product annually. As the company expanded, its yearly demand for limestone was expected to surge to 90 million tons. Traditionally reliant on truck transport, Jinfeng sought a more sustainable, efficient, and cost-effective method to connect its three limestone quarries with its cement and aggregates plant.

As the reliance on trucks not only led to high operational expenses (OPEX) but also contributed to substantial CO2 emissions, road wear, and safety concerns due to the heavy traffic of around 4,000 trucks daily, the company decided to explore alternative options for material transport and sought out BEUMER Group’s expertise in bulk material handling solutions.

To accommodate the natural terrain and logistical needs, the system features advanced engineering, including horizontal and vertical curves and nine carefully planned cross-sections. This comprehensive approach enhances adaptability and performance, ensuring smooth material transport. Integrating these modifications into the belt line and bridge design was made possible by BOLT.

Advanced Digitalisation

BEUMER Group integrated advanced digitalisation features, including a condition monitoring system and a mobile maintenance management app. These tools provide real-time data on the conveyor’s status, enhancing operational efficiency and reliability by enabling proactive maintenance and minimising downtime.

“With a complex system spanning up to 12 kilometres and numerous critical components such as idlers, belts drives and bearings, the ability to monitor each element closely is invaluable. Our custom online dashboards provide a comprehensive view of the system’s status, displaying all collected and analysed data.

 

By leveraging these digital tools, we move beyond standard service manuals and operate based on the actual wear and tear of the components. This targeted approach to maintenance not only saves time and resources but also extends the lifespan of our equipment, ensuring that we can continue to rely on our conveyor system for long-term, sustainable operation.”

A Testament to Efficiency and Sustainability

The newly installed curved conveyor system started operations in September 2023, achieving mechanical completion in record time despite challenges from the coronavirus pandemic. BEUMER’s solution incorporates high redundancy, ensuring continuous material flow even if one conveyor is out of service. The system has significantly reduced environmental impact and operational costs by eliminating the need for over 4,000 daily truckloads, achieving a remarkable CO2 emission reduction of 1.5 million tons per year.

The solution’s energy-efficient design, featuring low resistance components, halved the required drive power, resulting in substantial energy cost savings against an annual consumption of approximately 72,000 MWh. The compact integration of four conveyors into a bridge further minimised the necessary drive power, reducing the number of transfer points, pulleys, drives, and substations to a minimum. This streamlined approach not only led to significant savings in steel usage and maintenance requirements but also provided the customer with considerable savings in both project investment and ongoing operational expenses.

Additionally, the customer’s installation of a 35MW solar panel system allows for the use of renewable energy in operations, further contributing to a more sustainable approach.

Customer Satisfaction and Future Outlook

Jinfeng Cement Group expressed high satisfaction with the performance, efficiency, and sustainability of the conveyor system, which currently includes three curved belt conveyors. The design has already accounted for the installation of a fourth conveyor, allowing the customer to expand their operations even further in the future.

The project not only enhanced the company’s operational capabilities but also contributed positively to the local community by reducing pollution and traffic-related risks. BEUMER Group’s collaborative approach, from design and engineering to commissioning, underscored its commitment to delivering complex projects with excellence.