Overland Conveying System at Jiangsu Jinfeng Cement Group
Curved Overland Conveying System Transforms Long-Distance Bulk Material Handling
Jiangsu Jinfeng Cement Group replaces truck haulage with BEUMER Group's cutting-edge overland conveyor to enhance efficiency, improve reliability and reduce CO2 emissions, when transporting limestone from three quarries to their aggregates plant.
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.
Engineering a State-of-the-Art Overland Conveyor System
BEUMER Group was tasked with engineering and supplying an overland conveyor system to meet Jinfeng’s needs. The project’s scope included connecting the three quarries to the plant over almost 12km with a system capable of replacing the truck transport, thereby reducing environmental pollution and increasing capacity.
Innovative Design and Technical Excellence
After a comprehensive analysis and optimisation process, BEUMER Group proposed a solution that significantly diverged from the initial feasibility study.
Key Features
Three belt conveyors in one conveyor system
Double deck arrangement
Minimum number of transfer points
Horizontal and vertical curves
9 cross sections
3-pulley-drive arrangement at discharge
Elevated system
Condition monitoring system
The original plan, developed by another engineering company, suggested using 17 conveyors. Leveraging decades of experience and its proprietary BEUMER Overland Layouting Tool (BOLT), BEUMER Group re-engineered the system to require only three main overland conveyors, with a provision for a fourth for future expansion. This design not only reduced the system’s complexity and steel usage by approximately 8,000 tonnes but also minimised the number of transfer points, reducing maintenance and operational costs.
One of the key challenges during planning was arranging the four conveyors on the elevated structural bridge to minimise environmental interference. The strategic decision to use a double-deck layout for the BEUMER overland conveying system optimised space and facilitated efficient handling of increased limestone volumes. This design allows the conveyors to transition from a stacked configuration to a side-by-side arrangement for feeding at the three quarries and discharging.
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.”
Chen Zhihua
Operations Manager at Jiangsu Jinfeng Cement Group
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.
Shaping a Responsible Future in Material Handling
BEUMER Group’s innovative solution for Jinfeng Cement Group demonstrates how advanced engineering, sustainability, and operational efficiency can be harmoniously combined to address modern industrial challenges.
This project sets a benchmark for the material handling industry, showcasing the potential to significantly reduce environmental impact while improving operational efficiency.
Benefits
High redundancy
Reduced power consumption
Advanced digitalisation
High capacity
Reduced OPEX
Advanced monitoring
Reduced CO2 emissions
Reduced steel usage
Reduced dust, noise and wear on community roads
Do you have any questions?
Do you have any questions?
Your Contact Person
Alexander Tigges
Director Global Sales Minerals & Mining