Non-standard custom long-distance overland belt conveyor, tubular pipe belt and horizontal curved conveyor for open-pit mines, aggregate plants and bulk ports. Belt width 650–2400mm, up to 10,000 t/h. Turnkey EPC from engineering to commissioning
Custom Long-Distance Belt Conveyor System — Tubular / Curved / Overland Belt Conveyor for Open-Pit Mine & Aggregate Plant
Our custom heavy-duty belt conveyor system is purpose-built for long-distance overland material transport in open-pit mines, aggregate quarries, coal ports and mineral processing plants. We specialize in non-standard engineered solutions including overland horizontal curved belt conveyors, tubular pipe belt conveyors and high-angle / downhill conveying systems. With decades of design experience and turnkey EPC delivery capability, we deliver complete material-handling packages from engineering, steel structure, drive units, braking and safety monitoring to on-site commissioning. Belt widths range from 650mm to 2400mm, with maximum capacity up to 10,000 t/h.
Important Note: Standard surface belt conveyor equipment is designed for open-pit and above-ground applications only. Underground mines with explosive-gas hazards require certified flame-retardant belts and explosion-proof modification. Standard units cannot be deployed directly underground.
Core Key Advantages
- True non-standard customization, not off-the-shelf units: We design each conveyor according to terrain, material properties, tonnage and layout. Capable of multi-kilometer overland conveying, horizontal curve routing through mountains, and tubular closed-belt solutions — applications where standard straight conveyors fail.
- Long-distance & curved overland conveying expertise: Our engineering team has delivered overland conveyors spanning several kilometers with horizontal curves that follow terrain contours. This avoids costly intermediate crushing and transfer stations, and reduces truck haulage cost in open-pit mines.
- Tubular / pipe belt conveyor for environmental control: The enclosed tubular belt wraps material inside a hexagonal pipe cross-section, preventing spillage, dust leakage and rain contamination. Ideal for eco-sensitive zones, residential-adjacent quarries and coastal projects.
- Complete EPC package, not just steelwork: One-stop supply includes main conveyor, drive pulleys, magnetic pulleys, gearboxes, planetary drives, backstops, hydraulic brakes, take-up stations, idlers, chutes, steel truss/trestle structure, and intelligent protection system (belt sway, tear detection, bearing temperature, speed monitoring).
- High capacity & wide product range: Belt width 650–2400mm, belt speed up to 5 m/s, conveying capacity up to 10,000 t/h, single-unit motor power up to 710 kW. Suitable for iron ore, copper, gold, coal, limestone, granite and other bulk minerals.
- Intelligent monitoring & energy-saving options: Optional permanent-magnet motorized pulleys, variable-frequency drives, and AI-based无人值守 monitoring. Reduces long-term energy cost and enables remote diagnostics for mining operators.
Typical Conveyor Types We Provide
- Overland belt conveyor: Long-distance open or gallery conveyor across undulating terrain, suitable for pit-to-plant and plant-to-port transfer.
- Horizontal curved belt conveyor: Follows mountain contours without transfer towers, minimizes civil work and land acquisition.
- Tubular / pipe belt conveyor: Fully enclosed material transport, zero spillage, environmental-friendly routing through sensitive areas.
- High-angle / steep inclined conveyor: For limited vertical lift space, including steep-sidewall and sandwich-belt configurations.
- Downhill / regenerative conveyor: Steep downhill conveying feeds back generated electricity to the grid, reducing overall plant power consumption.
- Port & ship-loading conveyor: Movable or fixed ship-loader / stacker-reclaimer for bulk cargo terminals.
- Aggregate plant feed conveyor: Quarry crushing and screening plant interconnecting conveyors with durable wear-resistant liners.
Suitable Minerals & Materials
- Iron ore, copper ore, gold ore, bauxite, manganese ore and other metallic ores
- Thermal coal, coking coal, lignite and overburden in open-pit coal mines
- Limestone, granite, basalt, marble and sand & gravel aggregates
- Cement clinker, gypsum, phosphate, potash and other non-metallic minerals
- Sinter, pellet, slag and steel plant bulk materials
- Overburden / waste rock stripping in large open-pit operations
System Technical Specifications
| Item | Parameters |
| Belt Width Range | 650mm – 2400mm (customized) |
| Max. Conveying Capacity | Up to 10,000 t/h |
| Belt Speed | Up to 5.0 m/s |
| Single-Unit Motor Power | Up to 710 kW (multi-drive for larger systems) |
| Single Conveyor Length | Up to several kilometers overland (curved / straight) |
| Max. Inclination Angle | Standard up to 16°; high-angle / sidewall up to 60° |
| Belt Type | Steel cord belt / multi-ply fabric belt / tubular belt / flame-retardant belt |
| Driving Method | Tubular drive, planetary gear drive, VFD-controlled; optional permanent-magnet motorized pulley |
| Safety Protection | Belt sway switch, tear detection, bearing temperature, speed monitor, pull-wire emergency stop, chute-blocking detector |
| Backstop & Braking | Electromagnetic backstop, hydraulic disc brake, hydraulic rail brake for downhill |
| Steel Structure | Truss / gallery / trestle, hot-dip galvanized or painted; wind & seismic design per local code |
| Control System | PLC + HMI, remote SCADA, optional AI无人值守 monitoring & predictive maintenance |
| Surface Finish | Epoxy painting; optional C3–C5 anti-corrosion for coastal / salt-fog mine sites |
Typical Application Scenarios
- Open-pit mine overland transfer: Run-of-mine ore from pit to primary crusher and to processing plant, replacing heavy truck fleets to cut fuel and tire cost.
- Curved conveyor through mountain terrain: Routes that avoid transfer stations and blasting through hillsides, reducing civil work and environmental impact.
- Aggregate & sand plant: Quarry-to-crushing-to-screening-to-silo inter-plant conveying, with dust-controlled chutes and liners.
- Coal / ore port stockyard: Ship-loader, stacker-reclaimer and dock conveying for bulk cargo terminals.
- Cement & power plant: Limestone, coal and clinker conveying between quarry, plant and silo.
- Tubular belt through eco-sensitive area: Conveyor crossing towns, rivers or forest belts with zero spillage and near-zero dust.
Project Considerations
- Terrain survey first: Overland curved conveyors require detailed topographic survey and satellite imagery before routing design.
- Material properties matter: Abrasiveness, lump size, moisture, temperature and corrosiveness determine belt, liner and chute selection.
- Long lead time: Custom long-distance conveyors typically need 6–12 months for engineering, fabrication and installation; early ordering recommended.
- Export packing: Long steel trusses are knocked-down for container shipment; on-site bolted assembly requires qualified local crew.
- Spare parts strategy: Belt, idlers, pulleys and brakes are wear parts; we recommend keeping critical spares at site for continuous mine operation.
FAQ
Why choose conveyor over heavy mining trucks for long-distance ore transfer?
Overland belt conveyors move material continuously with lower energy per ton-km, lower labor, zero tailpipe emissions and higher availability than truck fleets. For distances above 1–2 km, the total cost of ownership is typically lower, especially for large open-pit mines.
Can the conveyor follow mountain curves instead of going straight?
Yes. We design horizontal curved belt conveyors that follow terrain contours, which avoids intermediate transfer towers and reduces land acquisition. Minimum curve radius depends on belt width and tension, and is calculated per project.
What is the advantage of a tubular / pipe belt conveyor?
The belt forms a closed hexagonal pipe that fully encloses the material. This prevents spillage, dust, rain contamination and visual impact, making it suitable for routes through residential areas, rivers or environmentally sensitive zones.
Can it be used for underground mines?
Standard surface conveyors are not suitable for underground hazardous areas. Underground deployment requires flame-retardant belts, explosion-proof motors and local mining safety certification. Please confirm your mine’s certification requirement in advance.
How long is the typical lead time for a custom long-distance conveyor?
Engineering and fabrication of a multi-kilometer overland conveyor typically takes 6–12 months depending on length, curve complexity and steel-structure tonnage. Early project scheduling is recommended to avoid delaying mine commissioning.
Do you provide turnkey EPC including installation?
Yes. We can supply engineering, equipment, steel structure, supervision of on-site erection, commissioning and operator training. For overseas projects, we also support local contractor supervision and CKD knocked-down export packing.
What about energy-saving options?
We offer variable-frequency drives, permanent-magnet motorized pulleys and regenerative downhill drives that feed generated electricity back to the grid. For long downhill conveyors, regenerative braking can significantly offset plant power consumption.
Which materials can be conveyed?
Iron, copper, gold, bauxite, manganese ores; coal, lignite, limestone, granite, aggregates; cement clinker, gypsum, phosphate and sinter. Material temperature, lump size and abrasiveness must be confirmed during design.
Get In Touch
Please share your mine type, material, required capacity (t/h), conveying distance, terrain map and project timeline. Our bulk-material handling engineering team will deliver a custom conveyor layout proposal and budgetary quotation.
Get in touch
Have a project in mind ? Send us your ore assay report, mine location and target capacity. Our mining engineers will prepare a customized process design, equipment list and quotation within 48 hours.