Indispensable ZR160SF Telescopic Stacker Conveyor for Mine Bulk Material Conveyance with 3500 Tonnes per Hour Capacity

In the current era of global mine transformation, capacity improvement no longer relies solely on the upgrading of mining equipment. After the mining capacity of open-pit mines and underground mines has exceeded the 10-million-tonne class, bulk material conveyance is no longer merely a simple material transfer process. Instead, it has to address core challenges such as "high-load operation for more than 16 consecutive hours", "adaptation to multiple working conditions (dust, high/low temperatures, complex terrain)", and "balance between zero material loss and stockpiling efficiency". Once the conveying equipment fails to meet these requirements, even if the front-end mining capacity is strong, the mine will still fall into the predicament of "capacity internal friction" where "materials can be mined, but cannot be transported or stored".

Zoomry Heavy Industry's ZR160SF Telescopic Stacker Conveyor meets the high-load demands of large-scale mines with a transport capacity of 3500 tonnes per hour. It not only reduces material spillage loss but also flexibly adapts to different stockpiling scenarios, ensuring the efficient operation of the bulk material conveyance link and directly guaranteeing the continuous capacity release of mines.

Features of ZR160SF Telescopic Stacker Conveyor

For large-scale mines with an annual capacity of over 15 million tonnes, "3500 TPH" is not just a numerical indicator. It requires the equipment to simultaneously solve three major pain points—"material separation, stockpiling capacity, and site constraints"—during 16 consecutive hours of full-load operation. Through precise parameter design, the ZR160SF achieves a balance between "high throughput" and "low loss". Its core parameters and industry adaptability are as follows:

Core Parameter Table of ZR160SF Telescopic Stacker Conveyor

Industry Adaptation Scenarios

Hard Rock Mines (Iron Ore, Copper Ore, etc.)

The materials such as iron ore and copper ore handled by hard rock mines generally have a Mohs hardness of 5-7 and often contain sharp edges and corners. Under the high transport capacity of 3500 TPH, the instantaneous impact load on the idler set when materials fall often exceeds the bearing capacity of conventional equipment. If ordinary steel idlers are used, problems such as radial deformation of idlers and bearing seizure may occur in as short as 3-6 months, leading to equipment shutdown for maintenance.

To address this pain point, the idler set of the ZR160SF Telescopic Stacker Conveyor adopts a composite structure of "wear-resistant steel outer layer + HDPE polymer inner layer". The outer wear-resistant steel can directly resist the scratch and wear caused by the edges and corners of materials, while the inner HDPE layer buffers the impact energy through its own toughness. Combined with the integrally forged idler shaft (tensile strength ≥ 800MPa), the impact resistance of a single impact idler set reaches 50kN, which is equivalent to being able to withstand the instantaneous impact of a 5-tonne heavy object.

Coal Mines

The core demands of coal mines focus on two aspects: first, preventing static electricity or sparks generated by friction from causing explosions during conveyance; second, reducing the calorific value loss and dust pollution caused by coal crushing. If conventional stackers use ordinary conveyor belts, they will not only fail to meet the coal mine explosion-proof standards but also easily lead to a crushing rate of over 3% due to the hard collision between the inner wall of the chute and coal. Based on a transport capacity of 3500 TPH, this can result in an annual loss of up to 1000 tonnes.

The conveyor belt of the ZR160SF Telescopic Stacker Conveyor can be optionally equipped with anti-static and flame-retardant materials certified by EU ATEX and US UL. Its surface resistance is ≤ 10⁸Ω, which can quickly discharge the static electricity generated by friction, and it also has the self-extinguishing property when exposed to fire. The inner wall of the chute is fully equipped with a 15mm-thick polyurethane liner. With a friction coefficient of only 0.15 (far lower than 0.45 of steel), this material can guide coal to fall smoothly along the liner, avoiding severe collision between materials and the chute wall. Finally, the coal crushing rate is controlled within 1.5%, which not only meets the explosion-proof safety requirements of coal mines but also reduces the invalid coal loss of the mine by more than 300 tonnes per year.

Aggregate Mines (Limestone, Granite, etc.)

Materials such as limestone and granite stored in aggregate mines are mostly lump-shaped (with a particle size often reaching 300-500mm), and local concentrated loads are easily formed under the stacking boom during stockpiling. If conventional stackers adopt a solid steel structure stacking boom, although it can bear the load, its large dead weight (the weight of a single boom often exceeds 20 tonnes) will increase the load on the equipment drive system, resulting in not only high energy consumption but also possible stockpiling accuracy deviation due to boom sagging.

The stacking boom of the ZR160SF Telescopic Stacker Conveyor adopts a "truss-type frame" design. Through finite element analysis, the frame joint layout is optimized. While retaining the key load-bearing structure, redundant steel is removed. Compared with the traditional solid steel structure, the overall weight of the stacking boom is reduced by 15% (the weight of a single boom is reduced to within 17 tonnes). However, through the stress dispersion design of the frame joints, its bending strength is increased by 20% (the maximum bending moment reaches 120kN·m). This not only reduces the power consumption of the equipment during operation (saving 8% more electricity than the traditional structure) but also stably bears the concentrated load of lump-shaped aggregates, preventing the stacking boom from deforming due to long-term stress and ensuring the accurate control of stockpiling height and range.

Technical Advantages

The reason why the ZR160SF Telescopic Stacker Conveyor can maintain stability under the high transport capacity of 3500 TPH lies in Zoomry Heavy Industry's technological breakthroughs in three major fields: "material conveying efficiency, equipment motion accuracy, and safety redundancy design", which directly solve the pain points of traditional stackers such as "insufficient capacity, uneven stockpiling, and frequent failures".

Efficient Material Conveying System

Dynamic Anti-Spillage Sealing System

Aiming at the material spillage problem that is prone to occur in telescopic stackers during radial rotation (±110°) and 20m telescopic stroke, the ZR160SF Telescopic Stacker Conveyor adopts a combined sealing solution of "high-density sidewall conveyor belt + multi-stage guide chute". The two sides of the conveyor belt are equipped with 150mm-high wear-resistant rubber sidewalls, which are integrally formed with the base belt through a continuous vulcanization process and can withstand the lateral impact of materials without deformation. It is matched with the three-stage sealing structure of the head guide chute—polyurethane elastic plate soft contact at the inlet section, wear-resistant steel liner installed in the middle section, and adjustable brush set at the outlet section—forming a fully enclosed channel from the material transfer point to the discharge end.

In terms of idler set design, closely arranged trough idlers (spacing ≤ 1000mm) are used to form stable support, ensuring that the conveyor belt maintains a U-shaped cross-section under full-load conditions. Combined with self-aligning idlers that correct belt deviation in real time (deviation amount controlled within 50mm), the measured data from Zoomry Heavy Industry Laboratory shows that under a rotation speed of 3000 r/h, the static sealing rate of this system reaches 99.7%, and the material loss rate can be controlled within 0.3%, far lower than the industry average of 1.5%.

Intelligent Material Distribution System

The particle gradation uniformity of mine bulk materials (especially concrete aggregates) directly affects the quality of subsequent processing. Due to the fixed material dropping trajectory of traditional stackers, stratification is likely to occur, where coarse particles settle at the bottom and fine powder floats on the surface. The chute of the ZR160SF Telescopic Stacker Conveyor is integrated with an adjustable material distribution baffle. Through the HMI touchscreen, 3 diversion modes can be preset: "gravity straight drop channel" for coarse particles of 30-50mm, "buffered inclined guide plate" for medium particles of 5-30mm, and "vortex deceleration chamber" for fine powder of <5mm, realizing the differentiated conveying trajectory control of materials with different particle sizes.

The baffle is made of high-chromium cast iron material, and its surface is subjected to quenching treatment (hardness ≥ HRC55). The wear amount is ≤ 0.1mm per year during long-term contact with ores. In practical application, this design can control the gradation deviation of the stockpiling section within ±3%, greatly reducing the rework rate in the subsequent crushing and screening process. It is particularly suitable for concrete aggregate mines and metallurgical pellet mines that have strict requirements on material uniformity.

Luffing Adaptive Material Dropping Control

The dropping height of materials from the head of the stacking boom to the stockpile is a key factor affecting the crushing rate. The fixed material dropping point design of traditional equipment often leads to high-altitude dropping of more than 5m, and the crushing rate of hard materials (such as granite) can reach more than 8%. The stacking boom of the ZR160SF is equipped with an angle sensor and a hydraulic luffing system, which can automatically adjust the boom elevation angle (range: -15°~+12°) according to the real-time stockpiling height, always controlling the dropping height within 3m.

By establishing a dynamic correlation model of "dropping height - crushing rate": when the stockpile height is detected to rise by 1m, the stacking boom is automatically lifted by 5° to keep the dropping height stable; for high-hardness ore materials, the system can further limit the dropping height within 2m. Combined with the polyurethane buffer layer at the bottom of the chute, the optimization effect of reducing the crushing rate by 60% is achieved (from 3% to below 1.2%). This adaptive adjustment not only reduces the invalid material loss but also avoids the dust emission problem caused by excessive fine powder, which is suitable for mine scenarios with strict environmental protection requirements.

Intelligent Motion Control

• Three-Mode Control: Supports three modes: "full-automatic PLC control, remote control, and manual operation". In the full-automatic mode, the stockpiling trajectory (such as "fan-shaped stockpiling" and "layered stockpiling") can be preset through the HMI touchscreen, and the equipment automatically completes the coordinated movement of radial rotation, telescoping, and luffing without manual intervention.
• Site Adaptation Algorithm: The equipment is equipped with a terrain detection sensor, which can identify obstacles (such as other equipment and slopes) in the stockpiling area in real time and automatically adjust the stockpiling range to avoid collision risks. For port mines with limited space, the "tracked chassis" (optional configuration) can achieve stable movement on soft ground (such as muddy mines), with far better adaptability than traditional wheeled stackers.

In addition, the "pre-assembly design" of the equipment greatly shortens the on-site installation cycle. Most components are pre-assembled in the factory, and commissioning can be completed on the mine site in only 10-20 days. Compared with other international brands, it can be commissioned 20 days in advance, creating additional capacity for the mine.

Safety Redundancy Design

• Power-off Self-locking Protection: The hydraulic winch system is equipped with an automatic locking mechanism. In case of sudden power failure, the telescopic boom can be locked within 0.01 seconds to prevent the boom from falling due to gravity. At the same time, the wire rope adopts "double mechanical limit". Even if a single wire rope breaks, the backup limit device can trigger braking immediately to prevent equipment damage.
• Key Component Condition Monitoring: Temperature and vibration sensors are built into core components such as idlers and rollers to transmit data to the HMI panel in real time. When the idler temperature exceeds 80℃ or the vibration value is abnormal, the equipment automatically alarms and shuts down to avoid fire risks caused by overheating components (especially suitable for explosion-proof scenarios such as coal mines).
• Protective Structure Enhancement: Double-sided walkways can be optionally installed on both sides of the stacking boom to facilitate daily inspection by operation and maintenance personnel. A polyurethane (PU) cleaning scraper is set at the head of the conveyor belt, which can remove residual materials (such as viscous coal slime) on the belt surface, reduce belt wear, and extend the service life of the conveyor belt to more than 3 years (the industry average service life is 2 years).

Choose Zoomry Heavy Industry's ZR160SF Telescopic Stacker Conveyor

Adapting to Exclusive Mine Needs

• For high-altitude mines, a "plateau-type power system" can be customized to optimize the motor heat dissipation performance and ensure full-load operation in environments above 3000m altitude.
• For low-temperature mines, a heating device can be added to the hydraulic system to avoid motion jamming caused by too low oil temperature, adapting to extreme temperatures of -30℃.
• For European mines with strict environmental protection requirements, it can be matched with a "non-powered dust removal chute". Through the airflow buffer design, dust emission is reduced (dust concentration is controlled within 10mg/m³, meeting the EU EN 15251 standard).

Customized Operation and Maintenance Training

Upon equipment delivery, Zoomry Heavy Industry will provide 2-3 days of practical operation training for the customer's local team, covering content such as "key points of daily inspection (e.g., checking hydraulic oil level daily, cleaning residual material in the chute weekly)" and "emergency handling of common faults". A customized operation and maintenance manual (including a list of equipment wear parts and a maintenance schedule) will also be provided to help the local team establish independent operation and maintenance capabilities and reduce reliance on remote support.

Warranty Policy Surpassing the Industry

The warranty period of similar equipment from international brands is mostly 1-2 years. Zoomry Heavy Industry provides a "5-year warranty for core components and 2-year warranty for the entire machine". The service life of self-produced idlers and rollers exceeds 50,000 hours, far higher than the 30,000-hour requirement of the national standard.

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