Coal Conveyors

In the coal industry (coal mining, coal washing and processing, coal storage and transportation), the conveyance of bulk materials (raw coal, cleaned coal, middlings, gangue) faces challenges such as "adhesion and clogging, dust pollution, long-distance and high-load requirements, and multi-scenario adaptation". Relying on core equipment including long-distance belt conveyors, pipe belt conveyors, radial telescopic stackers, and truck unloaders, as well as independently developed components like high-wear-resistant idlers, anti-corrosion rollers, and polyurethane cleaning scrapers, Zoomry Heavy Industry creates customized conveying solutions for the coal industry featuring "anti-adhesion & anti-clogging + sealing + high-load resistance".

Solution Advantages

Centering on the characteristics of coal — "high adhesion, easy dust generation, and large flow rate" — Zoomry's solutions have distinct advantages in three dimensions: "anti-clogging adaptation, environmental safety, and load resistance". All equipment and components have passed the strict certifications and inspections mentioned in the brochure, ensuring adaptation to the harsh operating scenarios of the coal industry:

1. Anti-Adhesion & Anti-Clogging and Scenario Adaptation: Equipment functions are customized based on different coal forms (raw coal adhesion, cleaned coal dust generation, gangue wear resistance). For example, belt conveyors are equipped with a dual cleaning system (polyurethane scrapers at the head + brushes at the tail), achieving a cleaning efficiency of over 98% to quickly remove raw coal adhering to the conveyor belt surface; pipe belt conveyors fold the conveyor belt into a tubular structure (supported by 6 sets of idlers forming a hexagon) to realize 100% sealed conveyance of cleaned coal, preventing dust diffusion; truck unloaders can be optionally equipped with 2-4 lane unloading ramps, adapting to simultaneous unloading of multiple coal transport trucks and reducing queuing and congestion;
2. Environmental Safety: All equipment and components comply with the ISO 9001 Quality Management System, ISO 14001 Environmental Management System, as well as CE (Europe) and EAC (Russia) certifications. Independently produced idlers have a noise level of ≤ 40-45 dB (surpassing China's GB standard of 55 dB), an water ingress of ≤ 100g in the 72-hour immersion test (better than the GB standard of 150g), and an IP65 protection rating, which can reduce equipment operation noise and dust intrusion; radial telescopic stackers avoid segregation and breakage of coal during storage through optimized stockpiling design, reducing resource loss;
3. Cost Optimization: Zoomry has built its own quality inspection center (including chemical laboratories, idler laboratories, etc., equipped with over 60 testing devices). Core components (idlers, rollers, cleaning scrapers) are independently produced with sufficient inventory, enabling fast supply within 48 hours and reducing equipment downtime. Long-distance belt conveyors adopt a high-carbon steel lattice frame and have a conveying capacity of 500-2000 tons per hour (tph), which can meet the demand for long-distance (several kilometers) continuous conveyance of coal and reduce transportation costs by 60% compared with the traditional dump truck transfer mode.

Application Solutions for Segmented Scenarios in the Coal Industry

Focusing on three core scenarios of the coal industry — "coal mine shaft conveyance, coal washing plant processing & conveyance, and coal storage yard stockpiling & transfer" — Zoomry Heavy Industry develops targeted conveying systems by integrating coal characteristics and production rhythms at each stage, ensuring seamless integration between bulk material conveyance and coal production processes:

Anti-Adhesion Conveying Solution for Raw Coal

Coal mine shafts need to transfer mined raw coal (moisture content 15%-25%, containing a small amount of large gangue) from underground to the ground crushing plant. Raw coal is prone to adhering to the conveyor belt and causing clogging, and the shaft space is limited, requiring high anti-clogging performance and compactness of equipment. Zoomry's solution centers on "belt conveyor + high-efficiency cleaning system" with anti-adhesion and anti-clogging design:

• Main Equipment Configuration: Select compact belt conveyors (belt width 1000-1400mm, conveying speed 2.0-2.5 m/s) with anti-corrosion coating treatment to adapt to the humid and dusty environment of the shaft. The tail of the equipment is equipped with an ultra-low receiving hopper (height adapted to the unloading of underground scraper conveyors), and the inner wall of the hopper is lined with polytetrafluoroethylene (PTFE) liners to reduce the adhesion rate of raw coal. One set of polyurethane (PU) cleaning scrapers is installed at both the head and tail, combined with one set of brush cleaning devices to remove raw coal adhering to the conveyor belt surface in real time;
• Component Assurance: Idlers are made of HDPE material with a rotational resistance of ≤ 2N (better than the GB standard of ≤ 3N), maintaining low-resistance operation even when adhering to raw coal. The conveyor belt is made of tear-resistant polyester canvas material with anti-slip and wear-resistant surface treatment, capable of withstanding the impact of small gangue. Meanwhile, belt deviation switches and pull cord switches are equipped; when the conveyor belt deviates or clogs, it can stop immediately for adjustment to ensure the safety of shaft operations;
• Application Advantages: This solution enables 24/7 continuous conveyance at coal mine shafts, with monthly equipment downtime controlled within 1.5 hours. The clogging rate caused by raw coal adhesion is reduced from 8% (with traditional equipment) to 0.5%, and the conveying efficiency is 30% higher than that of other equipment in the industry, effectively reducing the waiting time for shaft production.

Classified Conveying Solution for Cleaned Coal and Gangue

Coal washing plants need to conduct classified conveyance of sorted cleaned coal (particle size 0.5-5mm, requiring sealing to prevent dust), middlings (for power generation), and gangue (needing separate transfer and disposal), which requires high sealing performance and classification adaptability of equipment. Zoomry's solution centers on "pipe belt conveyor + truck unloader" to build a classified sealed conveying system:

• Main Equipment Collaboration: Pipe belt conveyors are used to convey cleaned coal. With a maximum turning angle of 110° (far exceeding the 70° of ordinary belt conveyors), they can flexibly bypass equipment in the coal washing plant workshop without the need to build additional transfer platforms, reducing space occupation. The conveyor belt is folded into a tubular structure to realize 100% sealed conveyance of cleaned coal; a non-powered dust-collecting chute is installed at the discharge end, controlling the workshop dust concentration below 5mg/m³ and complying with EU environmental standards. Middlings and gangue are transferred by truck unloaders (models such as ZRLS-TU1400/ZRLS-TU1800) with a conveying capacity of 200-1800 tph, equipped with 2-4 lane unloading ramps to support simultaneous unloading of multiple material transport vehicles;
• Environmental and Classification Design: The body of the pipe belt conveyor dedicated to cleaned coal conveyance is made of 304 stainless steel (or customized anti-corrosion coating) to prevent cleaned coal from caking due to moisture. The inner wall of the chute in the gangue conveying section is equipped with 15mm thick wear-resistant alloy liners to resist impact wear from gangue, extending the service life to over 8 years;
• Application Advantages: This solution enables the coal washing plant to simultaneously carry out "sealed conveyance of cleaned coal + efficient transfer of gangue". The dust loss rate of cleaned coal is reduced from 5% (with traditional equipment) to 0.8%, the transfer efficiency of middlings and gangue is increased by 40%, and the maintenance cost is reduced by 25% compared with other solutions in the industry, meeting the dual needs of environmental protection and production in coal washing plants.

Large-Flow Coal Stockpiling and Outward Transportation Solution

Coal storage yards need to store coal (cleaned coal or raw coal) on a large scale while matching the outward transportation rhythm of trains/ships, requiring high stockpiling capacity and flexible transfer capability of equipment. Zoomry's solution centers on "radial telescopic stacker + long-distance belt conveyor" to build an efficient stockpiling and transfer system:

• Main Equipment Configuration: Select ZR-SF Series Radial Telescopic Stackers with radial rotation (360° adjustable), boom telescoping (maximum telescoping length 20m), and luffing adjustment (-15° to +25°) functions. Through the windrow stockpiling method, they can reduce coal segregation and breakage, and the stockpiling capacity is increased by over 28% compared with traditional fixed-length conveyors. They are matched with long-distance belt conveyors (belt width 1400-2000mm, conveying capacity 1000-2000 tph) to transfer stored coal to outward transportation wharves or railway platforms;
• Component Assurance: The idler sets of the stacker adopt sealed double-row self-aligning spherical roller bearings with an IP65 dust and water protection rating, adapting to the dusty environment of coal storage yards. Rollers are made of 40Cr forged material (diameter ≥ 159mm, suitable for wide belts) and undergo ultrasonic flaw detection and stress tempering treatment; their load-bearing capacity is 25% higher than that of ordinary rollers, enabling them to withstand the impact of large-flow coal;
• Application Advantages: This solution enables seamless connection of "rapid stockpiling + efficient transfer" of coal in coal storage yards. The stockpiling efficiency is 30% higher than that of traditional equipment, and the coal stockpiling loss rate is reduced from 5% to 1.2%. In addition, through the flexible adjustment function of the stacker, the stockpiling position can be adjusted at any time according to the outward transportation rhythm, reducing the cost of secondary coal transfer.

Zoomry Heavy Industry's Service and Support System for the Coal Industry

1. Production Efficiency Improvement: The in-depth adaptation of equipment to coal characteristics increases the average coal conveying efficiency by 30%-50%. 24/7 continuous operation ensures the continuity of coal production, helping enterprises increase annual output;
2. Environmental Compliance: The sealed conveyance and low-noise design meet the environmental standards of the coal industry in regions such as the EU and North America, reducing the impact of dust pollution and equipment noise on the surrounding environment and lowering environmental compliance risks;
3. Cost Optimization: Independent component production reduces procurement costs, and long-service-life equipment (idlers and rollers with a service life of over 50,000 hours) decreases maintenance expenses, reducing the average annual conveying cost of coal enterprises by 25%-40% compared with other equipment in the industry;
4. Delivery Service: 70% of the equipment is pre-assembled before leaving the factory, accompanied by detailed installation manuals and video guides, with on-site assembly taking only 10-20 days. For the narrow space of coal mine shafts or complex terrain of coal storage yards, engineers can be dispatched to supervise on-site installation and adjust equipment parameters (such as the inclination angle of belt conveyors, the boom length of stackers) according to on-site working conditions, ensuring fast equipment commissioning;
5. Maintenance Support: Provide "1-year free maintenance + lifelong technical consultation". Spare parts warehouses are established in global coal resource concentration areas (such as Australia, Africa, North America). Common spare parts (idlers, rollers, cleaning scrapers) can be delivered within 48 hours. A remote monitoring system is built to real-time monitor key parameters such as conveyor belt tension, idler rotation speed, and motor temperature, predicting faults in advance (such as idler wear warning, conveyor belt adhesion and clogging warning) and reducing unplanned downtime;
6. Specialized Training: Provide "theoretical + practical" training for the operation teams of coal enterprises, covering daily equipment operation (such as adjustment of the turning angle of pipe belt conveyors, PLC control of stackers) and emergency troubleshooting (such as hopper clogging clearance, emergency shutdown of conveyor belts). This ensures that the team independently masters equipment maintenance skills and reduces equipment losses caused by human operation errors.