Long-Distance Flat Belt Conveyor

1. Key Features

The Long-Distance Flat Belt Conveyor is specifically engineered for extended conveying applications, focusing on practical performance rather than unnecessary features. It is ideal for continuous transportation of bulk materials across various industries:

Stable Long-Distance Conveying
Equipped with high-strength belts and reinforced structural support, a single conveyor can achieve horizontal conveying distances ranging from hundreds of meters to several kilometers. This eliminates the need for multiple transfer points, reduces material loss, and prevents spillage or damage during handling, ensuring smooth and continuous operation.

High Load Capacity and Large Throughput
Designed for heavy-duty applications with a load capacity exceeding 50 kg/m, and a conveying capacity of 500–3000 tons per hour. It meets the demands of high-frequency and large-volume material handling in industries such as mining and ports.

Reinforced and Durable Structure
The frame, rollers, and drive system are built for long-distance and heavy-load operation, offering excellent resistance to tension, deformation, and impact. It supports 24/7 continuous operation with low failure rates, minimizing downtime and ensuring production continuity.

Intelligent and Safe Operation
Features multi-drive systems, automatic tensioning, belt misalignment protection, overload braking, and full-line monitoring. It ensures stable operation without slipping, deviation, or material accumulation, making it suitable for automated and unmanned production environments.

Wide Material Adaptability
Capable of conveying coal, ore, grain, building materials, chemical raw materials, and packaged goods. It performs reliably under harsh conditions such as dust, humidity, low or high temperatures without requiring specialized equipment for different materials.

2. Core Structure and Key Components

Compared with standard short-distance conveyors, the long-distance flat belt conveyor is comprehensively reinforced to handle high loads and extended operation cycles.

2.1 High-Strength Flat Belt (Core Component)

The conveyor belt is typically a steel cord rubber belt (ST type) or high-strength polyester/nylon belt, specifically designed for long-distance use.

• Tensile strength: 2000–6000 N/mm

• Cover thickness: 3–8 mm with wear-resistant rubber

• Resistant to impact, abrasion, acid, alkali, and oil

• Suitable for abrasive materials such as coal and ore

Standard belt widths range from 500–2000 mm, with 800–1600 mm commonly used for long-distance applications. Smooth belts are used for packaged goods, while patterned belts are suitable for bulk materials, ensuring stable horizontal conveying without sidewalls or partitions.

2.2 Multi-Drive System (Power Core)

Instead of a single motor, the system adopts a combination of head drive and intermediate drives, typically one drive station every 500–1000 meters.

• Components: Variable frequency motor, hardened gearbox, fluid coupling, drive pulley

• Speed range: 0.8–5 m/s

• Features: Soft start, smooth acceleration, precise speed control

Drive pulleys are rubber-lagged (60–70 Shore A hardness) to enhance friction and prevent slipping. Safety devices such as backstops, brakes, and overload protection ensure safe operation.

2.3 Reinforced Idlers and Support Structure

• Carrying idlers: Diameter 89–159 mm, spacing 0.8–1.2 m

• Return idlers: Spacing 2–3 m

• Self-aligning idlers: Installed every 10–15 sets

High-precision sealed bearings reduce resistance and extend service life. The frame is constructed from heavy-duty carbon steel, with reinforced supports every 50–100 meters to prevent deformation and settlement.

2.4 Automatic Tensioning Device

A combination of gravity tensioning and hydraulic automatic tensioning ensures constant belt tension.

• Gravity tension: Stable and low-maintenance

• Hydraulic system: Real-time adjustment for load and temperature changes

This prevents slipping and misalignment during long-distance operation.

2.5 Intelligent Control and Safety System

• PLC control with touch screen interface

• Operation modes: Manual, automatic, and linked control

• Safety devices: Belt misalignment switches, pull-cord switches, slip detection, level sensors, temperature monitoring, smoke alarms

Optional IoT modules enable real-time monitoring of speed, tension, temperature, and current, along with fault prediction and remote diagnostics.

2.6 Auxiliary Components

• Cleaning devices: Head and tail cleaners to remove residual materials

• Discharge systems: Fixed plow or mobile tripper for multi-point unloading

• Protective systems: Safety guards, dust covers, rain shelters for outdoor use

These components improve efficiency, extend service life, and ensure environmental compliance.

3. Key Technical Parameters (Standard)

• Conveying length: 100–10,000 m (extendable)

• Belt width: 500–2000 mm

• Speed: 0.8–5.0 m/s (commonly 1.6–3.5 m/s)

• Capacity: 500–3000 t/h

• Load capacity: 50–200 kg/m

• Drive power: 15–200 kW per station

• Noise level: ≤85 dB

• Operating temperature: -20°C to +40°C

• Frame material: Carbon steel or optional stainless steel (304)

4. Main Applications

Mining and Coal Industry
Used for long-distance transport of ore, coal, and tailings from underground to surface operations.

Power and Building Materials
Applied in coal handling systems, cement production, and aggregate transport.

Ports and Logistics
Suitable for bulk cargo handling (grain, ore, coal) and long-distance package sorting.

Grain and Chemical Industry
Enables enclosed conveying of grains and chemical materials, meeting hygiene and safety standards.

Metallurgy and Light Industry
Used in steel plants, paper mills, and textile factories for continuous heavy-duty transport.

5. Selection Guidelines

• Based on distance:
  100–500 m → single drive + gravity tension
  500 m+ → multi-drive + hydraulic tension

• Based on material:
  Abrasive materials → steel cord rubber belt
  Food-grade materials → polyester belt
  Chemicals → corrosion-resistant belt

• Based on capacity:
  Optimize belt width and speed (recommended 1.6–3.5 m/s)

• Based on environment:
  Outdoor → rain and dust protection
  Dusty → enclosed covers
  Hygienic → stainless steel structure

• Based on automation level:
  Manual / VFD + PLC / Remote monitoring system

6. Key Advantages

Efficient Long-Distance Conveying
Reduces transfer points, minimizes material loss, and lowers infrastructure costs.

Stable and Durable
High-strength design ensures long service life and low maintenance.

Safe and Reliable
Comprehensive protection systems prevent operational risks.

Energy Efficient
Saves 15%–25% energy compared to multi-stage systems.

Highly Adaptable
Customizable for different materials, distances, and working conditions.