Overland Belt Conveyors

Long-distance high-tonnage cross country conveying

Overland Conveyor
  • Challenging applications
  • Important Considerations
  • World Class Technologies

Low energy designs

FLSmidth's overland conveyors minimize energy consumption with a combination of head, tail intermediate, and booster drives that run only during predetermined demand conditions. This results in substanstial energy savings and considerable operating cost reduction over the life of the project.

This was achieved in an FLSmidth project in Peru where some isolated operating conditions required 9,000 kW installed power, but the normal operating power was only 1,000 kW. Running all 9,000 kW motors continuously would have been uneconomical since motor efficiency is reduced when not operating at full load. FLSmidth's solution was the combination of head, tail intermediate, and booster drives that ran only during the predetermined demand conditions. This solution provided energy savings and reduced operating costs.


Minimize Earth Work

FLSmidth is a leader in the technology of designing Overland Conveyors with horizontal and vertical curves.

Designing Overland Conveyors with Horizontal and Vertical curves that follow the existing terrain can greatly reduce the earthwork requirements.  FLSmidth designed it's first conveyor with a horizontal curve in California USA in 1977.


Controlled Starting & Stopping

  • VFD Variable Frequency Drives
  • WRIM Wound Rotor Induction Motors
  • Fluid Couplings
  • Dodge CST

These drive components and cutting-edge technologies can provide solutions for complex drive challenges.

VFD Variable Frequency Drives

In an overland conveyor application VFDs can provide a number of benefits including smoother operation, acceleration control, different operating speeds, compensation for variables, and torque control.

FLSmidrth provided a 600 kW VFD drive for a Silver Project in Peru that required exact acceleration control because of the horizontal curves.

Wound Rotor Induction Motors

WRIMs offer controlled starts and offer higher efficiencies for conveyor running at constant speeds. 

Part of a project with many WRIMs, a 2800 kW WRIM provided the power for a 2.8 km overland conveyor in Western Australia.

Fluid Couplings

Fluid coupling can be a low cost method of providing a controlled soft start in many applications.

FLSmidth provided more than thirty 600 kW drives for a dam construction in the Phillipines.

Fluid Couplings were the best solution for this fast-track project in difficult jungle terrain.

Dodge CST

A planetary gear reducer with an integral wet clutch that is well suited for starting, accelerating and stopping overland conveyors in certain applications.  One of its unique features is the ability to provide unlimited starts per hour, torque limiting and inspection speeds.

FLSmidth chose the Dodge CST to power a 5.2 kM long overland conveyor in Peru that required 9 MW of power.


Minimize Field Work

Shop Pre-Assembly can significantly reduce field work and can reduce the construction schedule.  Here idlers are shop installed to support steel for a gold mine project in Western Australia

Design Considerations for Erection during the design process can also reduce field work and reduce the construction schedule.  FLSmidth engineers and designers have spent many hours in the field gaining experience that help reduce erection costs.

Dynamic Analysis

FLSmidth engineers are leading the industry by utilizing the most up-to-date licensed and proprietary software to meet the challenges of the most diverse and demanding applications in some of the most severe environments around the world.

Dynamic Analysis software allows the engineer to evaluate and anticipate a multitude of operating conditions and provide designs and equipment to meet these requirements.


CLICK This Link to Watch a Dynamic Analysis Video


Discrete Element Modeling (DEM)

It all starts with the design.  Discrete Element Modeling (DEM) helps the designer predict how the material will flow through the chutework and determine how the material will affect the life of the wear liners and the belt. 

Click this link to learn more about DEM and watch an actual DEM Model