INNOVATION INTELLIGENCE_proof 19/07/2016 13:44 Page 1
INNOVATION INTELLIGENCE
Stefano Cattaneo – Sales and
Marketing Manager Material
Transportation Systems, Leitner,
talks to John Chadwick about the
successful commissioning of this
7.2 km system
The Agudio Flyingbelt masterpiece
he LafargeHolcim cement plant in Barroso
came online in May and is the most
modern and efficient in Brazil. Leitner was
one of the main suppliers and made a significant
and very innovative contribution to the success
of the project.
Leitner Group is well experienced in facing
challenges: transporting people on top of the
mountains, aerial connections over congested
urban areas, moving millions of cubic metres of
concrete in a fast and efficient way to build the
biggest dams in the world, but the challenge
recently achieved is certainly one of the biggest
in the material transportation sector: the
longest aerial conveyor belt suspended on
ropes.
The Flyingbelt, built in about two and a half
years by a team of 200 people: engineers,
technicians, and others that worked hard to
T
design and erect about 2,000 t of components,
60, 000 m of steel ropes, 25,000 idlers and
15,000 m of steelcord belt, was tested for six
days before the hand over to LafargeHolcim.
At the end of the performance test the system
fully achieved the capacity of 1,500 t/h of
limestone, with a maximum energy consumption
of 1,700 kWh.
During the tests several “extreme” operating
conditions (accelerations, shut-down, +20%
overcapacity, etc) were simulated and the result
was the confirmation that the Flyingbelt technology
is fully applicable on long distances without any
problem of material stability on the belt.
The Flyingbelt is part of a longer chain
connecting the limestone mine to the cement
plant, including traditional conveyor belts and
equipment and the tests demonstrated that
thanks to a comprehensive control system
The performance tests of the Flyingbelt from
Agudio, a brand of Leitner ropeways dedicated
to material transportation system, have been
completed and from May the system has been
operating for the LafargeHolcim cement plant in
Barroso, Brazil.
managing signals from the Flyingbelt itself and
from the other equipment, it is possible to
transport the quantity of raw material required
at the cement plant in fully automated mode.
The Barroso cement plant has been designed
to the highest standards in terms of
environmental protection, energy efficiency, CO2
emissions and the choice of the method of raw
material transportation has been crucial.
LafargeHolcim engineers undertook detailed
analysis in order to identify the best solution in
terms of investment cost, operational costs,
environmental impact, noise, energy
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84 International Mining | AUGUST 2016