INNOVATION INTELLIGENCE_proof 19/07/2016 13:44 Page 2
INNOVATION INTELLIGENCE
consumption and CO2 emissions. The Agudio
Flyingbelt demonstrated it was the best choice
from all the perspectives against traditional
technologies such as trucks or conveyors.
For example, comparing the Flyingbelt with
trucks. To carry the 1,500 t/h would require
loading, running and offloading more than 40
trucks, one every 90 seconds. In the mine,
bigger trucks (more expensive) are used that
require larger roads to always be in good
condition (other costs), with significant fuel
consumption and CO2 emissions.
In Barroso, to transport 3.5 Mt/y of limestone
over a driving distance of 25 km means about
8,000 t of CO2. With the Flyingbelt the
connection between the quarry and the
production plant is straight over 7,2 km, and the
capacity is 1,500 t/h. The average energy
consumption is 1,400 kWh, so taking into
consideration the IEA composite electricity/heat
factor for Brazil, this means 325 t of CO2 – a
reduction of more than 95%!
Also in terms of environmental impact the
Flyingbelt has enormous advantages. The
system is a suspended line with no need for
deforestation, deviation of rivers and huge
earthworks, whereas the use of haul trucks
would have required the construction of a
dedicated road (three times longer) with all the
implications of safety, noise and dust.
“It is clear why LafargeHolcim, seeking an
innovative and low impacting transportation system,
chose the Agudio Flyingbelt,” says Cattaneo.
Agudio engineers faced several challenges
during the design of such system: capacity,
availability, reliability, need of a suspended
system, easy and reduced maintenance, no
spillage of material, and and low noise.
The result is a hybrid between ropeway
technology and belt conveyors, the longest
Flyingbelt in the world, one single 15 km rubber
belt , suspended by 18 towers and running at 4
m/s to bring the raw material to the cement
plant.
Cattaneo states: “the proof the Flyingbelt
technology over long distances opens new
perspectives and new ways of designing
transportation systems from mines to the
production plants with reduced costs and
environmental impact.”
supporting structures than a standard
conveyor belt with earthworks and visual
impact considerably reduced
n Flexible route design – can adapt to the most
problematic terrains: overcome obstacles
with a reduced number of supports, only
where necessary and at variable distances up
to 1,000 m
n Easy integration – can be integrated in a
longer conveyor with traditional overland
conveyors on the ground without material
transfer points
n Reduced capex – components are standard
conveyor belt parts and modular parts
specifically designed with simple and rapid
assembly procedure, thanks to a special
installation vehicle running on the tracking
ropes
n Reduced opex and maintenance costs – power
consumption is reduced compared to other
solutions and maintenance requirements
negligible thanks to the use of long life
components
n Energy efficiency and CO2 emissions –
compared with standard transportation by
truck, Flyingbelt is much more efficient,
power requirements are very low and in some
cases even positive (for downhill
transportation)
n Low noise – the Flyingbelt is very silent
thanks to low noise idlers. IM
Flyingbelt
advantages
Flyingbelt is a
patented raw
material
transportation
system combining
the advantages of a
conveyor belt system
with a material
ropeway system
such as:
n Low environmental
impact – has
considerably less
Cost-effective mining
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AUGUST2016 | International Mining 85