PUSHING THE BOUNDARIES OF ENGINEERING PERFORMANCE
The Flyingbelt is a remarkable example of engineering prowess and a more costeffective, efficient and environmentally-friendly conveying solution compared to conventional truck transportation. In Brazil, one just started running after a successful collaboration between Semperit and Agudio.
For the expansion of its Barroso cement plant in Minas Gerais, Brazil, Lafarge-Holcim was seeking an innovative conveyor solution which would withstand a demanding production capacity without wreaking havoc on the surroundings. Relying on our long-standing technical expertise and product flexibility, LafargeHolcim and Agudio chose Semperit as their partner of choice to develop a custom conveyor belt for this outstanding project. It involved the construction of a loading and unloading station, designed by Agudio, and a single 15-kilometre-long belt tailored by Semperit to meet the specific performance, cost and environmentconscious requirements of the customer. The longest Flyingbelt in the world was borne out of exemplary teamwork.
Semperit is the only conveyor belt manufacturer in the world producing such a complex belt.
Barroso Project in Numbers
|Location||Minas Gerais, Brazil|
|Transported Material||7.2 km from limestone quarry to cement works|
|Installation height||Up to 36 m above ground level|
|Conveyor belt length||Approx. 15 km|
|Conveyor belt width||1,200 mm|
|Transport capacity||1,500 tph|
|Track ropes||55 mm|
|Number of towers||18|
|Number of intermediate anchors||3|
|Motors nominal power (belt)||3 x 615 kW|
|Motors nominal power (maint)||4 x 30 kW|
|Speed of belt||4.00 m/s|
The Concept of the Flyingbelt
Fly with a conveyor belt over any obstacle by combining the advantages of a conveyor belt system and a material ropeway construction.
- Belt conveyor suspended on four track ropes
- Easy installation and low operation costs of a belt conveyor
- High versatility to overcome the most difficult surroundings
7.2 km & 36 m above ground level
Metaltrans from Semperit
7,2 km long and 36 m high
Standing on a ropeway 7,2 km long and up to 36 m high, this unique conveyor system transports 1,500 tph of limestone and clay from the quarry to Lafarge-Holcim’s cement plant, while crossing valleys and a dense vegetation without ever touching the ground.
Semperit’ Metaltrans belt is the perfect solution for the unusual structure. It has a unique steel carcass construction with a low elastic modulus which allows for optimum elongation. This feature ensures that the belt is supple and can stretch out enough to fit the deformation imposed by the very small radius curves on the pylon stations supporting the Flyingbelt.
- Tailored belt design requiring elaborate, structural engineering calculations and planning to fit unique Flyingbelt construction
- Production of 15 km of specialty Metaltrans conveyor belt
- Installation and positioning of several bits of belt in a record 75 days and 22 splices by six Sempertrans Service technicians 30 m above ground