A-Z Conveyor Lifecycle Service for a 120 Mtpa Iron Ore Mine

From Belt Supply and Installation to Smart Monitoring, Predictive Maintenance and Local Service Support

A-Z Conveyor Lifecycle Service for a 120 Mtpa Iron Ore Mine

Core Achievements

End-to-end support for a 120 Mtpa iron ore project

BOTON participated in the conveyor system development of a world-scale iron ore project with a planned annual capacity of 120 million tonnes, supporting key ore conveying operations from mine production to downstream logistics.

Smart monitoring under extreme terrain conditions

Smart monitoring equipment was deployed for long-distance, steep-slope and high-load conveying conditions, helping shift maintenance from reactive repair to risk-based, predictive management.

Localized service and talent development

BOTON established on-site service capabilities and supported local technical training through BOTON Academy, helping build a faster response network and long-term maintenance capability in Guinea.

BOTON provided an A-Z conveyor lifecycle service solution for the Simandou iron ore project in Guinea, covering belt supply, installation, pulley lagging, commissioning, monitoring, maintenance and operational support.

The project required reliable ore conveying across high-altitude mountainous terrain, long-distance transport routes and demanding construction conditions. BOTON supported both northern and southern mining blocks through high-strength conveyor belt products, smart monitoring systems and localized service resources.

Key Facts

  • Industry: Iron Ore Mining
  • Application: Long-Distance Ore Conveying
  • Site: Simandou Iron Ore Mine, Guinea
  • Planned Capacity: 120 million tonnes per year
  • Production Start: November 11, 2025
  • Operating Conditions: High-altitude mountain terrain, long-distance routes, steep gradients, heavy-duty loads and large day-night temperature differences
  • Service Model: A-Z end-to-end conveyor lifecycle service covering design, production, supply, installation, monitoring, maintenance and operation support
  • Northern Blocks: Approximately 15 km of high-strength steel cord conveyor belts, including ST5400 and ST6300 specifications
  • Processing Area: Approximately 8 km of flexible conveyor belts for ore processing and transfer applications
  • Southern Blocks: 28 km of conveyor belts supplied in cooperation with a European partner for long-distance mine-to-port transport
  • Key Technologies: Smart monitoring equipment, predictive maintenance, localized technical team and 1-hour service response network
Key Facts

Project Challenges

Extreme terrain and conveying conditions

The project operates in high-altitude mountainous terrain with long-distance routes, steep gradients and heavy-duty ore loads. These conditions place high demands on belt tensile strength, dynamic performance, splice reliability and overall system stability.

High cost of unplanned downtime

For a project of this scale, longitudinal tearing, splice issues or fatigue-related belt damage can lead to major production disruption. The conveying system required continuous monitoring and early risk detection to reduce the likelihood of unexpected shutdowns.

Difficult construction and service environment

Large day-night temperature differences, distinct wet and dry seasons, limited infrastructure and remote site conditions increased the complexity of installation, commissioning and maintenance. The project also required a service model capable of fast on-site response and strong technical judgment.

BOTON Solution

BOTON Solution

A-Z conveyor lifecycle service

BOTON provided end-to-end service support covering conveyor belt design, production, supply, installation, pulley lagging, commissioning, maintenance and operational support. For the northern blocks, BOTON supplied high-strength ST5400 and ST6300 steel cord conveyor belts for heavy-load mining applications, along with flexible belts for ore processing sections.

Smart monitoring and predictive maintenance

Smart monitoring equipment was deployed in the southern mining area to track longitudinal tear risks and splice condition in real time. By using operating data for early warning and maintenance planning, the service model shifted from post-failure repair to predictive maintenance.

Localized technical support and training

BOTON deployed professional technical teams on site to support installation, commissioning and lifecycle maintenance. Through local service resources and BOTON Academy training programs, the project built a localized technical support network designed to improve response speed and long-term service capability.

Project Gallery

Explore the conveyor belt supply, smart monitoring and lifecycle service behind BOTON’s support for the Simandou iron ore project.

Related Products

Steel Cord Conveyor Belt Solutions

Steel Cord Conveyor Belt Solutions

Fabric Conveyor Belts

Fabric Conveyor Belts

Autoscan

Autoscan

Vision Advanced

Vision Advanced

"*" indicates required fields

This field is for validation purposes and should be left unchanged.
Name*
Consent*

 

Let's Talk!

Whether you have a question about our services, a project idea, or just want to say hello, we're here to listen.

Desktop mode detected.
Please switch to mobile view for a better browsing experience.