Underground Coal & Longwall Conveyor Systems
Reliable, fire-resistant, and high-capacity conveyor solutions engineered for low-seam, confined, and hazardous underground environments.
Underground Coal Conveyor Belts & Integrated Systems
Underground coal mining requires specialised conveyor equipment engineered for confined spaces, strict safety regulations, and shifting seam layouts. Fenner combines the expertise of Fenner Conveyors, ACE, CPS and Belle Banne to design, manufacture, and install complete underground coal conveying networks. From high-voltage power distribution to fully automated control systems, we deliver end-to-end operational solutions engineered specifically for longwall and continuous miner applications.
Our engineering teams design and install complete operational infrastructure, spanning high-voltage incoming power distribution down to fully integrated conveyor control and automation platforms, delivering a unified turnkey system rather than standalone equipment.
Coal-Focused Quality and AS4606 Compliance
Underground coal operations demand uncompromising safety adherence. Fenner systems and FRAS conveyor belting are manufactured under rigorous QA frameworks to meet strict Australian underground mining standards, ensuring full statutory compliance, superior flame retardancy, and operational reliability.
Specialised Underground Lifecycle Support
Maximising longwall availability requires specialised maintenance capabilities. Fenner’s field teams utilise low-profile lifting equipment and custom tooling engineered explicitly for restricted roof heights, enabling safer, faster servicing where standard equipment cannot operate.
Specialised to the challenges of Coal Mining
Restricted Space and Low Install Heights
Stringent Safety and Compliance Requirements
Mobile and Relocatable Operations
As mining progresses, conveyor systems must move with the production face. Modular, mobile equipment enables faster installation and relocation, helping minimise downtime.
Water Management and Material Handling Challenges
Maintenance in Restricted Environments
Restricted Space and Low Instlal Height
Stringent Safety and Compliance Requirements
Mobile and Relocatable Operations
Water Management and Material Handling Challenges
Maintenance in Restricted Environments
Conveyor Solutions for Underground Coal Mine
- FRAS Conveyor Belting
- Electrical, Control and Power Systems
- Belle Banne Belt Handling Solutions
- Turnkey Conveyor Design & Engineering
- CPS Underground Coal Rollers
- Dewatering and Material Handling Solutions
- Conveyor Maintenance and Field Service
FRAS Conveyor Belting
Combustible coal dust and methane gas require strict fire-prevention standards underground. Fenner’s flagship FireBoss S is an AS4606-certified S-Grade FRAS conveyor belt specifically formulated for hazardous Australian underground coal environments. Unlike standard belts with surface-only treatments, FireBoss S delivers complete fire-resistant and anti-static protection throughout both the rubber covers and the internal carcass, pairing maximum safety with exceptional tear and abrasion resistance.
Electrical, Control and Power Systems
Fenner’s ACE Electrical Division designs, manufactures, and integrates specialised power and automation platforms for underground coal conveyors. Engineering complete control architecture, including explosion-proof infrastructure, PLCs, SCADA networks, and VSD/CST drive controls, ACE provides intuitive HMIs and advanced diagnostic fault-finding to streamline commissioning, simplify field troubleshooting, and increase conveyor system availability.
Belle Banne Belt Handling Solutions
Belle Banne manufactures compact, Australian-designed belt handling equipment built explicitly for tight underground quarters. Featuring low-profile belt winders, hydraulic pullers, heavy-duty clamps, flaking stations, and turning frames, Belle Banne equipment reduces manual handling hazards and dramatically speeds up belt splices, extensions, and change-outs during longwall moves.
Turnkey Conveyor Design & Engineering
Sourcing underground conveyor components from multiple vendors introduces system mismatches and fragmented project accountability. Fenner delivers complete turnkey conveyor systems through a single point of contact, managing engineering, belting, mechanical drives, electrical controls, and field installation under one roof to optimise longwall throughput and lower total cost of ownership.
CPS Underground Coal Rollers
Engineered specifically for hazardous underground coal environments, CPS supplies hybrid conveyor rollers featuring durable steel shells and FRAS-compliant end discs. Built to tight TIR tolerances to diminish vibration and improve belt tracking, CPS rollers incorporate sealed-for-life bearings and custom nylon press-to-fit housings to prevent shell-to-belt contact and minimise maintenance requirements in confined spaces.
Dewatering and Material Handling Solutions
Excess water from underground dust suppression can cause severe coal slurry carryback, spillage, and transfer chute blockages. ACE conveyor dewatering systems utilise automated cutter blades, augers, vibrating screens, and integrated PLC controls to separate free water from conveyed coal before it reaches transfer points, keeping belts clean and protecting downstream handling equipment.
Conveyor Maintenance and Field Service
Operating out of Australia’s largest dedicated conveyor service network, Fenner’s field technicians deliver specialised mechanical maintenance, belt splicing, laser alignment, and component overhauls tailored to low-clearance underground coal environments. Equipped with certified underground lifting gear and safety gear, our teams maximise uptime during routine maintenance and critical longwall relocations.
Frequently Asked Questions
FRAS stands for Fire Resistant Anti-Static. In underground coal mines, static electricity or friction-generated heat can ignite coal dust or atmospheric methane gas. FRAS belting is engineered with specialised flame-retardant and static-dissipative rubber compounds to prevent fire propagation and electrical discharge, making it a mandatory safety requirement under Australian mining regulations.
Underground coal conveyor belts in Australia must comply with AS4606, which dictates stringent testing protocols for fire resistance, drum friction ignition, electrical resistance, and full-carcass flame propagation. Fenner’s FireBoss S conveyor belting is independently tested and certified to meet or exceed all AS4606 performance criteria.
Longwall and seam-development environments often have restricted roof heights. Low-profile conveyor structures and compact drive systems fit into tight seam dimensions, reducing the need for costly rock excavation while allowing rapid installation and relocation during mining retreat or advance.
Water applied underground for dust control creates wet coal slurry, leading to spillage, belt slippage, and severe transfer point blockages. Inline dewatering systems (like ACE’s automated auger/screen systems) strip excess water off the belt before transfer points, preserving coal quality, reducing carryback, and lowering maintenance downtime.
