Engineered Conveyor Solutions for Iron Ore Mining Applications
Reliable, efficient, and high-quality conveyor systems designed for remote operations and harsh conditions
Conveyor Belts, Powering Your Operation
As a decades-old household name in Australian mining, Fenner Conveyors brings unmatched experience and technical expertise to the iron ore sector. Across the Pilbara and international mining hubs, our heavy-duty conveying systems perform reliably in the world's most severe operating environments, backed by dedicated field service teams to ensure maximum throughput and uptime.
By unifying the specialist capabilities of Fenner Conveyors, ACE, CPS, and Belle Banne, we deliver complete, custom-engineered conveyor solutions for iron ore extraction, processing, and rail load-out facilities.
Our engineering teams design and install complete operational systems—from high-voltage incoming power distribution down to fully integrated conveyor control and automation platforms.
Custom Belt Compounds for High-Abrasion Ore Types
Iron ore handling poses severe wear challenges, with hard hematite and highly abrasive magnetite rapidly degrading standard belt covers. Fenner Conveyors formulates, tests, and manufactures custom rubber cover compounds engineered specifically to resist sharp, heavy-lump ore impact and continuous gouging. Solutions like our Dynaflex steel cord and UsFlex woven-straight-warp belting provide maximum rip resistance, extended service life, and reliable throughput across high-tonnage iron ore crushing and processing circuits.
Iron Ore Lifecycle Support & Field Service
Maintaining uninterrupted uptime across high-capacity iron ore export chains requires proactive maintenance and rapid response. Fenner Conveyors provides complete lifecycle support, combining 24/7 on-site belt splicing, heavy-duty chute liner inspections, and diagnostic belt monitoring. Our specialised field crews utilise heavy-lift equipment to safely execute fast change-outs, optimise transfer point skirt alignment, and prevent catastrophic belt failures across pit, rail-loadout, and port facilities.
Specialised to the challenges of your operation
Abrasive Ore Handling and Equipment Wear
Iron ore is typically highly abrasive, sharp and hard, accelerating wear on conveyor components and reducing equipment life. Irondrive compounds, supported by breaker fabrics and unique steel cord or UsFlex designs improve belt durability and resistnace to coarse ore impacting at high-speeds.
Skirt Alignment is critical to belt life
With ore ejected from the chute at high speed, it can be a common issue that it presses the belt down, and becomes trapped against the skirting systems. Fenner Conveyors is adept at designing skirting systems with self-clearing capabilities, reducing the risk of trapped ore causing damage to the belt.
Abrasive wet ore & carryback
When wet ore is introduced to a conveyor system, the water can act as a lubricant, making it easier for ore travelling at speed through the chute to cut through the belt's top cover and risk penetrative damage to the system.
Fenner Conveyors' supplies washboxes, spiral cleaning rollers, and cleaning stations to help reduce carryback and decrease risks from wet, sharp ore.
Dust Generation and Environmental Controls
Crushing, conveying and transferring dry ores can generate significant dust, creating safety, environmental and housekeeping challenges. Conveyor sealing systems, skirting solutions and effective transfer point design help contain dust and improve workplace conditions.
High Throuput Demands
Large-scale copper concentrators require conveyor systems capable of handling substantial volumes of material around the clock. Robust conveyor components and high-capacity belt systems support continuous production and minimise bottlenecks.
Trapped Material in Pulley System
Especially common in reclaimer systems, as material hits the side of the chute exiting the reclaimer it can strike the belt at speed and bounce down onto the pulley cover side, causing premature wear to the pulley side. Effective skirting and sealing systems reduce these risks, sealing the underside of the belt or offering self-clearing designs to bounce the ore out should it enter the underside.
Energy Efficiency and Operating Costs
Rising energy costs place increasing pressure on mining operations to improve efficiency. Low rolling resistance conveyor belts and optimised conveyor system design help reduce power consumption and lower total operating costs.
Ore Spillage and Material Containment
Material spillage at transfer points can create safety hazards, increase clean-up requirements and result in product loss. Engineered transfer systems, belt cleaners and containment solutions help improve material control and maintain operational efficiency.
Remote and Harsh Mining Environments
Many copper and zinc mines operate in isolated regions where access to parts, labour and technical support can be challenging. End-to-end conveyor support, regional service networks and condition monitoring solutions help reduce downtime and improve maintenance planning.
Conveyor Solutions for Iron Ore Mining
- Electrical, Control and Power Systems
- Belle Banne Belt Handling Solutions
- Turnkey Conveyor Design & Engineering
- Dewatering and Material Handling Solutions
- Conveyor Maintenance and Field Service
- Custom Belt Compounds
- CPS (Conveyor Products & Solutions)
Electrical, Control and Power Systems
Fenner Conveyors’ ACE Electrical Division delivers integrated power and control solutions engineered for high-tonnage iron ore operations. Combining electrical and mechanical engineering expertise, ACE designs, manufactures, and tests custom conveyor control platforms, VSD/CST drive technologies, HMIs, and automated diagnostics to streamline commissioning and minimise unplanned downtime across mines, processing plants, stockyards, rail load-outs, and ports.
Belle Banne Belt Handling Solutions
Belle Banne, part of the Fenner Conveyors portfolio, supplies Australian-designed belt winders, pullers, clamps, flaking stations, and turning frames to improve safety and efficiency during conveyor installations, extensions, and repairs. Trusted across major global mining operations, Belle Banne equipment integrates with Fenner belting and field services to reduce manual handling and minimise operational downtime across copper, gold, nickel, lithium, and other non-ferrous sites.
Turnkey Conveyor Design & Engineering
Fenner Conveyors works directly with mine operators to engineer specialised rubber cover compounds paired with DynaFlex, UsFlex, and Steel Cord belt constructions tailored to specific ore hardness, lump size, and drop heights. Built to withstand severe cutting, gouging, and abrasion from hematite, coarse lump, and wet ore, our locally manufactured conveyor systems optimise throughput, increase availability, and lower total lifecycle costs from pit to port.
Dewatering and Material Handling Solutions
Managing excess moisture in non-ferrous mineral processing is critical to preventing material carryback, transfer point blockages, and accelerated equipment wear. ACE conveyor dewatering systems utilise automated cutter blades, augers, vibrating screens, and integrated PLC controls at transfer points or trippers to remove free moisture from conveyed ore streams, ensuring efficient bulk material flow while protecting downstream infrastructure.
Conveyor Maintenance and Field Service
Supported by Australia’s largest conveyor service network, Fenner provides 24/7 mechanical field services across open-pit mines, processing plants, overland lines, stockyards, rail load-outs, and port facilities. Our field technicians perform routine inspections, laser alignments, pulley overhauls, gearbox repairs, chute maintenance, and on-site belt splicing for stackers, reclaimers, crushers, and screens to ensure safe, continuous operation.
Custom Belt Compounds
Formulated to replace underperforming imported belts, Fenner’s custom-engineered rubber compounds combat severe cutting, gouging, and impact across underground, surface, and processing plant applications. By evaluating ore hardness, particle size, moisture, and conveyor geometry, our technical team matches custom cover formulations with DynaFlex, UsFlex, and Steel Cord belting to extend wear life and increase system reliability across copper, nickel, lithium, and rare earth operations.
CPS (Conveyor Products & Solutions)
CPS engineers custom conveyor pulleys, advanced bearing sealing systems, and spiral cleaning rollers designed to withstand heavy impact, high belt tension, and abrasive carryback in iron ore handling circuits. By preventing dust/moisture ingress and eliminating sticky material accumulation on return belts, CPS solutions improve belt tracking, protect bearing assemblies, and reduce overall maintenance costs across high-capacity handling systems.
Frequently Asked Questions
High-tonnage iron ore loading typically requires Steel Cord belting or heavy-duty Ply Belting equipped with impact-resistant cover compounds (such as UltraTuff). These compounds absorb heavy impact from falling lump ore and protect against gouging, tearing, and surface wear.
Overland iron ore conveyors cover vast distances and require significant electrical power. Low rolling resistance compounds, like Fenner's PowerSaver, reduce energy consumption across long conveyor runs, lowering operational costs and total carbon emissions.
Yes. Fenner delivers complete end-to-end conveyor solutions for iron ore mining, processing plants, and port loading facilities, including custom system design, heavy-duty belting, pulleys, idlers, and 24/7 field maintenance support.
Premature wear is primarily caused by sharp material drop impact at transfer points, high belt speeds, misaligned idlers, and continuous abrasion from fine ore particles. Regular diagnostic audits and proper cover compound selection significantly extend belt life.
