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This article provides a comprehensive technical overview of heavy-duty apron feeders, covering structure, working principles, specifications, advantages, applications, and real-world project cases—helping mine owners and engineers select the right feeder for their operations.
A heavy-duty apron feeder is a mechanical device that continuously conveys loose or block materials. Featuring a series of overlapping steel aprons mounted on robust chains, it is capable of handling extremely harsh operating conditions—high temperature, high moisture, heavy impact, and outdoor exposure.
Unlike vibrating feeders or belt feeders, an apron feeder:
Handles very large lump sizes (up to 1100 mm)
Endures high silo pressure (up to 10 m)
Operates reliably under heavy impact and abrasion
Maintains stable output even with sticky, wet, or high-density materials
Apron feeders are typically positioned beneath dump hoppers, coarse ore bins, or silos, delivering regulated feed to primary crushers or downstream conveyor systems. In a mineral processing flowsheet, they ensure stable, controlled material flow—crucial for maintaining throughput and protecting downstream equipment from overload.
A well-designed apron feeder integrates mechanical strength, smooth motion, safety, and maintainability. Xinhai’s apron feeders incorporate advanced engineering features across all major assemblies.
The drive system includes:
High-torque motor (15–45 kW)
Heavy-duty reducer
Torque arm and drive sprocket
Frequency inverter for adjustable speed control
Variable-frequency drive (VFD) allows precise adjustment of feed rate from 0.02 to 0.1 m/s, providing operators with flexible process control for different ore types and plant conditions.
The chain and apron assembly is the heart of the feeder.
Key features:
Apron plates made from ≥20 mm high-strength alloy steel
Single or double arc overlapping structure prevents material leakage
Engineering-grade mechanical chains with:
High tensile strength
Minimal pitch deviation
Smooth operation
No lubrication required due to special design
High wear resistance and excellent impact tolerance
Unlike lighter feeders, Xinhai’s apron plates maintain full contact and overlap during operation, preventing spillage even under shock loads or large lump feeding.
Supporting components use 40Mn2 or 50Mn materials for high mechanical strength.
Carrying rollers distribute the load evenly
Supporting rollers ensure stable chain motion
Main shaft design withstands heavy impact
Rollers and chains feature full-lifecycle lubrication, reducing maintenance frequency and extending service life.
Xinhai uses a rear tensioning mechanism with composite spring shock absorption.
Benefits:
Automatically compensates chain elongation
Reduces vibration and impact force
Ensures stable chain tracking
Extends component life
The heavy-duty frame supports high loads and continuous operation in demanding environments:
Working temperature ≤ 400°C
Installation angle ≤ 20°
Resistant to moisture, dust, and outdoor exposure
This robust structure allows Xinhai apron feeders to perform reliably at mines, cement plants, and metallurgical facilities.
Xinhai’s GBZ series apron feeders are engineered for a wide range of capacities and ore types.
Capacity: 110–900 t/h
Maximum feed size: up to 1100 mm
Suitable for lump ore with particle size up to 50% of apron width
This makes the feeder ideal for primary crusher feeding in large-scale open-pit and underground mining operations.
Apron width: 1200–2400 mm
Chain speed: 0.02–0.1 m/s (VFD adjustable)
Different speed settings allow precise control of throughput based on ore hardness, moisture, and downstream equipment capacity.
Motor power: 15–45 kW
High operational efficiency due to stable mechanical transmission
Ideal for continuous, long-cycle operation
Material temperature ≤ 400°C
Silo pressure up to 10 m
Horizontal or inclined installation (≤20°)
These specifications make Xinhai apron feeders suitable for harsh industrial environments where other feeders fail.
Xinhai integrates advanced engineering design, robust materials, and global EPC expertise to deliver apron feeders with superior performance.
Handles ore density ≤ 2400 kg/m³
Maximum single block weight ≤ 500 kg
Stable performance under high bin pressure
This capacity ensures uninterrupted feeding even with large, heavy, or abrasive materials.
Xinhai’s apron feeder is designed for durability:
Arc-overlapping plates absorb impact
Rollers and chains made of 40Mn2/50Mn for maximum toughness
Engineering machinery chains provide:
High load resistance
Smooth motion
Long service life
Low maintenance
The feeder maintains continuous operation even with highly abrasive and blocky ore.
Xinhai apron feeders are suitable for:
Coarse ore (gold, copper, lithium, iron, base metals)
Fine granular materials
High-temperature feed
Sticky or wet ore
Outdoor or dusty environments
Support for horizontal or inclined installation enables flexible plant layout.
Full-lifecycle lubrication for chains and rollers
Simple structural layout for convenient inspection
High reliability reduces downtime
Fewer lubrication points and longer intervals
For mines prioritizing continuous production, these advantages directly translate into operating cost reductions.
Heavy-duty apron feeders are widely used across various industries:
Ideal for:
Gold mines
Copper mines
Lithium (spodumene) mines
Iron ore mines
Polymetallic mines
They provide controlled feed from coarse ore bins to jaw crushers or gyratory crushers.
Stable feeding of limestone to crushers and kilns
Suitable for abrasive raw materials
Hot slags
Calcined materials
Sinter feed
Ability to handle materials up to 400°C makes apron feeders essential in smelting and metallurgical plants.
Xinhai apron feeders have been successfully applied in multiple large-scale mining projects worldwide.
4 units installed : 3 × GBZ120-8 , 1 × GBZ200-10
Ensured stable feeding and increased crusher efficiency under high-pressure bin conditions.
1 × GBZ120-5
Significant improvement in ore handling stability
Reduced downtime and maintenance
1 × GBZ120-6
Excellent performance in damp and high-moisture ore environments
1 × GBZ180-9
Enhanced durability under extremely abrasive copper ore conditions
These global cases demonstrate Xinhai’s strong engineering capability and reliable equipment performance in diverse mining conditions.
Choosing the right apron feeder requires evaluating several key factors:
Density
Lump size
Abrasiveness
Moisture and stickiness
Required t/h output
Maximum bin pressure
Crusher feed requirements
Available footprint
Inclination angle
Maintenance access points
Motor power
VFD compatibility
Efficiency under continuous loading
Xinhai Mining offers:
Equipment manufacturing
Mineral processing testwork
Customized feeder selection
Complete EPC solutions (Engineering, Procurement, Construction)
Xinhai Mining stands out due to:
Over 20 years of mineral processing equipment experience
Global EPC solution provider
Custom apron feeder design for different ores
Proven reliability in African, Central Asian, and Asian projects
Robust after-sales service and technical support
Whether for greenfield mining projects or plant upgrades, Xinhai provides safe, efficient, and long-lasting apron feeder solutions tailored to client needs.
Conclusion
Building a new plant? Replacing that tired old feeder that keeps snapping? Or just done gambling on the cheapest quote? Xinhai Mining can draw it up properly, size it so it actually fits your tonnage, and even handle the whole EPC headache if you want. Just say the word — we’ve done it plenty of times before.
+86 13811510145