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And with item stacking on belts, yellow works very fine.
That said, is there anything wrong with the upgrade planner and using bots to do the replacing?
Red is a 100% improvement over yellow. Green is another 100% over red while blue is only 50% over red.
Blue costs iron- A lot of iron to be sure, at 31.5 iron each, but, Iron is plentiful on Nauvis at least, by the time you can make blue belts you can probably automate them just fine. Green ones cost Tungsten though, which you're going to be more limited by since you'll also want it for making science packs and artillery shells and railgun turrets n whatnot.
Generally I'm with Strategic sage, You probably shouldn't be replacing EVERY belt with blue(or green), You should, if playing 'efficiently'/'optimally' be using lower rank belts where better belts aren't needed... You don't need blue or green belts to transport 0.5 items/second that you might get out of something that crafts very slowly for example, just use yellow at that point.
And there is also the fact that combining 2 belts into 1 or splitting 1 into 2 is simple, while 1 or 2 to 3 (or vice versa) is messy. A yellow->red->green sequence makes sense, with blue just not fitting in well. I have almost always only used blue belts where the extra speed is really necessary, but am expecting to make greater use of green.
It depends on rates - like red circuits take 4 copper wire per circuit so until you get upgraded stack inserters you are going to want to use a faster input belt than output belt.
Yellow belts just aren't worth the hotkey space. Sure, red belts are technically more expensive but it's entirely negligible. Blue start getting a little pricier for less benefit - and having two different underground belts can be very useful so I want to keep red around for that anyway.
Green is for very specific instances rather than taking stuff all the way across the factory.
Although the BIG thing you're likely to want to replace from Vulcanus isn't belt related at all.
Or rather, to use it best you may want to rip most of the belts out of your factory
When I really sit down and do calculations I try to use only the belts I need and then yellow ones crop up. The end game has changed now though with stack inserters (are they called that?) and the quality mechanics. I'm looking forward to getting there.
For main belts though you will get much more gain using stack inserters rather than upgrading the belt to green. One big downside also is that you can only ship half stacks of the green stuff in one rocket so getting a good amount of them to another planet is more difficult.
PS
I am really thinking about moving some science production on the Vulcanus too, since it will be cheaper and easier then to move huge about of Calcite
Do it. The purple science packs (the ones that use rails) are really easy to make in bulk in Vulcanus due to all the stone you get as a lava byproduct. Doubly so if you import some electromagnetic labs to make the circuits and advanced circuits. With those and the metalurgic science, as well as the basic 3 science packs, Volcanus alone will be able to run several infinite techs. (Mining productivity, Steel productivity, and low density structure productivity to name 3 that do not even require space or military science.)
That can be really helpful if one of your space platforms has an issue and shipments to Navius stop.
But by the time green belts are available and you're absolutely eating iron for purple and yellow science packs it's not really a big deal