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Aramid in Conveyor Belts - A strong energy-saving solution
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Arnhem, 12 March 2009
Aramid in conveyor belts
A strong energy-saving solution
Ko Arts
Technical Sales Manager Teijin Aramid BV
What is (para)aramid
• Aramid fibers are a class of heat-resistant and strong synthetic fibers*
*Wikipedia
Energy-consuming factors in long conveyor
belts • Belt Weight
• Indentation Rolling Resistance
Reinforcement materials
• Conventional materials:
• Steel (cords and fabrics)
• Textile (polyester or polyamidefabrics)
• Combination of positive properties (Best of two worlds)
• Para-aramid (straight warp and cord fabric)
Reinforcement materials
Textile Steel
Common Aramid carcasses
Cordfabric
• Straight Aramid cords
• Transversal binder threads
• Thin carcass
• Good troughability
Straight-Warp-fabric
• Straight Aramid cords
• Transversal Nylon cords on each side
• Thicker carcass
• Good impact and slit resistance
PA 6.6 PET St Ar
BS (N/mm2) 910 1100 2360 2710
Spec Dens
(Kg/dm3)
1.14 1.12 7.85 1.44
Tenacity (mN/tex) 780 820 330 1940
Lase 1% (mN/tex) 30 80 150 440
EAB (%) 20 13 2.0 3.5
E-mod (GPa) 7 14 180 70
Melting Point (oC) 260 260 1540 >500
Continous use (oC) 180 180 800 300
Heat resistance
(48h, 200 oC) (%)
45 55 100 90
Heat shrinkage
(160 oC) (%)
4 3 0 0
Properties reinforcement material PA 6.6 PET St
BS (N/mm2) 910 1100 2360
Spec Dens
(Kg/dm3)
1.14 1.12 7.85
Tenacity (mN/tex) 780 820 330
Lase 1% (mN/tex) 30 80 150
EAB (%) 20 13 2.0
E-mod (GPa) 7 14 180
Melting Point (oC) 260 260 1540
Continous use (oC) 180 180 800
Heat resistance
(48h, 200 oC) (%)
45 55 100
Heat shrinkage
(160 oC) (%)
4 3 0
Recommended take-up lengths
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
Polyamid 6.6 Polyester Aramid RE Aramid LE Steelcord
HE
Steelcord
Belt Types
Elo
ng
ati
on
/ t
ake-u
p len
gth
in
%
Elongation min.
Elongation max.
Conveyor take-up
Effect on weight compared to steelcord belt
Belt KW-01 KW-03
Belt width (mm) 1200 1050
Rating (St) St1400 St900
Belt covers [mm] 6+4 6+4
Rubber 80%NR/
20%SBR
80%NR/
20%SBR
Belt mass [kg] 31.7 22.6
Rating (Ar) DPP1400 DPP900
Belt covers [mm] 6+4 6+4
Rubber 80%NR/
20%SBR
80%NR/
20%SBR
Belt mass [kg] 18.8 15.9
Conv data: The Optimum collieries, Mpumalanga province, Republic of South Africa
Effect of reduced weight on energy
consumption Belt KW-01 KW-02 KW-03 KW-05
Capacity [MTPH] 2.200 2.200 1.800 1.800
Installed Power [kW] 1.890 945 945 945
Speed [m/s] 5,75 5,75 5,75 5,75
Belt width [mm] 1.200 1.200 1.050 1.050
Belt covers [mm] 6+4 6+4 6+4 6+4
Rubber 80%NR/ 20%SBR 80%NR/ 20%SBR 80%NR/ 20%SBR 80%NR/ 20%SBR
Length [m] 5.280 2.700 3.720 3.304
Elevation change [m] 26.5 3.3 -13.4 -5.05
Rating (Steel) St1400 St1400 St900 St900
Belt mass [kg] 31.7 31.7 22.6 22.6
Power req empty (kW) 505.2 194.8 241.1 295.5
Power req loaded (kW) 1497.8 508.6 464.8 690.6
Rating (aramid) DPP1400 DPP1400 DPP900 DPP900
Belt mass [kg] 18.8 18.8 15.9 15.9
Power req empty (kW) 294.7 (-/-41.7%) 113.6 (-/- 41.7%) 164.3 (-/- 31.9%) 201.4 (-/- 31.9%)
Power req loaded (kW) 1266.0 (-/- 15.5 %) 423.6 (-/- 16.7%) 397.1 (-/- 14.6%) 599.8 (-/- 13.2%)
Conv data: The Optimum collieries, Mpumalanga province, Republic of South Africa
Examples
• Tunisian Phosphate Mines:
• 10 years succesful operation
• Belt lengths 3 and 4 km
• Maritsa Istok-2
• 10% energy savings obtained
• In operation since 2000
• Belt lengths 2.5 and 5.6 km
Energy-consuming factors in long conveyor
belts • Belt Weight
• Indentation Rolling Resistance
Indentation Rolling Resistance
• Area W
• Energy loss per hysteresis
cycle
• Multiple idlers cause high
loss
• Use energy optimized
compounds
Sulfron® 3001
• SULFRON is a rubber ingredient based on Twaron®
fibers, which are modified by chemicals to activate the
surface of the p-Aramid fibers
• SULFRON is intended for dynamic rubber applications
Sulfron® effect
0 10 20 30 40 50 60 70 80 90 100 110
0,000
0,020
0,040
0,060
0,080
0,100
0,120
0,140
0,160
0,180
0,200
0,220
0 10 20 30 40 50 60 70 80 90 100 110
0,000
0,020
0,040
0,060
0,080
0,100
0,120
0,140
0,160
0,180
0,200
0,220
0 10 20 30 40 50 60 70 80 90 100 110
0,000
0,020
0,040
0,060
0,080
0,100
0,120
0,140
0,160
0,180
0,200
0,220
0 10 20 30 40 50 60 70 80 90 100 110
0,000
0,020
0,040
0,060
0,080
0,100
0,120
0,140
0,160
0,180
0,200
0,220
los
s f
ac
tor
(ta
n
)
Tempearture (oC)
CMP1 (Control)
Dynamic strain: 2 %
Frequency: 10 Hz
CMP2 (1,5 Phr S3001)
CMP3 (2,0 Phr S3001)
CMP4 (3,0 Phr S3001) • Reduction of tanδ
• Improving hysteresis
Maximum Rolling Coeffecient
• Jonker’s Theory
Effect of Sulfron ® 3001 on energy
consumption Belt KW-01 KW-02 KW-03 KW-05
Capacity [MTPH] 2.200 2.200 1.800 1.800
Installed Power [kW] 1.890 945 945 945
Speed [m/s] 5,75 5,75 5,75 5,75
Belt width [mm] 1.200 1.200 1.050 1.050
Belt covers [mm] 6+4 6+4 6+4 6+4
Length [m] 5.280 2.700 3.720 3.304
Elevation change [m] 26.5 3.3 -13.4 -5.05
Rating (Steel) St1400 St1400 St900 St900
Belt mass [kg] 31.7 31.7 22.6 22.6
Rubber 80%NR/ 20%SBR 80%NR/ 20%SBR 80%NR/ 20%SBR 80%NR/ 20%SBR
Power req empty (kW) 505.2 194.8 241.1 295.5
Power req loaded (kW) 1497.8 508.6 464.8 690.6
Rubber 80%NR/ 20%SBR
+ 2phr Sulfron
80%NR/ 20%SBR
+ 2phr Sulfron
80%NR/ 20%SBR
+ 2phr Sulfron
80%NR/ 20%SBR +
2phr Sulfron
Power req empty (kW) 438.4 (-/-13,2%) 169,6 (-/- 12,9%) 209,3 (-/- 13,2%) 256,6 (-/- 13,2%)
Power req loaded (kW) 1321,8 (-/- 11,8 %) 445,5 (-/- 12,4%) 394,4 (-/- 15,1%) 596,2 (-/- 13.7%)
Conv data: The Optimum collieries, Mpumalanga province, Republic of South Africa
Compound changes
Power Savings [%]
Belt KW-01 KW-02 KW-03 KW-05
NR/SBR 0 0 0 0
NR/SBR incl 2 phr Sulfron 11.8 12.4 15.1 13.7
NR/BR 14.7 15.5 19.0 17.1
NR/BR incl 2 phr Sulfron 26.9 28.4 34.7 31.3
Combined effect: Aramid carcass + Sulfron Belt KW-01 KW-02 KW-03 KW-05
Capacity [MTPH] 2.200 2.200 1.800 1.800
Installed Power [kW] 1.890 945 945 945
Speed [m/s] 5,75 5,75 5,75 5,75
Belt width [mm] 1.200 1.200 1.050 1.050
Belt covers [mm] 6+4 6+4 6+4 6+4
Length [m] 5.280 2.700 3.720 3.304
Elevation change [m] 26.5 3.3 -13.4 -5.05
Rating (Steel) St1400 St1400 St900 St900
Rubber 80%NR/ 20%SBR 80%NR/ 20%SBR 80%NR/ 20%SBR 80%NR/ 20%SBR
Belt mass [kg] 31.7 31.7 22.6 22.6
Power req empty (kW) 505.2 194.8 241.1 295.5
Power req loaded (kW) 1497.8 508.6 464.8 690.6
Rating (aramid) DPP1400 DPP1400 DPP900 DPP900
Rubber 80%NR/ 20%SBR
+ 2phr Sulfron
80%NR/ 20%SBR
+ 2phr Sulfron
80%NR/ 20%SBR
+ 2phr Sulfron
80%NR/ 20%SBR +
2phr Sulfron
Belt mass [kg] 18.8 18.8 15.9 15.9
Power req empty (kW) 255.7 (-/-49.4%) 98.9 (-/- 49.2%) 142.6 (-/- 40.8%) 174.8 (-/- 40.8%)
Power req loaded (kW) 1120.6 (-/- 25.2 %) 371.6 (-/- 26.9%) 335.7 (-/- 27.8%) 517.3 (-/- 25.1%)
Conclusions
• Para-aramid carcasses is a valuable candidate for carcass-material for
long conveyor belts
• Low weight -> reduced energy-consumption -> lower CO2 emission
• Proven principle
• Only small amounts of Sulfron added to compound give low rolling
resistance -> reduced energy -> lower energy
• Sulfron testing is ongoing
• Combination of both gives increased energy-savings
Thank you for your attention
Ko Arts
Teijin Aramid BV
Ko.arts@teijinaramid.com
+31 88 2689133
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