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