Cost Reduction in Belt Conveying

Conveying & Transportation

Cost Reduction in Belt Conveying

Cost-efficient and Application-oriented Design of Steel Cord Conveyor Belts for the Mining Industry
Conveyor belts in the mining industry are facing ever higher demands as regards conveying capacity, conveyor length, service life and energy efficiency. In addition to designs according to various general standards manufacturers further develop their products for better economy.
(ed. WoMaMarcel - 23/4/2015)
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The cause for the indentation rolling resistance of a conveyor belt resides in the viscoelastic material behavior of the bottom cover made of rubber. The indentation rolling resistance results from the loss deformation of the bottom cover of a conveyor belt when running over an idler.

A buildup, which is configured in the shape of the so-called buildup bulge can be recognized while running over an idler of the bottom cover because of the incompressibility of the rubber [6] (Fig. 3).

Fig. 3: Loss deformation of the bottom cover of a belt when running over an idler. (Picture: ©Wennekamp [6])

The R&D department of Contitech is continually engaged in the further development of extra low loss conveyor belts with the rubber compound “XLL” (XLL = eXtraLowLoss). Thus, for example, Fig. 4 shows a 28% reduction in the required drive power from approx. 11 500 kW down to 8280 kW for a 5000 m long horizontal conveyor with a conveying capacity of 30 000 metric t/hr at conveying velocity of 7.5 m/s when a modern XLL conveyor belt is used compared to the conveyor belt with the bottom cover made of a standard commercially available compound.

Fig. 4: Belt with extra low loss bottom cover "XLL" vs. standard commercially available conveyor belt – 28% reduction of the required drive power for the long-distance conveyor 5000 m in length with a conveying capacity of 30 000 metric t/hr. (Picture: ©ITA Leibniz University Hannover)

This means for the example in Fig. 4 b, that:

  • The emissions of CO2 can be reduced by 32 523 metric tons/year (assuming the CO2 emission coefficient for lignite of 1.153 kg/kWh and 24/7-operation per year consisting of 365 days)
  • With the 3220 kW energy saved, up to 8955 private households can be supplied per year (assuming an average power consumption of one German household of 3150 kWh per year).
  • €1.41 million/year can be saved by a lignite power plant (assuming the average electricity generation costs of €0.05/kWh in Germany).

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