Detailed Introduction of Steel Cord Conveyor Belt

1. What is a Steel Cord Conveyor Belt?

A steel cord conveyor belt is a crucial component in the field of material handling and transportation. It consists of a flexible belt made of rubber or other polymeric materials with high-strength steel cords embedded within. These steel cords provide the belt with exceptional tensile strength, enabling it to carry heavy loads over long distances efficiently and reliably.

2. Structure and Composition

The structure of a steel cord conveyor belt is carefully engineered. The steel cords, usually made of high-quality steel alloys such as carbon steel with a tensile strength ranging from 1500 N/mm² to 4000 N/mm², are arranged in a specific pattern within the rubber matrix. The rubber compound used not only serves to protect the steel cords from corrosion and wear but also provides flexibility and adhesion. The typical thickness of the rubber top cover can vary from 4 mm to 8 mm for light-duty applications and up to 12 mm or more for heavy-duty and abrasive material handling. The bottom cover thickness is generally around 2 mm to 6 mm. Additionally, the belt may have various layers, including a top cover for abrasion resistance and a bottom cover for better grip on the conveyor rollers.

3. Key Features and Advantages

• High Tensile Strength:

  The steel cords give      the belt the ability to withstand extremely heavy loads. For example, a      standard steel cord conveyor belt can handle tensile forces up to several      thousand kilonewtons, making it suitable for transporting bulk materials      such as ores, coal, and aggregates in mining, power plants, and ports.

• Long Service Life:

  Thanks to the      durability of the steel cords and the quality of the rubber, the conveyor      belt has a long lifespan. Under normal operating conditions, it can last      for several years without significant degradation. The abrasion resistance      of the rubber cover, measured in terms of volume loss per unit of distance      traveled, is typically in the range of a few cubic centimeters per million      meters for well-designed belts.

• Low Elongation:

  It exhibits minimal      elongation under load. The elongation rate of a good quality steel cord      conveyor belt is usually less than 0.2% under maximum rated load, ensuring      stable and accurate material conveyance without significant sagging or      stretching, which is vital for maintaining the integrity of the conveyor      system.

• Good Flexibility:

  Despite its high      strength, the belt can be bent around the conveyor pulleys and idlers with      relative ease. The minimum pulley diameter that the belt can wrap around      without excessive stress on the steel cords is typically specified based      on the cord diameter and construction. For example, for a certain type of      steel cord with a diameter of 5 mm, the minimum pulley diameter might be      around 300 mm.

4.Applications

• Mining Industry: Used to transport mined      ores and minerals from the extraction site to processing plants or      stockpiles. In a large-scale copper mine, a steel cord conveyor belt might      be required to carry several hundred tons per hour of ore over a distance      of several kilometers.

• Power Generation: For conveying coal to      boilers in thermal power plants. A typical power plant conveyor system      might use a belt with a width of 1.2 meters to 2 meters and a capacity to      transport 1000 tons to 5000 tons of coal per day.

• Port and Bulk Material      Handling:      Facilitates the loading and unloading of various bulk commodities in ports      and terminals. In a busy port, conveyor belts can handle containerized      cargo, grains, and other bulk goods with a throughput of thousands of tons      per hour.

• Cement and Aggregate      Industry:      Transports raw materials and finished products in cement plants and      aggregate quarries. A cement plant conveyor might need to handle      limestone, clay, and cement clinker with different particle sizes and      weights.

5. Installation and Maintenance

• Installation: Proper installation is      crucial. The belt must be spliced correctly, usually using mechanical      fasteners or vulcanization techniques. The vulcanization temperature for      splicing is typically around 140°C to 160°C, and the pressure is      maintained at 1.5 MPa to 2.5 MPa for a certain period, usually 30 minutes      to 60 minutes, to ensure a seamless and strong joint. The tension of the      belt also needs to be carefully adjusted to optimize performance and      prevent slippage. The initial tension is usually set based on the belt's      rated tension and the length of the conveyor system, generally around 1%      to 3% of the belt's breaking strength.

• Maintenance: Regular inspections are      essential to check for signs of wear, damage to the rubber cover, or any      issues with the steel cords. Lubrication of the conveyor rollers and      pulleys helps reduce friction and prolong the life of the belt. The      recommended lubricant viscosity is usually in the range of 100 cSt to 500      cSt. In case of any damage, timely repairs or replacement of the affected      sections should be carried out.

6. Quality Standards and Certification

Steel cord conveyor belts are manufactured according to strict international and national quality standards. Certifications such as ISO 9001 ensure that the production process adheres to quality management principles. Compliance with standards like DIN 22102 in Europe and ASTM D 3953 in the US guarantees the reliability and performance of the belts. These standards specify various parameters such as belt strength, cord spacing, and rubber quality requirements.