Steel Cord Conveyor Belt
What is Steel Cord Conveyor Belt
Steel cord conveyor belts are highly wear-resistant and used principally for long-haul conveying, heavy loads and physically demanding applications. They are especially suitable for high-mass or high-volume flows and for abrasive materials. Steel Cord Conveyor Belt using steel cords as its carcass, barely has the elongation, so it is widely used in cement plant, power plant, quarry, mine, etc which are carrying heavy materials. Especially, it’s quite suitable for long lines requiring a high tension.
Advantages of Steel Cord Conveyor Belt
Long centre distances
Steel cable has much lower elongation than fabrics, and this, in addition to the strength, lets belts be designed with long distances between pulleys; and takeups and transfer points are less constraining.
High impact resistance
Typically, steel cord belt design leads to a greater proportion of rubber in the whole belt compared to textile conveyor belts. Additional rubber means that impact energy is better absorbed by the belt; making steel cord belts a good choice for any application where there can be sudden heavy individual pieces.
Excellent troughability
Even the highest rated steel cord belts trough perfectly on deep troughed idler sites. This ensures easy belt training, and gives the belt a larger effective capacity; allowing the user to either increase throughput, or use a narrower belt.
Long life expectancy
Steel cord belts can be supplied with a thinner carcass and thicker cover rubber for the same rating as an equivalent fabric belt; which increases the belt life. The carcass also has a greater life than an equivalent fabric carcass.
Splice life and strength
Properly provided belt splices can last as long as the belt itself. They can also achieve spliced strength equivalent to almost 100% of the strength of the belt.
Easy reconditioning
Steel cord belts can be repaired with hot or cold vulcanization and the damaged edges can be restored to their original width by hot repair. Worn out covers can be replaced with fresh rubber, durable enough to completely rejuvenate the belt, delivering even greater economy for the customer.
Why Choose Us
Our Product
The company's main products are steel cord conveyor belt, heat resistant conveyor belt, PVC/PVG mining conveyor belt, pattern conveyor belt, oil resistant conveyor belt, Guard side conveyor belt and fabric core conveyor belt.
Product Application
The products can be widely used in coal, mining, metallurgy, port, electric power, food, construction and transportation industries.
Production Equipment
The company has advanced production equipment, wire rope conveyor belt flat vulcanizing machine, fabric core flat vulcanizing machine (including coiling device), semi-automatic building machine, automatic expansion force building machine, pin type cold feeding rubber extruder, four-roller calender, open mill, mixer, 16-station automatic small material weighing machine, etc.
Our Certificate
The company has passed GB/T19001 standard quality management system certification, GB/T24001 standard environmental management system certification, GB/T28001 standard occupational health and safety management system certification.
Steel Cord Conveyor Belt Market Overview and Report Coverage
A steel-cord conveyor belt is a type of conveyor belt that is reinforced with steel cords embedded in the rubber cover. These steel cords provide extra strength and resistance to the belt, making it ideal for heavy-duty applications in industries such as mining, construction, and manufacturing. Steel-cord conveyor belts are designed to handle large volumes of bulk materials and have high durability and impact resistance.
The future outlook of the steel-cord conveyor belt market is expected to be positive. The increasing demand for efficient material handling systems and the growth of industries such as mining, construction, and power generation are driving the market. Additionally, the development of innovative conveyor belt technologies, such as self-monitoring systems and advanced rubber formulations, is expected to contribute to the market's growth.
Furthermore, the current outlook of the steel-cord conveyor belt market is promising. The market is witnessing steady growth due to increased investments in infrastructure projects globally. Moreover, the rising focus on safety and productivity in industries is driving the demand for high-performance conveyor belts. The market is also benefiting from advancements in manufacturing technologies, enabling the production of durable and long-lasting steel-cord conveyor belts.
According to the provided information, the steel-cord conveyor belt market is expected to grow at a compound annual growth rate (CAGR) of % during the forecasted period. This growth is attributed to various factors such as increasing industrialization, urbanization, and the need for efficient material handling systems. Additionally, the market is likely to witness further expansion due to the introduction of smart conveyor belt technologies and the rising demand for environmentally friendly conveyor belts. Overall, the steel-cord conveyor belt market is poised for steady growth in the coming years.
Applications of Steel Cord Conveyor Belt
The mining industry places extreme demands on conveyor belts, requiring them to transport heavy loads of ore and other materials over long distances. Steel cord conveyor belt have proven to be highly effective in this demanding environment. A major mining operation in australia reported significant improvements in conveyor belt performance and reduced maintenance costs after switching to steel cord conveyor belt. The belts’ high tensile strength and durability allowed them to handle the heavy loads and abrasive materials typically encountered in mining operations, resulting in increased efficiency and productivity.
In the steel production industry, conveyor belts are used to transport raw materials such as iron ore, coal, and limestone. These materials are often abrasive and can cause significant wear on conventional conveyor belts. Steel cord conveyor belt, with their excellent resistance to abrasion and impact, have been successfully used in steel production facilities to transport these materials. Marked increase in belt lifespan and a reduction in downtime after implementing steel cord conveyor belt, leading to enhanced operational efficiency and cost savings.
The cement industry requires conveyor belts that can handle heavy loads and withstand harsh operating conditions. Steel cord conveyor belt have been widely used in cement plants around the world. A cement plant in south america experienced frequent belt failures and high maintenance costs with their previous conveyor belts. After switching to steel cord conveyor belt, the plant saw a significant reduction in belt failures and maintenance costs, as well as improved overall productivity. The belts’ durability and resistance to heat and abrasion were key factors in their success in this challenging application.
Conveyor belts are essential in power generation facilities for transporting coal and other fuels to the boilers. Steel cord conveyor belt have been successfully used in power plants to ensure reliable and efficient fuel transport. A power plant in north america faced issues with frequent belt replacements and maintenance due to the abrasive nature of coal. By adopting steel cord conveyor belt, the plant achieved a notable increase in belt life and a reduction in maintenance requirements, leading to more stable and efficient operations.
Common Ratings for Steel Cord Conveyor Belt
Steel cord conveyor belts come in various ratings to match different industrial applications. These ratings typically denote the belt’s tensile strength, with higher numbers indicating stronger belts. Here are some common ratings for steel cord belts:
ST500
This rating signifies a belt with a breaking strength of 500 N/mm. ST500 belts are suitable for light to medium-duty applications where moderate loads and shorter conveyor lengths are involved.
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ST1000
With a breaking strength of 1000 N/mm, ST1000 belts are designed for medium-duty applications. They offer a balance between strength and flexibility, making them suitable for a variety of industrial settings.
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ST2000
ST2000 belts have a breaking strength of 2000 N/mm and are used in heavy-duty applications. These belts are ideal for transporting large quantities of materials over long distances, providing excellent durability and resistance to wear.
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ST3150
These belts, with a breaking strength of 3150 N/mm, are used in very heavy-duty applications. They are designed to handle extremely high loads and harsh conditions, such as in mining and quarrying operations.
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ST5400
ST5400 belts represent some of the strongest steel cord belts available, with a breaking strength of 5400 N/mm. These belts are used in the most demanding applications, where maximum strength and durability are required.
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How to Choose Steel Cord Conveyor Belt
Assess load requirements
Evaluate the maximum load the conveyor system will need to carry. Consider both the weight of the materials and the operational conditions, such as speed and incline. This assessment will help determine the necessary breaking strength for the belt.
Consider conveyor length and speed
Longer conveyor systems and higher operating speeds require belts with higher ratings to handle the increased tension and dynamic forces. Ensure the selected belt steel cord rating can accommodate these factors to prevent premature failure.
Analyze environmental conditions
Take into account the environmental conditions in which the belt will operate. Factors such as temperature, humidity, and exposure to chemicals or abrasive materials can affect the belt’s performance. Choose a belt with the appropriate rating and protective features to withstand these conditions.
Factor in safety margins
It’s essential to include safety margins when selecting a belt rating. This practice ensures that the belt can handle unexpected loads or operational stresses without compromising safety and reliability.
Consult with manufacturers
Engaging with belt manufacturers or suppliers can provide valuable insights and recommendations. They can offer guidance on the best rating based on your specific application requirements and operational conditions.
Perform regular maintenance and inspections
After selecting and installing the appropriate belt, regular maintenance and inspections are crucial for ensuring continued performance. Monitoring the belt’s condition helps identify any potential issues early, allowing for timely interventions and prolonging the belt’s lifespan.
Comparing Steel Cord Belts and Fabric Belts
Strength and Load Capacity Differences
Steel Cord Conveyor Belt
Steel cord conveyor belts are renowned for their exceptional strength and high load-carrying capacity. They are constructed with longitudinal steel cords embedded in the rubber matrix, providing superior tensile strength. This design allows steel cord belts to handle extremely heavy loads and withstand high tension. The steel cords offer minimal elongation under load, ensuring that the belt maintains its shape and tension over long distances and under significant stress. This high strength makes steel cord belts ideal for heavy-duty applications, such as mining, quarrying, and bulk material handling, where substantial loads and long conveyor runs are common.
Fabric Belt
Fabric belts, also known as textile belts, are made from layers of synthetic fabrics like polyester, nylon, or cotton, which are coated with rubber. While fabric belts are strong and versatile, they generally have lower tensile strength and load-carrying capacity compared to steel cord belts. Fabric belts are more elastic, allowing for greater flexibility but also resulting in higher elongation under load. This flexibility makes fabric belts suitable for lighter to medium-duty applications, such as packaging, food processing, and short-distance conveying, where the loads are not as demanding.
Longevity and Maintenance Requirements
Steel Cord Conveyor Belt
Steel cord conveyor belts are designed for durability and long service life. The steel cords provide excellent resistance to impact, wear, and abrasion, making these belts highly durable even in harsh operating conditions. The robust construction reduces the frequency of replacements and lowers the overall maintenance costs. However, when maintenance is required, it can be more complex and costly due to the need for specialized equipment and techniques, such as splicing and repairing the steel cords.
Fabric Belt
Fabric belts, while durable, typically have a shorter lifespan compared to steel cord belts, especially in demanding applications. The fabric layers can be more susceptible to wear, tearing, and degradation from environmental factors such as moisture and chemicals. Maintenance of fabric belts is generally simpler and less expensive than steel cord belts, as they can be repaired or replaced more easily. However, the higher frequency of maintenance and replacements can lead to increased downtime and overall costs in the long run.
The Structure of Steel Cord Conveyor Belt
Reinforcement material (steel cord core)
The steel cord core provides higher strength and lower elongation of use for the conveyor belt, so the steel cord conveyor belt is suitable for long-distance, high strength, and high power transmission.
Steel cord core glue (adhesive)
The core rubber compound has good bonding strength between the steel wire ropes, can transmit stress well, and prevents the steel wire core from being pulled out during use.
Covering glue
The cover rubber of the steel cord conveyor belt has the same function as the cover rubber of the fabric core conveyor belt and is also a guarantee for the normal operation of the conveyor belt.
Edge glue
The edge glue can protect the outer wire of the reinforcing wire rope from eroding, absorb the pressing force from the side of the conveyor belt, and prevent the wire rope from being pulled out and leaking.
Common faults of Steel Cord Conveyor Belts
Fatigue-related damage
The steel cores must constantly and continually bend around the rollers and pulleys when the conveyor belt is working due to space limits. The repeatedly bent belt core is exposed to fatigue forces throughout each working cycle, resulting in repetitive fatigue damage. When increasing the life of a steel cord conveyor belt, take into account factors such as the conveyor's driving mechanism, installation size, and drum quality.
The tension on the conveyor belt is not distributed evenly
Steel cable conveyor belts are frequently troughed to increase coal load-bearing capacity. The margins of the steel cord conveyor belt will encounter higher tensile stress than the center as it passes from the horizontal to the trough portion. Because of the unequal distribution of belt load, the belt is more likely to break.
An overpowering external force
The conveyor belt will be damaged or even fractured if it is suddenly extended as a consequence of external pressure. Material lodged in the guiding trough or distribution plate, on the other hand, increases the likelihood of the belt breaking.
Corrosive
Steel cord conveyor belts are used for a long time and ultimately show symptoms of wear, cracking, and aging on the upper and lower covering layers. The upper layer cracks as a result of the connection fractures. The steel chord will become exposed if not repaired immediately, enabling water to leak into the conveyor belt and cause corrosion.
Steel Cord Conveyor Belt Maintenance Instructions
1. During transportation and storage, the conveyor belt should be kept clean and protected from direct sunlight or rain or snow to prevent contact with acids, alkali oils, organic solvents and other materials, and one meter away from the heating device.
2. The temperature in the warehouse should be maintained between -18℃and 40℃ during storage, and the relative temperature should be kept between 50-80% RH.
3. During storage, the product shall be placed in rolls and shall not be folded. It shall be turned once every season during the period of storage.
4. Conveyor belts of different types and specifications should not be used together, and the joints are preferably glued.
5. The type, structure, specification and number of layers of the conveyor belt should be reasonably selected according to the conditions of use.
6. The running speed of the conveyor belt is generally not as large as 2.5 m/s. The block size is large, the material with large wear and the fixed plough type discharging device should use low speed as much as possible.
7. The diameter of the transmission drum of the conveyor and the closing of the conveyor belt, the conveying drum, the reversing drum and the requirements for the groove angle of the conveyor should be reasonably selected according to the design regulations of the conveyor.
8. The feeding direction should be in the running direction of the tape. In order to reduce the impact on the tape when the material falls, the chute should be used to reduce the falling distance of the material; the receiving section of the tape should shorten the spacing of the idler and use the buffer roller to prevent leakage. The belt side should adopt a soft and moderate baffle plate to avoid the baffle plate being too hard and scraping the belt surface of the conveyor belt.
