Why Conveyor Belts Matter in the Chemical Industry
Aramid in Conveyor Belts for Extended Lifetime, Energy Savings and Environmental Effects
In addition to textile and steel cord reinforcements for conveyor belts, Aramid can be found in numerous applications, mainly due to its heat and corrosion resistance. But it can also help reduce installation costs, energy usage and, thus, the carbon footprint.
In recent years, aramid fabric as reinforcement in conveyor belts has gradually found its position among the traditional textile and steel cord reinforcement materials. The main arguments for this trend are enhanced lifetime and energy savings. Aramid has already been in use for more than three decades in some niche applications such as phosphate mines and steel production plants because of its corrosion and heat-resistant properties.The background of aramid as reinforcement material is briefly described here. Practical examples are reported, demonstrating increased lifetime, which consequently reduces maintenance and maximises output.In mining operations, the transportation of minerals and overburden accounts for a significant share of energy consumption and CO2 emissions. Aramid in conveyor belts reduces the weight of the belt and lowers the system rolling resistance. This leads to energy savings and lower CO2 emissions.With the Customer Benefit Model, an eco-efficiency tool, quantitative proof is provided that saving the environment and financially sound business practices can go hand-in-hand. The potential energy saving by using aramid in the carcass and as an additive in cover compounds is an input parameter for the Customer Benefit Model. An energy saving calculation tool, based on DIN 22101, has been developed and will be explained in this paper.
The properties of aramid will only be briefly described here, since these have already been covered previously at Beltcon by Arts and Lodewijks [3,4]. For the sake of completeness, the relevant details are summarised.Poly-paraphenylene terephthalamide, also known as aramid from ‘aromatic amide’, is a very strong and lightweight synthetic fibre. It has a high modulus, is thermally stable, and highly impact and chemically resistant. It can be used in conveyor belts in two different ways:
as aramid-reinforcement fabric in the carcass;
as a chemically treated aramid-based additive to the bottom cover compound in order to lower rolling resistance.
For the carcass, the so-called straight warp fabric construction is most commonly applied. A schematic view of the fabric embedded in rubber is shown in Fig. 1.
It consists of aramid cords in the warp direction, polyamide 6.6 in the weft direction, held together by a polyamide binder yarn in the warp. Similar to the commonly used textile fabric (EP), the aramid fabric is treated with a Resorcinol-Formaldehyde-Latex (RFL) dip formulation to obtain sufficient adhesion between the fabric and skim compound.The key advantage of using an aramid-based fabric over a steel cord carcass is its lightness, as shown in Fig. 2. Aramid fibres have a density of just 1.44 g/cm3 and are thereby five times stronger than steel on a weight-to-weight basis.
Fig. 2: Tenacity and elongation characteristics of reinforcement materials.
Compared to the textile materials, polyamide 6.6 and polyester, the high tenacity and heat resistance of aramid are the most important parameters to consider, since they allow the use of a single fabric layer reaching high strength classes up to at least 3150 N/mm.The second use of aramid in conveyor belts is the addition of the aramid-based additive to the bottom cover compound. During mixing at an elevated temperature, it reduces the carbon black filler-filler interaction (Payne effect), resulting in a compound with improved hysteresis properties [5]. The result, a lower ratio of the loss and storage modulus of the compound, expressed as tan δ, can be measured using ASTM D5992 Dynamic Mechanical Analysis (DMA) [6]. To this end, a standard NR/BR compound formulation was mixed with 3 phr of aramid-based additive. The tan δ of the control and the aramid-based additive compound were measured in Gabo Eplexor DMA equipment at 2% dynamic strain at a frequency of 10 Hz.The effect of adding the aramid-based LRR component to a compound on the indentation rolling resistance has also been tested at the University of Hannover, Institute of Transport and Automation Technology, according to DIN 22123 [7]. The compound compositions as mentioned above were extruded over a steel plate with cover thicknesses of 6 to 8 mm. The results obtained from both analyses are shown in Fig. 3. The tan δ of the aramid-doped compound was 6% to 15% lower, depending on the temperature. Both outcomes, DMA and IRR, are expressed as a relative improvement against the control compound.
Extended Lifetime and further Advantages of using Aramid|
One of the traditional applications of aramid fabrics in conveyor belts has been in corrosive environments. Good examples are in Tunisia at the CPG (Gafsa) phosphate mine, where a 4.6 km aramid belt had been in operation for nine years before it was replaced, again with aramid. Another aramid belt in a phosphate mine in Tampa (Florida, USA) was replaced last year after 13 years of operation. The aramid fabric retained about 85% of its original strength [8]. In both cases, rubber cover wear and tear was the reason for replacement. With its unique set of properties, aramid can be a solution for belts that are applied under extreme conditions and have a short lifetime. However, it should be studied case by case. Some design parameters (for example, transition length) should also be taken into account before replacing textile belts.The flexibility of the aramid fabric compared to steel cord has proven its functionality in a 110 m reclaimer belt in the China, This class St1600 belt had an average lifetime of six months, because of the high turning frequency around the pulleys, it continually broke. The aramid belts have already reached an average lifetime of fifteen months.As a consequence of its dense and strong weft (the weaving threads in transversal direction), the aramid fabric also acts as an integrated breaking layer. This means that in the conveying of sharp and heavy rocks, such as in copper mining, there is intrinsic protection against belt slitting, and no costly additional breaking layer or slitting detection is needed.For example, in a copper mine, where short steel belts typically have a very limited service life – often as little as one month – an aramid belt recently ran for a full six months, which is well beyond the life expectancy of the previous non-aramid belts in this installation. After six months, the belt, which was still working satisfactorily, was taken out for residual testing by a Polish Mining University and showed no strength loss.
Table 1: Belt weights and roll diameters of typical St2500 and DPP2500 belts.
In Table 1, a St2500 and aramid DPP2500 belt with typical dimensions are listed. Based on the assumption that the same safety factor can be used for both, the roll diameters were calculated. It can be seen that at an equal diameter of 2.71 m, the roll length of the aramid belt exceeds the length of the steel cord belt by far. Consequently, the number of splices in a long-haul conveying system can be reduced considerably. For a 5 km belt the number of splices is reduced from 17 to 12 in the example shown. This certainly contributes to limiting downtime of the system and saves installation costs.
Estimating potential Energy Savings by using Aramids
It has been clearly demonstrated that using aramids in conveyor belts, both as a strength member and as a rubber compound additive, can yield significant savings due to increased lifetime and/or energy savings in combination with positive environmental effects. The software programs Energy Model and Customer Benefit Model provide a quick scan of the conveyor belt system in order to determine whether it is worthwhile to make a change from the traditional reinforcing materials to aramid.
Role of Conveyor Systems in Chemical Plants
Conveyor belts are integral to the operation of chemical plants, where they streamline the handling and transfer of raw materials, semi-processed goods, and finished chemical products. The ability to transport volatile or sensitive substances efficiently ensures continuous production and reduces labor risks.
Common Materials Transported
Common materials include acids, alkalis, powders, granules, solvents, and corrosive chemicals. Each material demands specific belt properties to maintain integrity and safety during transit.
Environmental and Safety Considerations
The chemical industry operates under strict safety and environmental regulations. Conveyor belts reduce human exposure to hazardous materials, help contain spills, minimize emissions, align operations with OSHA and EPA standards.
Impact on Operational Efficiency
Well-designed conveyor systems significantly enhance throughput, reduce manual handling, and lower operating costs. They ensure a consistent material flow, leading to optimized production schedules and minimized downtime.
Challenges of Material Handling in Chemical Environments
Corrosive and Hazardous Materials
Chemical substances can corrode conventional belt materials, leading to failures and potential safety hazards. Selecting belts resistant to acids, bases, and solvents is vital.
Temperature Extremes and Chemical Reactions
High-temperature environments or exothermic reactions demand belts that withstand heat without degrading. Teflon-coated and steel mesh belts are ideal in such conditions.
Risk of Contamination and Equipment Failure
Contamination risks are especially critical in pharmaceutical-chemical hybrids. Incompatible belt materials may cause contamination, impacting product quality and safety.
Regulatory and OSHA Compliance
Complying with OSHA, REACH, and other industry-specific standards is non-negotiable. Conveyor belts must meet flame resistance, anti-static, and material safety requirements.
Key Features of Conveyor Belts for Chemical Industry
Chemical-Resistant Coatings (e.g., PVC, PTFE, Teflon)
These coatings protect belts from aggressive substances, extending lifespan and ensuring safe transport. Teflon offers exceptional resistance to high temperatures and corrosives.
Antistatic and Flame-Resistant Properties
To prevent static discharge and potential ignition, belts are engineered with anti-static properties. Flame-resistant features protect both products and personnel.
Material Compatibility (Acids, Alkalis, Solvents)
Fabric conveyor belts are often reinforced or coated to resist degradation from specific chemicals, ensuring long-term performance.
Resistance to Abrasion, UV, and Temperature
In addition to chemical resistance, belts must resist physical wear, UV exposure, and thermal stress to maintain durability in demanding environments.
Types of Conveyor Belts Used in Chemical Plants
Modular Plastic Belts
These belts are durable, easy to clean, and resistant to various chemicals. They are ideal for bulk transport and wet environments.
Teflon Coated Fiberglass Belts
Excellent for high-temp and corrosive environments, these belts offer low friction and high resistance to chemical attack.
Steel Mesh Belts for High Temp
Steel belts handle extreme heat and mechanical stress, commonly used in processes involving drying or high-temperature reactions.
FDA-Approved Belts (for pharma-chemical overlaps)
Used where contamination control is critical, FDA-approved belts ensure product safety in pharmaceutical-grade environments.
Selecting the Right Belt for Your Chemical Application
Evaluating Chemical Resistance Needs
Understanding the exact chemicals and their concentrations helps determine the most suitable belt composition and coating.
Belt Speed and Load Considerations
Belt selection should consider load weight, volume, and desired transport speed to avoid over-stressing the system.
Maintenance and Safety Best Practices
Regular Inspection Protocols
Scheduled inspections help identify early signs of wear, misalignment, or chemical attack, enabling proactive maintenance.
Cleaning and Decontamination Procedures
Proper cleaning with compatible agents prevents residue buildup and contamination, essential in sensitive chemical processes.
Safety Signage and Emergency Stops
Clearly marked belts and emergency stops are essential for protecting workers and complying with regulatory requirements.
Extending Belt Lifespan with Proper Storage
Storing belts in cool, dry conditions away from UV and chemicals prolongs their service life.
Case Studies: Conveyor Solutions for Real-World Chemical Plants
Acid-Resistant Belts in a Sulfuric Acid Plant
A leading chemical manufacturer adopted Monster Belting’s acid-resistant fabric conveyor belts to improve durability and safety under continuous exposure to sulfuric acid.
High-Temperature Belts in Fertilizer Manufacturing
Monster Belting supplied steel mesh belts that withstood 300°C heat in a fertilizer drying application, significantly extending operational uptime.
Anti-Static Belts in Solvent Handling Applications
For a solvent processing facility, Monster Belting engineered anti-static belts that eliminated static-related ignition risks.
How Monster Belting Supports the Chemical Industry
Custom Engineering Solutions
From belt design to installation, Monster Belting offers bespoke solutions tailored to unique chemical plant challenges. Top Quality Alkali Resistant Conveyor Belt for Chemical Industry. We have more than 800 units advanced manufacturing equipments, including 20 large and main units and three automatic production lines. The factory covers 253,000 square meters. It’s registered capital is 71,550,00 USD, There are more than 300 employees which contains 30 with middle-level titles and 125 technical workers with high technical skills. Our Multi-Ply Fabric Conveyor Belt can be offered with a wide range of rubber covers to suit a diverse range of applications from extreme abrasion, cutting and gouging to light duty conveying of non-abrasive materials.
Features & Benefits:
• The low-elongation polyester fibres are used in the warp direction to reduce the length of the tension travels;
• The more elastic polyamide fibres are used in the weft, to ensure good troughing;
• Exceptional fatigue and impact resistance;
| Purpose | General Use | |||
| Grade | W | X | Y | Z |
| Main Characteristic | Superior anti-abrasive covers with good mechanical properties. | Abrasion and cut resistant cover for sharp-edged or lumpy material, High abrasion resistance. | Cover with good mechanical properties or heavy-duty applications. | Cover for normal service application. |
| Abrasion Loss (mm3) | 90 | 120 | 150 | 250 |
| Tensile Strength (Kgf/cm2) | 180 | 250 | 250 | 150 |
| Elongation at Break (% min) | 400 | 450 | 450 | 350 |
| Constant Material Temperature (ºC) | 80 | 80 | 80 | 80 |
Technical data
| |||||||||||||||||||||||||||||||
| Classification | Immersion solution | Density | Soaking condition TemperatureXtime | Soak the rate of change of front and back performance | |||||||||||||||||||||||||||
| Volume expansion rate | Change rate of strength | ||||||||||||||||||||||||||||||
| A1 | HCL | 18% | 50°C×96h | +10% Following | -10% within | ||||||||||||||||||||||||||
| A2 | H2SO4 | 50% | 50°C×96h | +10% Following | -10% within | ||||||||||||||||||||||||||
| A3 | NaOH | 48% | 50°C×96h | +10% Following | -10% within | ||||||||||||||||||||||||||
It is suitable for conveying materials with chemical corrosiveness in chemical factory, chemical fertilizer factory, paper mill, mining industry and etc.
Fast Global Delivery & Reliable Quality
With worldwide logistics and strict quality controls, Monster Belting ensures timely delivery and dependable performance. Our products can be used in metallurgy, building materials, electric power, coal, port and other industries, products have been covered the whole domestic market, and exported to the United States, Germany, France and other EU countries, Australia, Brazil, along the Belt and Road countries, Southeast Asian countries and African emerging markets, totally more than 50 countries, gained the customers’ the best products with high quality and competitive price for our customers and share success with you together.
Ripcheck Conveyor belts for Chemical Plant, Fertilizer, Paper-Making Factory
Conveying bulk solids can sometimes cause difficulties; sharp-edged, large pieces of undefined shapes, unfavourable feeding conditions, material pileups could result in longitudinal cuts or punctures in the belt. Engineers have identified the problem and searched for a technical and costefficient solution. Their effort resulted inthe development of a Ripcheck conveyor belt with an additional impact-resistant breaker installed above the carcass.
With regard to the intended use and breaker, the following types are available:
• RC type – elastic cross-reinforcement with steel cord
• RCH type – very narrow and elastic reinforcement with steel cord for severe conditions
• BR type – elastic reinforcement with textile cord (for magnetic separators or in devices for metal detection, used in the timber industry)
| RIPCHECK STEEL CORD | RC | RCH |
| Wire diameter (mm) | 1,19 | 1,19 |
| Avarage distance between the wires (mm) | 14,0 (+/- 2,0) | 0,9 (+/- 0,2) |
Technical Data
Physical property of cover rubber under hot air accelerated aging test (test condition: 70ºC*96h)
Acid/Alkali Resistance Performance
| Cover | Name | Item | |
| Tensile Strength | ≥12Mpa | ||
| Elongation at Break | ≥400% | ||
| Acid Resistance(15-25ºC),24h 40%H2SO4 | ≥0.8 | ||
| Abrasion Loss | <=220mm3 | ||
| The Whole Thickness | The Adhesive Strength of Rubber and Cloth | Cover>1.5mm | ≥3.2N/mm |
| Cover<=1.5mm | ≥3.2N/mm | ||
| The Adhesive Strength of Rubber and Cloth(Longitudinal) | 3.2N/mm | ||
| Elongation at Break(Longitudinal) | ≥10% | ||
Our major products include: normal conveyor belt below B2400MM, NN/EP conveyor belt, PVC PVG fire resistant conveyor belt, large dip angle conveyor belt, acid&alkali resistant conveyor belt, patterned conveyor belt, oil-resistant conveyor belt, steel cord anti-tear conveyor belt, ring conveyor belt, roller, pulley,etc.
Strong technical support and R&D capacity
We have a separate design, research and development capability and can be customized according to customer demand.
Our company possesses a complete set of detection apparatus, the independent chemical analysis and physical labs, ensuring all the raw materials. Semi-products and finished products are under control and there no unqualified materials and no unqualified product.
1.Pre-sales service
* Inquiry and consulting support
* Sample testing support
* View our factory
2.After-sales service
* We provide 24hour/7days after-sales service
* Regularly visit our client and keep quality tracking
3. Warranty
No damage to human factors, one year warranty, life-long maintenance.
- general belts, guarranty period is 12months
- heat resistant belt : above 180℃ for 6 months, above 250c is 3 months.
- steel cords belts guarranty period is 24months.
Future Innovations in Chemical Conveyor Belt Technology
Smart Sensors for Wear Detection
Next-gen belts will include embedded sensors to alert maintenance teams about wear or misalignment in real-time.
Eco-Friendly, Recyclable Belt Materials
Sustainable, low-impact materials are being adopted to reduce waste and improve environmental compliance.
Predictive Maintenance with IoT Integration
IoT-enabled systems can track belt performance data to predict failures before they occur, minimizing downtime.
Industry Trends and Standards (REACH, RoHS, ISO)
Manufacturers are increasingly aligning with international standards, driving innovation in materials and design.
Final Thoughts: Choosing the Right Partner for Chemical Conveyor Solutions
Summary of Key Considerations
Chemical compatibility, durability, safety compliance, and ease of maintenance should all guide conveyor belt selection.
Questions to Ask Suppliers
- Is the belt material compatible with our chemicals?
- What certifications does the belt meet?
- How quickly can replacements be delivered?
- Are there anti-static or flame-resistant options?
How to Request a Sample or Quote
To find the ideal conveyor belt for your chemical application, visit Monster Belting for personalized support and a custom quote. For expert guidance on selecting the right conveyor belts for chemical industry applications, including fabric conveyor belts, Contact Monster Belting today!
Frequently Asked Questions
Q1: What are fabric conveyor belts and why are they important in chemical plants?
Fabric conveyor belts use textile layers to improve flexibility and chemical resistance, making them ideal for harsh chemical environments.
Q2: Can a single conveyor belt handle multiple types of chemicals?
Not always. It depends on the belt’s material compatibility. Consult an expert to match belts to specific chemicals.
Q3: How often should chemical conveyor belts be replaced?
With proper maintenance, belts can last several years. However, harsh chemicals may necessitate more frequent replacement.
Q4: Are there belts that meet FDA standards for pharmaceutical applications?
Yes, Monster Belting provides FDA-approved belts suitable for chemical-pharmaceutical overlaps.
Q5: What are the safety features to look for in a chemical conveyor system?
Look for flame resistance, anti-static properties, clear safety signage, and accessible emergency stops.