By Mathew Augustine
Like most industries today, manufacturers are faced with increasing prices, supply constraints and environmental impacts when it comes to the materials and components they use to manufacture mining equipment. These challenges are passed along to mining operators in the form of higher costs, longer lead times and delays.
Some manufacturers are looking to innovative, new materials to overcome these challenges. Nylon, for example, has long been the go-to material for conveyor belts due to its impact resistance and tensile strength. However, nylon presents risks that are resulting in price inflation and production delays, which can have a negative impact on mining operation profit margins. These risks include:
- Higher costs: Nylon is an expensive reinforcement material and already-high prices are on the rise. The raw material costs of nylon have increased significantly over the past few years, and according to data from Data Bridge Market Research, fluctuation in cost and availability of raw material is projected to challenge the nylon market until 2029.
- Limited supply and risk: Nylon’s production capacity is constrained, leading to supply risks and market instability. Unforeseen events like weather, fire and transportation delays can lead to further supply issues. In addition, geopolitical tensions, including uncertainty around tariffs, have added to supply chain challenges, leading to increased costs and uncertainty in material availability.
- Environmental concerns: Producing nylon requires considerable energy, resulting in high carbon emissions and making the environmental sustainability impact of nylon difficult for environmentally conscious manufacturers and end users.
Global shortages of key materials, exacerbated by the pandemic and geopolitical issues, have forced the industry to seek alternative materials and innovate in material science to maintain production levels. Two new materials – High Energy Polyester (HEP) and polyketone – are gaining traction as viable alternatives to nylon, particularly when it comes to conveyor belt manufacturing.
High Energy Polyester
High Energy Polyester (HEP) is derived from polyester, but with more “nylon-like” characteristics than standard polyester and can be used in place of nylon in all textile belts in mining. HEP is designed to provide the features and benefits of nylon yarn that can be used in either the weft (impact resistance) or warp (lengthwise tension-carrying) direction of the belt, or both, and is suitable for any weave design.
While the performance of HEP is equal to or better than that of nylon, the availability of HEP far surpasses that of nylon. In fact, HEP has 10 times more global production capacity than nylon, which provides more stability in supply, pricing and lead times.
HEP is also a more environmentally sustainable material than nylon. Less energy is used in the production of HEP, reducing the CO2 – and thereby the carbon footprint – of HEP material development. The sustainability benefits of HEP are further demonstrated by the fact that HEP is recyclable, making this beneficial material part of the circular economy that is integral to sustainability in manufacturing.
At the same time, customer feedback and internal testing at Continental, where HEP is being integrated into conveyor belt manufacturing, validates the performance of HEP for aggregate and mining applications when it comes to rip, tear, tensile strength and other variables.
Polyketone
Polyketone is another material to watch for this year. Polyketone is a green polymer composed of carbon monoxide and olefins, and it can replace nylon in certain applications. While the science behind polyketone is not brand new to the marketplace, using it in mining applications is.
Polyketone responds better than nylon to humidity, with low moisture absorption, and is more stably priced, while also providing excellent wear and abrasion resistance and greater overall durability. Products using polyketone perform the same as or better than traditional nylon products, making it another viable replacement for nylon in select applications.
Like HEP, polyketone requires significantly less energy than nylon to produce, reducing the carbon footprint of the material development process substantially. Polyketone is also non-toxic and is free from several toxins including formaldehyde, lead, chrome and phthalates, among others, making it an overall more environmentally friendly product.
Challenges in processing polyketone needs adaptations in process equipment and process modifications. A strong commitment to sustainability is essential to make all these materials work.
Mining the Future With New Materials
HEP and polyketone are more than just material innovations – they represent a shift toward cost stability, sustainability, and long-term supply security. Mine operators who are frustrated with rising costs and equipment delays that have a negative impact on profit margins can discuss new, more readily materials with their equipment providers.
Alternatives like HEP and polyketone may be just what the industry needs to replace traditional nylon, moving conveyor belt technology toward a more sustainable – and more stable – future.
Mathew Augustine is the head of product development at Continental, with more than 20 years of experience in tires, hose, coatings and polyurethane industries.