World’s First Φ600 mm Aramid Pipe Conveyor Belt at Sutong Power Plant

A 1,458 m enclosed coal conveying system designed for 3,250 t/h at 5 m/s, combining large-diameter pipe-form stability with lightweight aramid reinforcement.

World’s First Φ600 mm Aramid Pipe Conveyor Belt at Sutong Power Plant
Case Chanllenges

At Sutong Power Plant in Jiangsu, China, BOTON supplied a Φ600 mm aramid pipe conveyor belt for the C11B coal conveying line. The 1,458 m fully enclosed pipe conveyor is designed to handle up to 3,250 t/h of coal at a belt speed of 5 m/s. By combining lightweight aramid reinforcement with large-diameter pipe belt engineering, the solution supports stable pipe formation, lower system load and high-capacity enclosed coal conveying. BOTON also developed an innovative belt replacement method and purpose-built winding equipment, completing the retrofit five days ahead of schedule.

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Core Achievements

World-First Φ600 mm Aramid Pipe Conveyor Belt

BOTON delivered the world’s first Φ600 mm aramid pipe conveyor belt, combining lightweight, high-strength aramid reinforcement with the pipe-form performance required for large-diameter enclosed conveying.

3,250 t/h High-Capacity Enclosed Coal Conveying

The 1,458 m conveyor is designed for up to 3,250 t/h at 5 m/s, supporting continuous fully enclosed coal transport at Sutong Power Plant.

10× Faster Recovery, Completed 5 Days Early

BOTON’s purpose-built belt winding equipment and optimized replacement method increased old-belt recovery efficiency by approximately 10 times and helped complete the retrofit five days ahead of schedule.

Key Facts

  • Industry: Power Generation
  • Application: Coal Conveying
  • Site: Sutong Power Plant, Jiangsu, China
  • Product: High-Performance Aramid Pipe Conveyor Belt
  • Pipe Diameter: Φ600 mm
  • Conveying Distance: 1,458 m
  • Lift Height: 23.8 m
  • Design Belt Speed: 5 m/s
  • Design Capacity: 3,250 t/h
  • Conveying Mode: Fully enclosed pipe conveyor
  • Delivery Scope: Belt design, product supply, replacement planning, site execution support
Key Facts

Project Challenges

Pipe-Form Stability at Φ600 mm Diameter

A Φ600 mm pipe conveyor belt must balance transverse rigidity with sufficient flexibility to open, close and reform continuously along the conveyor route. For this project, overlap retention, resistance to twisting and stable pipe formation were critical design considerations under high-capacity, high-speed operation.

High-Capacity Conveying with Lower System Load

At 1,458 m and a design capacity of 3,250 t/h, belt weight and running resistance can significantly influence conveyor load and energy demand. The project therefore required a belt structure that could maintain the tensile strength and pipe-form stability needed for continuous coal conveying without adding unnecessary belt mass.

Complex Belt Replacement Geometry and Tight Shutdown Window

The new belt staging position was approximately 6 m offset from the conveyor centerline, making a conventional straight-line belt replacement impractical. The team needed to control belt pulling, alignment and entry into the existing conveyor structure while working within a limited shutdown window for a critical coal handling line.

BOTON Solution

BOTON Solution

Lightweight Aramid Reinforcement for Large-Diameter Pipe Conveying

BOTON combined high-strength aramid conveyor belt reinforcement with the structural requirements of a pipe conveyor belt. The high strength-to-weight ratio of aramid helps reduce belt mass and system load while maintaining the mechanical performance required for long-distance, high-capacity conveying.

The belt structure was engineered specifically for the Φ600 mm pipe diameter, balancing longitudinal strength, transverse rigidity and flexibility to support stable enclosed operation.

Pipe-Form Engineering and Test Validation

For the Φ600 mm pipe structure, BOTON optimized transverse rigidity, overlap behavior and repeated flexing performance to support stable opening, closing and pipe formation throughout operation.

Before field deployment, the belt structure was evaluated through pipe-form validation and dynamic flexing fatigue testing, helping verify pipe stability, overlap retention and durability under repeated operating cycles.

Innovative “Suspension-Bridge” Belt Replacement Method

To overcome the approximately 6 m parallel offset between the belt staging position and the conveyor centerline, BOTON developed an innovative “suspension-bridge” replacement method.

The controlled transition path allowed the new belt to enter the conveyor structure at approximately 35°, improving belt guidance and making replacement possible without major modification to the existing conveyor structure.

Purpose-Built Belt Winding Equipment

BOTON deployed purpose-built belt winding equipment to accelerate old-belt recovery and improve site handling efficiency. Combined with optimized pulling, guiding and recovery procedures, the equipment increased old-belt recovery efficiency by approximately 10 times and contributed to completing the overall retrofit five days ahead of schedule.

Project Gallery

Explore the development, testing and field application behind the world's first Φ600 mm aramid pipe conveyor belt.

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