30+ km Steel Cord Conveyor Belts for High-Speed Coal Conveying in Indonesia

Steel Cord Conveyor Belts Supporting 9.5 m/s Long-Distance Overland Conveying

30+ km Steel Cord Conveyor Belts for High-Speed Coal Conveying in Indonesia
Case Chanllenges

A large open-pit coal mine in Indonesia operates several long-distance overland conveyors connecting mining areas, crushing facilities and downstream logistics.

Individual conveyor routes extend approximately 10 km and handle several thousand tonnes of coal per hour, making reliable belt performance critical to continuous production.

When sections of the existing conveyor belts entered their replacement cycle in 2024, BOTON was introduced as a new supplier. The challenge was not simply to meet a specification, but to integrate a new belt into a mature conveyor system with established operating and maintenance practices.

Following field validation, BOTON was subsequently selected for a second overland conveyor line, bringing cumulative supply to more than 30 km.

Core Achievements

30+ km Cumulative Supply

Since the initial installation in 2024, BOTON has expanded from the first replacement section to a second overland conveyor line, bringing cumulative supply at the mine to more than 30 km.

Reliable Operation at Up to 9.5 m/s

The conveyor operates at speeds of up to 9.5 m/s on 10 km-class overland routes, placing sustained demands on belt wear resistance, dimensional stability and rolling efficiency.

Successfully Integrated into an Established Conveyor System

BOTON’s ST2000 belts were successfully integrated through phased replacement and direct splicing with the existing belt system, supporting continued supply.

Key Facts

  • Industry: Mining
  • Location: Indonesia
  • Material: Coal
  • Application: Long-Distance Overland Conveying
  • Conveyor Route: Approximately 10 km
  • Operating Speed: Up to 9.5 m/s
  • Capacity: Several thousand tonnes per hour
  • Initial Trial Belt: ST2000 Steel Cord Conveyor Belt
  • Top Cover: SUAR™ Abrasion-Resistant Compound
  • Bottom Cover: Low Rolling-Resistance Compound
  • Initial Supply: 2024
  • Total Supply: More than 30 km
Key Facts

Project Challenges

Integrating into an Established Conveyor System

The existing conveyor system had operated for many years with belts supplied by another international manufacturer.

Because replacement was carried out in stages, the first BOTON belt section had to be spliced directly to the existing belt. Compatibility, splice quality and dimensional stability were therefore critical to introducing the new belt without disrupting established operating practices.

High-Speed, Continuous Operation

The conveyor operates at up to 9.5 m/s.

With approximately 20 km of belt in the system, continuous operation means the belt can travel more than 800 km per day. Under these conditions, even small amounts of cover wear and indentation rolling resistance accumulate rapidly.

Tropical Mining Conditions

The mine operates in a hot, humid and rainy environment typical of Indonesia’s tropical climate.

The belt therefore needs to maintain stable rubber performance under continuous exposure to heat, moisture and heavy-duty coal conveying conditions.

BOTON Solution

BOTON Solution

ST2000 Steel Cord Conveyor Belt

BOTON initially supplied ST2000 steel cord conveyor belt for the first replacement section. Following field validation, supply was expanded to additional sections and a second overland conveyor line.

SUAR™ Abrasion-Resistant Top Cover

At 9.5 m/s, the carrying surface is continuously exposed to friction, impact and coal abrasion.

BOTON applied its SUAR™ abrasion-resistant conveyor belt cover to help control top-cover wear under high-frequency operation and support longer replacement intervals.

Low Rolling-Resistance Bottom Cover

For long overland conveyors, indentation rolling resistance can become a significant source of energy loss.

BOTON therefore applied a low rolling-resistance bottom cover designed to reduce hysteresis losses as the belt repeatedly passes over idlers.

More information on this technology is available in BOTON energy-saving conveyor belt solutions.

On-Site Splicing Support

Because the new belt had to connect directly with the existing belt, splice quality was a critical part of the replacement program.

BOTON engineers provided on-site technical support and quality supervision throughout the splicing process.

This capability forms part of BOTON conveyor belt lifecycle and field services.

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