Digital Integration Meets Eco-Efficiency: BOTON’s Aramid Conveyor Overhaul Powers Zhuanlongwan Coal Mine

Slashing Annual Energy Costs by 2.2 Million RMB and Doubling Asset Lifespan via "Body-Armor" Grade Engineering

Digital Integration Meets Eco-Efficiency: BOTON’s Aramid Conveyor Overhaul Powers Zhuanlongwan Coal Mine

Core Achievements

Energy Consumption Reduction

Reduced per-ton electricity consumption by 16.3%, yielding over 2.2 million RMB in annual power bill savings.

Asset Lifespan Doubled

Extended the conveyor belt's operational life to 8–9 years through an ultra-high impact-resistant structure that acts like industrial body armor.

Digital-Twin Management

Embedded RFID technology paired with non-destructive AI diagnostic systems to fully merge physical asset monitoring with digital workflows.

The Zhuanlongwan Coal Mine, operated by Yan Energy under Shandong Energy Group, is a modern mega-mine with an annual capacity exceeding 10 million tons. Its original 200-meter-deep underground main haulage system relied on traditional steel cord flame-retardant belts, which suffered from excessive dead weight, high energy draws, and labor-intensive joint maintenance.

By the end of 2024, the mine partnered with BOTON's subsidiary, Shandong New Balong, to carry out a comprehensive intelligent transformation. Releasing 547.2 tons of legacy steel cord belting, the project deployed a lightweight, high-performance digital aramid conveyor system, spearheading a green, smart transition for underground mining logistics.

Key Facts

  • Industry: Underground Coal Mining
  • Application: Underground Main Haulage System (Main Belt Slope / Roadway)
  • Site: Zhuanlongwan Coal Mine, Ordos, Inner Mongolia
  • Customer: Yan Energy, Shandong Energy Group
  • Product: Fire Resistant Aramid Conveyor Belt for Underground Coal Mine
  • Ore Type: Coal
  • Conveyor Length: 3,800 Meters (7,600m total belt length)
  • Design Capacity: 10,000,000+ Tons annually
  • Key Benchmark Metrics (Steel Cord vs. BOTON Aramid Upgrade):
    • Unit Weight: Reduced by 25% from 72 kg/m to 54 kg/m.
    • Spliced Joints: Eliminated 13 potential failure points system-wide.
    • Reel Capacity: Increased maximum spool length from 230m to 350m.
    • Impact Resistance: Penetration energy tolerance reached 2,550 Joules (2.5× that of steel cord).
    • Specific Power Draw: Dropped from 0.759 kWh/t to 0.635 kWh/t.
  • Specialized Technologies: Embedded RFID chips, anti-tear mesh reinforced edging, real-time AI non-destructive monitoring.
  • Belt Length: 7,600 Meters
  • Delivery Scope: High-Performance Flame-Retardant Aramid Belting, Integrated RFID Chips, AI Diagnostic Monitoring Suite, and Splicing Services
Key Facts

Project Challenges

Excessive Parasitic Dead Load

The massive weight of the legacy steel cord belt (72 kg/m) forced the drive motors to operate under high baseload conditions, bloating power bills.

Frequent Impact and Puncture Degradation

Falling coal lumps and sharp tramp material frequently caused hidden tears in the top cover or catastrophic belt slitting, threatening operations.

Maintenance Blind Spots

Relying on manual inspections across miles of underground tunnels made pinpointing early defect locations extremely slow, risking costly unplanned shutdowns.

BOTON Solution

BOTON Solution

Material Transformation via Advanced Aramid Synthetics

BOTON swapped out the heavy steel infrastructure for an advanced aramid woven fabric core. By taking advantage of aramid's high strength-to-weight ratio, the upgrade cut the conveyor's dead weight by 25%, drastically reducing the structural inertia and operating power required by the drive motors.

Engineered High-Impact and Anti-Tear Architecture

To withstand severe material impacts at transfer points, the belt features an advanced dual-layer weft yarn design that diffuses perpendicular impact forces horizontally across the matrix. Paired with a specialized anti-tear mesh encapsulated along the belt edges, this creates an industrial "body-armor" protective envelope that prevents puncture propagation.

Digital Integration and Real-Time AI Diagnostics

BOTON embedded heavy-duty RFID tracking chips into the belt structure at precise 20-meter intervals, assigning the system a continuous digital coordinate map. This array works alongside an automated, non-destructive AI scanning system that monitors splice movement and core condition 24/7, turning traditional manual tracking into automated predictive maintenance.

Related Products

Fire-Resistant Conveyor Belt

Fire-Resistant Conveyor Belt

Aramid Conveyor Belt

Aramid Conveyor Belt

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