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STOP THE SLIP – GET THE GRIP with MICKE ultra wear resistant CERADRIVE and CERASINT NORUB directly bonded pulley lagging technology ceramics (Ceramic Pulley Lagging).
One of our customers, Public Power Corporation of Greece (PPC), is a 51% state-owned company which employs 22,000 people and operates three large lignite mining sites with hundreds of kilometers of belt conveyors for the transport of lignite and the overburden.
PPC also operates a total of 94 thermal and hydroelectric power plants and three wind parks distributed throughout Greece. The largest lignite mines are situated between Kozani and Ptolemaida, in Amyntaio within Florina province and around Megalopolis. These operations represent the primary energy source for Greece. In 2010, PPC’s turnout reached approximately 5.8 billion euros.
1. Material alternative against the existing hot or cold vulcanized rubber friction laggings for the conveyor pulleys.
2. Achievement of continuous, physically highest-possible adhesion/friction coefficients µ >= 1.0 between drive pulley and belt in order to eliminate belt slip.
3. At least 100% increase of bonding strength between friction laggings and pulleys.
4. Considerable increase of lifetime of friction laggings by a factor of 3 – 5.
5. Considerable reduction of belt wear on the belt underside, by >= 80% of existing value.
6. Considerable reduction of mechanical wear of pulley mantle metal on all drive and non-drive pulleys, down to <= 10% of existing value.
7. Considerable reduction of belt tensions, down to 75 – 50% of existing value.
8. Cost-saving and fast-on-site repair of damaged laggings, or complete change of laggings in an installation.
9. Maximum reduction of repair and maintenance cost for all belt conveyor pulley issues.
STOP THE SLIP – GET THE GRIP with MICKE ultra wear resistant CERADRIVE and CERASINT NORUB directly bonded pulley lagging technology ceramics (Ceramic Pulley Lagging).
One of our customers, Public Power Corporation of Greece (PPC), is a 51% state-owned company which employs 22,000 people and operates three large lignite mining sites with hundreds of kilometers of belt conveyors for the transport of lignite and the overburden.
PPC also operates a total of 94 thermal and hydroelectric power plants and three wind parks distributed throughout Greece. The largest lignite mines are situated between Kozani and Ptolemaida, in Amyntaio within Florina province and around Megalopolis. These operations represent the primary energy source for Greece. In 2010, PPC’s turnout reached approximately 5.8 billion euros.
1. Belt widths reach 2500 mm with conveyor lengths of >= 5 km and belt speeds of >= 5 m/s.
2. Belts carry moist and often wet lignite and overburden sands.
3. Extremely high belt tension, which often destroys pulleys, belts, laggings, and bearings.
4. Overburden above the lignite, and between lignite layers, is highly abrasive sand frequently interspersed with sharp rocks which cut and perforate belts and rip rubber laggings from belt pulleys.
5. In wintertime, freezing temperatures, snow, ice, and heavy rains are the biggest challenges for excavating operations and material transport in the mountainous mines.
Exchange of existing rubber friction laggings on drive pulleys against full ceramic, directly bonded wear resistant MICKE CERADRIVE NORUB high-friction laggings featuring high adhesion-/friction coefficients µ 1.0-1.5 between pulley and belt.
Exchange of existing rubber friction laggings on all non-drive pulleys (tension, snub, reverse pulleys) against full abrasion resistant ceramic directly bonded MICKE CERASINT NORUB low-friction wear protection laggings featuring low adhesion-/friction coefficients µ 0.2-0.3 between drive pulley and belt.
Implementation of our MICKE NORUB CERABOND organo-ceramic bonding system in order to ensure the fail-safe bond of the friction laggings under 1 and 2 on the pulley.
Implementation of our MICKE NORUB CERABOND organo-ceramic bonding system in order to ensure the fail-safe bond of the friction laggings under 1 and 2 on the pulley.
Mechanically extremely strong and sturdy built ceramic blocks 20 wide x 10 thick x 30 mm long, supplied in easy-to-bond sheet form.
Maximum pressure resistance of ceramic blocks is 3000 N/mm².
A single ceramic block has 2 different action surfaces, one of which is structured/profiled for use on drive pulleys the opposite side being smooth for use on all non-drive pulleys.
The structured surface features a sophisticated finite-element-designed profile of technically perfected and superior, triangular high adhesion/friction teeth which are extremely resistant to all kinds of impact, glide, and friction wear due to their broad base and conical shape. An aspect unique to us is the 2 mm height feature of our high friction teeth, which guarantees at least double the performance lifetime and wear resistant as the small round or square shaped and maximum 1 mm high mini-dimples on our competitors’ laggings. Our high friction abrasion resistant teeth create slippage-free 100% positive locking/micro-cogging with the rubber belt (with or without steel cable reinforcement) resulting in slippage-free conveyor operation. Continuously reproduced adhesion/friction coefficients of µ 1.0-1.5 in dry and fully wet operation between conveyor belt and ceramic lagged pulleys have been proven during tests carried out at the DMT Institute in Germany. The parallel rows of ceramic blocks are spaced apart by 2 mm and ensure a perfect and superior 3-dimensional drainage system for wet operation in connection with the 2 mm high high-friction teeth. Our CERADRIVE NORUB has become a synonym for "drive-without-slippage" on all kinds and sizes of drive pulleys, whatever the drive-power installed.
The smooth surface of our wear resistant MICKE NORUB ceramic blocks creates the desired low friction coefficient µ 0.2-0.3 on all non-drive pulleys due to their missing tooth structure, and is likewise available in easy-to-bond ceramic sheets under the product name CERASINT NORUB.
The extreme wear resistance of our NORUB ceramic blocks guarantees a long lifetime of the laggings of 5-20 years and ensures the same long time span of protection against pulley mantle wear.
The organo-ceramic MICKE NORUB bonding system CERABOND is the technical backbone of our NORUB ceramic blocks, ensuring at all times and over the entire lagging life the failsafe bond of the ceramic blocks on the pulley and high wear protection. The typical bonding strength values of MICKE NORUB are 30-50 N/mm² as compared to only 5-10 N/mm² of rubber laggings. Detachment of ceramics or ripping lagging off the pulley surface by excessive belt tensions or high drive momentum during start-up of high-powered, heavy-duty, and overloaded conveyors are now a thing of the past at PPC.
In the unlikely case of damage to the lagging, the respective ceramic blocks may be exchanged on site within 30 minute. Immediately after this procedure, belt conveyor operations may be fully resumed. A total exchange of lagging in the installation is possible as well.
MICKE CERADRIVE / CERASINT NORUB full porous ceramic versions and the rubber-ceramic versions of CERADRIVE and CERASINT are German LOBA approved for underground mine use and meet the requirements of inflammable / flame resistant products for mining operations.
1. All PPC lignite mines and their affiliated power stations have now made MICKE CERADRIVE / CERASINT NORUB all-ceramic laggings their standard pulley lagging solution, and included them in their technical drawings and tenders. By 2011, more than 150 large and high-powered drive pulleys in problematic sites had been equipped with MICKE CERADRIVE NORUB and more than 50 non-driven pulleys with CERASINT NORUB by our local agency Messrs Petsos and Company. All installations have run successfully without problem since.
MICKE NORUB ceramics have solved all of “PPC’s” critical issues, as laid down in the “Objective” chapter, such as:
In general, PPC’s mines and power stations have been successfully operating with MICKE ceramic pulley laggings since 1973, and fully rely on MICKE latest advanced ceramic pulley laggings.
Learn more about conveyor pulley lagging on our website (click on the product group or download our latest Company and Products Presentation (enquire for the link by emailing us).
Industrial Friction Materials
Grabenstr. 210
D- 47057 Duisburg
Germany
© 2023 – Industrie-Reibbeläge M.I.C.K.E. Brühmann GmbH
© 2023 – Industrie-Reibbeläge M.I.C.K.E. Brühmann GmbH