Testing Almex presses at Kansanshi,

Zambia.

By: Marc Middendorp

 1. Introduction
We were asked to check the accuracy of the ALMEX presses that Kansanshi uses to splice
their belts. The tests were done on site between January 30th- February 1st, 2012. The presses
tested were ALMEX sectional vulcanisers (type SVP). On site the following platen sets were
available for testing:

 2 platen sets (4 plates) with dimension 64” x 56”. Kansanshi indicates this with plate
1A, 1 B, 1C and 1D.
 4 platen sets (8 plates) with dimensions 30”x 84”. Kansanshi indicates this with plate:
2A to 2 H.

2. Scope of research
We checked the following

a. Rubber splice materials that are used.

b. Work method of Kansanshi splicers.
c. Working conditions of the presses
d. Temperature readings of the presses.

2a. Splice material

The use of bad splice material (degenerated) has been excluded. There was enough
deformation to be “fresh” (not elastic).
 2b. Splice method

The Kansanshi splicers were asked to prepare one splice in order to see if the method they use
could be a cause of concern. Special attention was given to:

1. Measuring: This was OK

2. Cutting of the splice: This was perfect. No cuts were noticed through the next layer.
3. Buffing: This was NOT good.
4. Cleaning and applying solution: This was NOT good.

Buffing and solution

All the procedures were fine except for the buffing and use of solution. We advise NOT to
buff the place where the fabric is. The fabric is an EP or Nylon that has been dipped in the
factory. This dip is orange and actually is the agent that bounds the fabric to rubber. When
buffed like I saw, the fabric gets damaged and NO adhesion will occur on that spot. It is
thereforea dvised NOT to buff (except for the edge as seen on the picture).

After the buffing, 2 layers of solution were applied. The only function of solution is to create
a sticky surface so that the splice will not move when the press is closed. SOLUTION DOES
NOT have any other function than that. Therefore NO or very little solution should be applied
because too much will actually reduce the quality of the splice. This is especially the case
when the fabric has been damaged by buffing..
 2c. Working condition of the press
The 4 large platens (1A-1D) were in working condition and could be tested. Out of the 8
smaller platens (2A-2H), only 4 could be tested because 2A, 2B, 2 G and 2 H had broken
connectors:

Also all the press plates had damaged and “soaked” insulation. The main reason for this is that
after vulcanising the press is water cooled. After the vulcanising process, the remaining water
should be blown out by means of a compressor. What is happening now is that when the press
is used again, the water vaporises when it reached 100 C. The damp and water gets into the
insulation and “sucks up” the moist and thereby expanding the insulation package and thereby
reducing the effectiveness of the press. The heat should be transferred to the belt, instead
some heat is “escaping” due to the condition of the insulation.
 2d. temperature readings on presses

The temperature test procedure

For the testing we put a total of 8 thermo couples on a piece of belt that matches the size of
the platens. We placed 4 thermo couples on top of the belt and 4 on the bottom (see sketch).
The temperature was measured from the moment the press was switched on until 60 minutes.
This is the same as a normal splice procedure which is about 40 minutes heat up till 150 C and
then vulcanising.
 The results part 1 C and D

These platens 64” x 56” were tested by setting the control at 150C. As you can see at 95 C the
remaining water started “cooking” (please note, at Kansanshi water starts cooking at 95 C
because its height is 1250 m). The vaporising of the water takes time which causes a distorted
heating profile. However when the controller indicated 150C , the actual temperature at the
thermo couples was between 138 and 142C. This means it was lagging behind around 8-12C.

The results part 1 A and B

Also here temperature was set at 150C. Also here temperature was set at 150 C. Same
distorted heating graph because of the water remaining in the press after vulcanising. When
the controller indicated 150 C, the thermocouples measured about 140 C. At the end I
adjusted the controller temperature to 160 C and the plates heated up to the required 150C.
Again temperature was lagging about 10C behind.

The results part 2 D and E

The smaller platens showed the same issues as the previous ones. Water in the cooling platens
distorted the heating graph. Still when the controller indicated 150C, the thermo couples
showed about 144 C. In the end I increased the controller to 155 and the thermocouples
showed about 148 C. The temperature lagged behind about 6 C.

The results part 2 C and F

Same a s other plates. Water in the cooling platens, distorted heating patterns, temperature
lagging behind about 6 C.

3. Conclusions

The following main conclusions can be drawn:

1. Overall splice skills of Kansanshi team are OK provided that they do NOT buff the
steps and they use only very little solution. When these recommendations are
followed, the quality and lifetime of the splices will improve!!
2. The press bars are very heavy because they were designed for doing steel cord splices
(14 kg/cm2).
3. There were 4 platens we could not test because the connectors are broken and need
to be replaced.
4. At least one pressure bag was leaking and should be replaced.
5. None of the original T4 control boxes had working power cables. This should be
repaired.
6. The condition of the platens were bad. All insulation plates are soaked with water
and have expanded thereby reducing the effectiveness of the press. The heat should be
transferred to the belt, instead heat is “escaping” due to the condition of the insulation.
7. Mainly due to the above the temperature is lagging behind. In other words, when
splicing it is assumed that the temperature is 150 C but in reality it is about 10 C less.
This has a negative effect on the quality of the splice. This can be solved by
calibrating the control box regularly or setting the control box at 160 C instead of
150C.
8. Some of the tools that are used do not work properly. The winch that is used for
pealing the steps is too light. Kansanshi is using 1000 pound winch now and should be
replaced by a more heavy duty one (2000 pounds). Also the belt clamps Kansanshi has
are dmaged beyond repair. Replacement is suggested.

4.Recommendations

The presses that are used now are in bad condition. As said before, they need to be
reconditioned (new insulation plates for all, new connectors for at least 4 platens, new
pressure bag for one press, repair and recalibration of controllers).

Also the bars that are used are very heavy because they were designed for steel cord splicing.
The weight of the platens is also relatively high (112 and 150 kg each). The weight is a
complaint of the splicers.
I could not check the quality of the bolts but I did see that the bolts are used as “hammers”
which might cause small cracks. This can be potentially dangerous because if there are cracks
and these bolt are used under pressure, they might “explode” and cause harm.

Recommendations for Kansanshi to consider:

1. Purchase newest generation ALMEX press. These are much lighter and safer (new
rope system) than what is used now. This press is suitable for EP belts. Quote can be
submitted by MES on demand.

2. Recondition existing presses. I suggest that we will recondition the presses on site. If
you order the parts we will send someone over to actually refurbish the presses. Quote
can be made on demand through MES.
3. Pressurise with air instead of water: Now water is used for pressurising and cooling.
Water is also the cause of the problem with the insulation packages. EP belt require 7
kg/cm2 pressure. This can be done by using air instead of water. A standard
compressor can be used for this (ALMEX can provide through MES). This same
compressor can be used for blowing out remaining water after cooling.
4. Use a cooling canister and cooling hoses: you want to avoid water going into you
system. The cooling hoses should be connected to the plates also during heating. In
this cause the water that remains vaporise outside the press.
5. Regularly calibrate the control boxes: I suggest that a data logger is purchased as used
during our testing. Test the control boxes once a year and calibrate if necessary. Quote
on demand through MES.

6. New tools: heavier duty winches are required, new belt clamps is recommended.

7. Ceramic lagging: Side note is that we would like to suggest to lag one of your pulley
with our patented ceramic lagging.