Desenvolvimento de nanocompósitos de borracha com formulação comercial para aplicação em correias transportadoras de minério

Abstract

Belt conveyors (BCs) are widely used across various industrial sectors, especially in mining, due to their efficiency and versatility in handling bulk materials. However, their continuous operation is often compromised by failures in the rubber covers, which are subject to abrasive wear and tearing, leading to unplanned downtime and significant financial losses. This technical limitation poses a major challenge for the industry, particularly due to the well-known trade-off between abrasion resistance and tear resistance in conventional rubber formulations. In this context, this thesis proposes the development of rubber nanocomposites incorporating carbon nanomaterials, such as graphene and carbon nanotubes, into commercial formulations, aiming to simultaneously enhance these mechanical properties. The work involved the careful selection of nanomaterials, the development of an effective methodology for their dispersion in the elastomeric matrix, and the determination of the optimal reinforcement concentration. Materials collected at different stages of this project were examined using various analytical techniques. Rheometry, swelling, tensile, tear, and abrasion resistance tests were also conducted to evaluate the performance of the resulting composites. The formulation containing 50 phr of carbon black and 5 phr of carbon nanotubes, pre-dispersed in sulfur, showed the best performance among the developed nanocomposites, with average gains of 8% in tensile strength, 10% in pin-on-drum abrasion resistance, and 18% in rubber wheel abrasion resistance compared to the reference rubber. Other formulations, containing 60 phr of carbon black and 2 or 5 phr of carbon nanotubes, also stood out with significant improvements in the main properties evaluated. The results indicate that the application of carbon nanomaterials in BC covers may represent a promising alternative to overcoming current limitations, contributing to increased durability and operational reliability of these systems in the mining industry.