Tag Archives: Linatex

Namdeb receives the Linatex treatment at Sendelingsdrift

The installation by Weir Minerals Africa of a Linatex® 808 hard wall rubber hose with wear indicator system is, Weir says, reducing downtime and operating costs at Namdeb’s Sendelingsdrift treatment plant in Namibia.

Sendelingsdrift was previously having to change out the incumbent competitor’s rubber hoses every four weeks due to excessively high wear rates. In addition to the ongoing downtime, the plant also risked losing concentrate due to the hose failures. As the concentrate media contains diamonds, additional security was required when dealing with hose failures that result in concentrate leakage – adding to the operating costs.

The Weir Minerals Africa service teams regularly visited Sendelingsdrift to engage with the plant manager, area engineers and other operational staff to get a better understanding of their requirements and problematic applications. After an audit of the site, the team considered all the parameters and proposed a trial of a Linatex 808 rubber hose fitted with a wear indicator system.

The proposed solution would be capable of withstanding the slurry flow rate of 84 litres per second with a slurry density of 2,65 t/cu.m. The wear indicator system installed on the hose would indicate when the hose was nearing the end of its life; no physical inspections would be necessary. In addition, Sendelingsdrift would save the cost of additional security requirements by eliminating premature hose failures.

Sendelingsdrift agreed to the proposed trial, and the Weir Minerals Africa service team conducted weekly site visits to inspect the hose and the wear indicator system. While the competitor hose generally failed after delivering 32,000 t of ore, the trial showed that the Linatex 808 rubber hose surpassed 162,000 t, according to the company.

The hose lasted seven-and-a-half months before being replaced – more than six times longer than the competitor’s hose, representing a significant cost saving for the customer. The Linatex rubber hose processed over 2.5 Mt of concentrate and a similar volume of slurry during this time.

Designed for dual delivery and suction applications, Linatex 808 rubber hose can be custom manufactured to any size and is available with a range of flange types, Weir Minerals says.

Weir Minerals strives for unmatched hydrocyclone performance with release of Cavex 2

Almost 25 years after the original Cavex® hydrocyclone came into the classification market, Cavex 2 is set to introduce a step-change in performance and sustainability, with water and energy savings, according to Weir Minerals.

The launch of Cavex 2 marks a new generation of hydrocyclones, Weir says. Like the original Cavex hydrocyclones did more than two decades ago, Cavex 2 introduces new geometric features to offer performance unmatched by any cyclone in operation today, the company claims.

Debra Switzer, Global Product Manager for Hydrocyclones at Weir Minerals, said: “Our Cavex 1 design set an industry benchmark over two decades ago with its unique 360° laminar spiral inlet geometry, which significantly reduced turbulence. This design was so successful and desired by the market that it was widely replicated by competitors.

“Following years of research, development and trials, we have improved upon this design with the creation of LIG+™ inlet and chamber design. This unique design produces a more stabilised flow pattern, further reduces turbulences and friction throughout the hydrocyclone and provides up to 30% additional capacity.”

The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir. This allows operators to achieve more throughput with fewer operating hydrocyclones, reducing the upfront capital expenditure.

The new design has taken into consideration the shape and angle of the hydrocyclone to ensure particles report to the correct stream, Weir says. This reduces recirculation and misclassification, further improving separation efficiency.

“Cavex 2 allows our customers to do more,” Switzer says. “A more sustainable circuit, with lower energy and water requirements. Expand the capacity of their existing circuits, without increasing the footprint of the cyclones or clusters. It’s the kind of generational engineering leap that will change the way circuits are designed for decades to come.”

Cavex 2 takes advantage of Weir Minerals’ Synertrex® IIoT technology, which enhances the overall performance of the hydrocyclone. Armed with this technology, operators are automatically alerted to roping or blockage conditions ahead of time, ensuring the hydrocyclone runs under the most optimal operating conditions.

“To minimise the amount of bypass that is produced in any hydrocyclone, it is favourable for it to operate in the semi-roping condition,” Switzer said. “This is often difficult to do continuously because any upset in the hydrocyclone’s feed conditions could move it into the roping condition, but, with Synertrex, this balancing act can be closely managed.”

Cavex 2 hydrocyclones can be customised to suit almost any application, according to Weir, with a variety of spigots, vortex finders and liners. Liners are available in a range of material options, including Weir Minerals’ proprietary R55® rubber compound or Linatex® premium rubber, both of which have been proven to outlast competitors elastomers in similar applications, Weir says. Liners can be replaced via a ‘snap-in’ system requiring zero adhesive, while smaller models (400CVD and below) are available with moulded fibreglass housings, the company says.

Switzer concluded: “Every stage of the Cavex 2’s design has been guided by the needs of our customers. As a consequence, it has been tested in multiple mining applications throughout the globe. These tests revealed outstanding results of up to 30% additional capacity.

“Decreasing ore grades and increasing need to reduce both water and energy usage have created the need for a low maintenance, highly efficient hydrocyclone, which can be readily retrofitted into existing circuits to increase throughput and maximise returns.

“I can’t wait for our customers to see what this new range is capable of.”

New Weir Minerals Sand Wash Plant to boost recoveries

Weir Minerals has released a complete sand wash solution that draws on its long experience in the sand and aggregate industry.

The Weir Minerals Sand Wash Plant comes with Linatex® lining, produces more saleable product than conventional sand screw plants, with fewer moving parts, and has an optimised process that produces a drier, higher-quality product with less fines, according to the company.

The solution has already proven effective at sites like Coimbatore Minerals in Tamil Nadu, India, Weir says, where a custom-built wash plant reduced its total cost of ownership by 51%, while offering a 23% reduction in fines that helped the company consistently meet the industry’s high standards for a saleable product.

Bruce Cooke, Global Product Manager – Sand Wash Plants for Weir, said: “We know the most important thing for quarry operators in washing is recovering as much sand as possible to maximise their sales, which is why we’ve designed an integrated solution for washing their product, with a hydrocyclone which can deliver greater recovery than sand screws. In addition, every component has been selected by our expert engineers for its long-service life, interoperability and ease of maintenance.”

The compact solution features a range of Weir Minerals equipment designed for high efficiency in sand and aggregate applications, including Warman® WGR pumps, Cavex® hydrocyclones, Enduron® dewatering screens, Linatex hoses and Isogate® knife gate valves.

The Warman WGR is a popular pump in the sand extraction industry, according to Weir, combining top of the line hydraulic design with an adjustable impeller, long bearing life and a simplified wet end, making replacement predictable and cost effective.

Precision moulded and lined, Linatex premium rubber is used for wear zones throughout the plant due to its proven wear performance in wet sand applications in operations around the world, Weir said.

Cavex hydrocyclones provide “exceptional classification efficiency” thanks to their unique 360° laminar spiral, delivering more saleable product than a sand screw solution would, the company said. Enduron dewatering screens, meanwhile, reliably separate product with a high degree of efficiency. And, finally, Isogate knife gate valves contribute to the plant’s straightforward maintenance.

Surendra Menon, President, Weir Minerals India, said: “For the new sand wash plant, we focused on making it quick and easy for quarry operators to get up and running. Its straightforward design means it can be assembled in just two days while its compact skids make it easy to drag into any operation.

“Efficient, reliable and easily integrated into flowsheets, we think the plant is a game changer for quarry owners.”

Weir Minerals improves plant uptime at mineral sands, gold mines

Two African mines are achieving increased production time and plant availability after converting to Weir Minerals rubber lining solutions, the company says.

A mineral sands operation in Mozambique approached Weir Minerals just over two years ago, after experiencing high wear on its pipe and launders. This was leading to frequent maintenance, leaks and downtime. The Weir Minerals team observed that part of the challenge was worn out and corroded metal work on the mine’s wet concentrator plants due to the proximity to the coast.

Access to reline the existing launders was difficult and posed safety risks necessitating a more effective solution, the company said.

The solution was to replace the competitors’ products – chemically-cured rubber – with Linatex® rubber and Linard® 60 rubber. This was done during the mine’s monthly shutdowns.

Whereas the competitors’ rubber lasted only two to three months, the Linatex and Linard linings are still in operation after 25 months, according to the company.

The Linard 60 rubber lining solution was also applied at a gold mine in South Africa’s North West province. The mine’s maintenance team had been replacing the rubber lining on mill feed hoppers and spouts every 10 days, but the Mechanical Foreman was looking for a more resilient solution.

The Foreman was not familiar with Linatex rubber products, so a trial using Linard 60 rubber was arranged, with the entire feed hopper and spout lined with this silica-reinforced natural rubber.

The results saw wear life increase to 12 weeks. With only the partially worn areas requiring relining, there was a reduction in relining costs. This, in turn, increased plant availability, resulting in fewer stoppages and reduced operating costs.

Linatex premium rubber is a proprietary vulcanised natural rubber produced through a process that uses high quality natural latex, according to Weir. “It has outstanding strength, resilience and resistance to cutting and tearing – with high performance in wet, abrasive conditions,” the company said.

Linard 60 rubber, which is silica reinforced, retains the natural strength and nerve of latex, while combining with the toughness needed for handling coarse materials, according to the company.

Weir Minerals Pumped Up by new dewatering game for miners

Weir Minerals says it has created a “fun and simple game” to educate its customers on the OEM’s dewatering capabilities.

Pumped Up! uses a variety of Weir Minerals dewatering equipment to move water around a fictional mine site, according to Ian Ross, Global Product Manager for Dewatering at Weir Minerals.

Each of the 10 levels present players with a different dewatering obstacle to overcome, from recycling, to flooding, to underground mines and long distance pump requirements. Levels increase in difficulty, and the number of points awarded is determined by how long each level takes to complete.

Products included as part of Weir Minerals’ dewatering solution in Pumped Up! include Warman®, Geho®, Floway®, and Multiflo® pumps as well as Isogate® and Delta® valves, and Linatex® hoses.

The game was released as part of Weir Minerals’ 2019 Take Control Of Your Water dewatering solutions campaign. Through articles, expert profiles, and case studies, the campaign demonstrates how Weir Minerals use its engineering and project management capabilities, together with a wide range of equipment, to deliver an optimised dewatering solution unique to every customer site, the company said.

Head to www.dewateringsolutions.weir to play the game.

Weir Minerals Africa on the importance of application-specific valves

Weir Minerals Africa has stressed the importance of using quality original equipment manufacturer (OEM) products “engineered specifically for their application” when it comes to using valves in abrasive and corrosive slurry conditions.

Without such components, valves can be quickly worn out and costly downtime can occur, the company said.

Ronald Govender, General Manager – Process Equipment at Weir Minerals Africa, said: “With our comprehensive range of slurry valves, we can help customers select the right equipment to suit the pressure of their system, the chemical make-up of their slurries, and the physical nature of the solids they process.

“We can provide the right wear options, actuation mechanisms and control accessories that will ensure optimal plant uptime.”

Weir Minerals’ Isogate® range of slurry valves is proven to be reliable and versatile, according to Weir, operating under wide pressure and temperature ranges. “For longer life, valve sleeves come in a variety of materials including genuine Linatex® premium abrasion-resistant natural rubber. To reduce downtime and overall cost of ownership, all wear parts are easily replaced in the field,” the company said.

The range includes mechanical pinch valves, with open or closed body, and pneumatic pinch valves with one-piece sleeve or two-piece liner. Isogate knife gate valves are known for their heavy-duty performance, even in coarse slurries, with pressure ratings from 10 to 51 bar, Weir said. These are uniquely designed with both ease of maintenance and low overall cost of ownership in mind and are engineered to handle the harshest and most abrasive process flow conditions, according to the company.

Weir Minerals’ check valves are single, non-return units that benefit from 20 years of in-field experience in the most arduous slurry applications, Weir said. Within this range, Autoball® valves, which are actuated with differential pressures, enable quick changeover between duty and standby pumps.

“An exciting addition to our offering is the Delta Industrial™ range of knife gate valves, which set the standard for high performance in slurries,” Govender said. “These valves guarantee zero leakage, due to their unique transverse seal and shear gate design.”

The design protects the primary elastomer seal from the slurry flow to avoid wear, while a precision-machined metal seat provides a secondary seal. “The transverse seal features an upper and lower scraper, with an elastomer that is energised by a pliable compound – even while the valve is in service.”

Designed for the most demanding processes, Delta Industrial valves have been in use for over two decades in mill circuits, tailings transport, mineral separation and leaching applications for slurries up to 120 bar working pressure.

“We bring a full basket of valve solutions to customers,” Govender said. “Other valves in our liquid service range include butterfly, diaphragm, globe and trunnion-mounted ball valves.”