FLSmidth says it has launched redesigned mill lining components engineered to suit the specific functions and differing operating environments of the mining industry with its.
The new PulpMax™ mill liners are designed to increase the throughput of semi-autogenous (SAG) mills and substantially boost the wear life of liners, the company said.
FLSmidth said: “Delivering on a promise to provide increased productivity to the mining industry, the composite design incorporated in FLSmidth’s new PulpMax mill liners ensure that users enjoy reduced downtime and maintenance, increased throughput and improved worker safety.”
With lighter weight mill liners, installation is faster and safer as each liner is easier to manipulate, according to the company. There are also fewer parts, and, hence, fewer movements are required to perform a reline, resulting in a significant decrease in scheduled downtime.
The composite nature of the liner reduces its weight by almost 50%, according to FLSmidth, which allows the plant to increase its ball charge level without increasing the total weight of the mill.
This higher ball charge further contributes to the higher throughput.
“The lighter weight of these liners has an important impact on size, design and installation time,” the company said. “Each liner can now be larger – subject to the size of the mill opening – and the mill can be lined with fewer of them, reducing the downtime required to conduct replacement.
A lighter liner means fewer bolts to hold it in place, a factor further reducing installation time, according to the company. This shorter downtime also means less time for contractors inside the mills, leading to a faster and safer liner changeout.
Another important benefit of the composite material used in many of FLSmidth’s redesigned liners is it is not necessary to torch the liners, as is sometimes required when removing old steel liners, the company said. “This torching process in the mill is best avoided, as it can cause costly damage to the mill shell,” FLSmidth explained.
Finally, there has also been the development of composite material shell liners bolted from the outside of the mill, once again, speeding up installation and reducing risk.
Jack Meegan, Product Line Manager for Comminution at FLSmidth, said: “As mines increasingly recognise the positive financial impact derived from just a few more percentage points in throughput improvement, many are looking beyond conventional steel cast liners for mills. FLSmidth’s innovations, based on combinations of steel, rubber and ceramic components, allow the liners to be thinner, resulting in a larger volume inside the mill, making higher charge levels possible.”
He continued: “Responding to the continuous assessment of customer needs, FLSmidth has launched a mill liner solution based on extensive data on mill operations, shutdowns, wear profiles and other factors. These have been used to develop a high-end technical and financial solution.”
Following installation, an ongoing measurement of actual wear, tonnage processed and estimated wear life is conducted so further recommendations can be made to improve performance, Meegan explained.