Tag Archives: Wear parts

Bradken highlights Duaplate D80 wear performance in WA iron ore mine trial

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Steel and iron ore, Sustainable mining, , , , ,

Bradken’s Duaplate® DX has recently been trialled in the lower section of a surge bin, at an iron ore mine in Western Australia’s Pilbara region, showcasing the weld overlay material’s ability to perform under extremely abrasive operating conditions.

The trial was completed back-to-back with Duaplate D80, a chromium carbide weld overlay that can withstand very high impact and very severe abrasive environments in the fixed plant industry, Bradken says.

Duaplate DX is manufactured to Bradken’s proprietary composition to create an incredible fine microstructure that provides a substantial improvement in the operational life over a traditional chromium carbide based overlay, the company says.

In the study, the two – Duaplate DX and Duaplate D80 – were compared with each other in identical chute lining applications. The DX chute was lined with 8 mm overlay, while the D80 chute was lined with 9 mm of overlay. The chutes were in service for six months and processed comparable material and tonnages, according to Bradken. At the end of the six-month trial period, the bins were removed from service and thickness testing was conducted to compare wear and impact performance between the two overlay materials.

Thickness testing data showed that similar locations were prone to high wear on both bins, however the DX material showed significantly less wear compared with the D80 material. In particular two areas were worn past the D80 overlay and through the mild steel fabrication. In the corresponding locations on the DX chute, there was still a minimum of 4 mm of overlay, or 50% of the wear life remaining.

The trial, therefore, showed that:

  • Bradken’s new Duaplate DX has up to 2.5 times longer wear life than Duaplate D80;
  • 8 mm of Duaplate DX is equivalent to at least 17 mm of Duaplate D80 in sliding abrasion conditions; and
  • A 50% reduction in liner mass; giving a significant reduction in manual handling risks, therefore improving safety concerns.

Metso boosts wear life on premium rubber offering with Skega Life

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining services, Sustainable mining, , , , , , ,

Metso is introducing to its mill lining portfolio an innovative rubber, Skega™ Life, with, it claims, up to 25% longer wear life compared with the current premium rubber, Skega Classic.

The new rubber type is developed in Metso’s own laboratory and validated by field studies. Skega Life is a part of Metso’s Planet Positive offering, enabling increased sustainability and safety, optimised throughput, and increased uptime due to improved wear resistance and lower maintenance, the company says.

Fredrik Johansson, Global Product Manager, Rubber and Poly-Met mill linings, Metso, said: “We are excited to introduce Skega Life rubber to our mill liner portfolio. The new rubber is specially developed to have a very good wear resistance in grinding mills processing high abrasive ores. It can be used anywhere where a customer has a rubber application, but it is most beneficial in ball mills larger than 14 ft (4.3 m), AG, and SAG mills of 18 ft or smaller.”

Lars Furtenbach, Director, Research & Technology Development, Metso, added: “Mill liners play a crucial role in the mining process and Metso’s liners are always designed by our experts to meet the customers’ production targets and the mill conditions and enhancing overall process reliability. Field studies and tests have shown that our new rubber compound can have up to 25% longer wear life. The longer wear life reduces CO2 emissions and less liner material will end up in the tailings.”

Metso calls itself a world leader in developing and manufacturing high-performance mill liners. It pioneered the use of rubber linings and invented Poly-Met™, Megaliner™, and Orebed™ mill linings. New products are constantly being developed to enhance customers’ ever more advanced processes, it says, adding that the recent innovations include 3D wear scanning, a full Megaliner range, trommel deflector, Turbo Pulp Lifter, Liner Positioning System and a mill liner recycling service.

Metso launches VertiSense to optimise mineral and hydromet plant process performance

Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining services, Sustainable mining, , , , ,

Metso is introducing a new solution to its Sense series portfolio of intelligent instruments targeted at solving specific process challenges and enabling optimisation of mineral and hydrometallurgical plant process performance.

VertiSense™, Metso says, enables real-time wear monitoring of screw liners and enhances the grinding process in Vertimill® stirred mills.

Rodrigo Rizzoli, Vice President, Stirred Mills & HPGR Services at Metso, said: “We are excited to introduce VertiSense to our Sense series portfolio of specialised instruments that provide analytical data to better understand processes. VertiSense complements the series well and gives Vertimill stirred mill users a unique tool to maximise operational efficiency through intuitive software and analytics. What VertiSense does in practice is to ensure that wear parts are being replaced at the best time, thereby reducing waste and optimising mill availability.”

The VertiSense solution, part of Metso’s Planet Positive offering, is easy to install, maintain and use, the company says. It monitors liner wear rate and provides frequent reporting on the screw liners to assist plant maintenance personnel. Its wear measurement functionality facilitates the prediction of service life and spare stock planning.

Like the rest of the Sense series products, VertiSense is suited for both new and existing operations.

The Metso Sense series portfolio covers the entire minerals and hydrometallurgical process, helping customers to maximise their profitability and minimise their operating costs and environmental risks. In total, Metso’s intelligent instruments include more than 10 technologies to optimise the mining process.

Weir Minerals heralds 100 years of Linatex Premium Rubber

Environmental, Equipment maintenance, Mining consumables, Mining services, Sustainable mining, , , , ,

Linatex® Premium Rubber, manufactured solely by Weir Minerals Malaysia, is celebrating its 100-year anniversary as an industry leader in defence against abrasion.

The distinctive red rubber, renowned for its resilience, strength, resistance to wear and abrasion, offers exceptional performance in the harshest of mining and aggregate environments, according to Weir Minerals.

It has been field-tested in mine sites for a century, starting with the tin industry in Malaysia in the 1920s and continuing to the present day.

“Found in all the leading operations globally, it is the mining industry’s preferred first line of defence and protection against abrasion for expensive capital equipment – delivering best-in-class wear life and overall total cost of ownership,” the company says.

Brandon Greer – Processing Maintenance Supervisor, Pinto Valley Mine, Capstone, said: “I would definitely recommend the Linatex rubbers to really any mine. The life that we’ve seen is just phenomenal in comparison to what we’ve had in the past.”

Akhbayar Enkhsaikhan – Concentrator Maintenance Manager, Oyu Tolgoi Mine, added: “It significantly reduces material costs associated with changing out too frequently. On the cost side, most importantly, it enabled us to produce more copper.”

Dedicated to meeting customer demand and providing the most advanced solutions, Weir Minerals says it is continually working to modernise the manufacturing process for Linatex. The rubber manufacturing facility, located in Batu Caves, Malaysia, has recently been expanded to include a new Continuous Rubber Process (CRP2) facility, a new Banbury mixer to manufacture masticated dry rubber and additional rubber presses to support the growth within this area of the business.

The proprietary formula of Linatex Premium Rubber includes a unique liquid compounding phase which maintains the natural state and characteristics of the 95% natural rubber product, the company explains. The formula has remained unchanged since it was developed and patented in 1923 by Bernard Wilkinson. To ensure a consistent high-quality product, Linatex Premium Rubber routinely undergoes rigorous testing throughout the entire manufacturing and delivery process.

“Linatex Premium Rubber is the most sustainably manufactured rubber on the market,” Weir Minerals says. “The natural and renewable resource (pure latex is 100% sap of the rubber tree) is complemented by sustainable processes, minimal waste and a renewable solar energy system at the site.”

PROK ready to highlight conveyor pulley and wear solutions at Expomin 2023

Bulk handling, Equipment maintenance, Mining consumables, Mining equipment, Mining events, Mining maintenance, Mining services, , , , , , ,

PROK, a leader in conveyor equipment manufacturing, is planning to showcase its range of engineered pulleys, PROK HDPE and ROXDUR wear solutions at the upcoming Expomin 2023 event in Santiago, Chile, from April 24-27.

Visitors to the PROK booth will have the opportunity to participate in live product demonstrations, view products in augmented reality, and experience PROK’s holographic display. This interactive display will allow visitors to explore PROK’s conveyor components in an entirely new way, it says.

PROK Chile General Manager, Andres Virot, said: “At PROK, we are committed to innovation and pushing the boundaries of conveyor component technology. Our team of experts has designed and manufactured products that have revolutionised the industry. We are proud to showcase our range of products at Expomin 2023, and we look forward to meeting visitors and demonstrating the capabilities of our conveyor components.”

One of those products on display is PROK HDPE (pictured), a high-performance non-metallic composite roller that has helped mining companies across the globe reduce costs and improve safety, according to the company. PROK HDPE includes dual-layer wear indicator technology which provides a proactive tool for improving roller maintenance scheduling. The lightweight construction also assists to avoid manual handling injuries when changing out rollers.

Bradken expands mining wear solutions offering and Americas presence with Linings buy

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining mergers and acquisitions, Mining services, , , , , , , ,

Bradken has confirmed its growth aspirations in the mining wear solutions space with the acquisition of Linings, a Peru-based leader in composite mill liners.

Bradken says its expansion into the manufacturing of rubber composite mill liners and other products confirms its focus on serving the mining sector with innovative wear solutions and the importance of South America to Bradken.

“Over our 100-year history, Bradken’s customer focus has always shaped our innovation and growth,” Bradken CEO, Sean Winstone, said. “This acquisition is a perfect example of us listening to our mining customers and seeing immense value in broadening our range of solutions to fuel our growth.

He added: “We are proud to lead the market in steel mill liners and, as mining operations develop, so will we. It’s great to expand our product offering into rubber composites and leverage the expertise and innovation of the Linings team to continue solving the challenges our customers face.”

Bradken, a subsidiary of Hitachi Construction Machinery, began as an Australian foundry organisation and has grown to be a global entity focused on the mining sector and backed by an extensive manufacturing capability. Outside of wear solutions for mineral processing, mining fixed plant and mobile plant applications, Bradken delivers engineered bespoke castings for a range of industries in North America and supports the Australian sugar industry. This is the first manufacturing facility Bradken will have in South America.

Linings CEO, Manuel Marquez, said: “Joining Bradken is an excellent opportunity to combine the innovative composite products we have developed over the past 11 years with the depth of Bradken’s centenary of foundry experience, innovation and customer focus.

“This will allow us to have world-class tools and systems to provide our customers with outstanding pre- and post-sales service, as well as continuing to strengthen our supplier partnerships.”

Weir Minerals expands Linatex rubber manufacturing facility in Malaysia

Equipment maintenance, Mining consumables, Mining equipment, Mining services, Sustainable mining, , , , , , , ,

Weir Minerals, the sole producer of Linatex® premium rubber products, has expanded its rubber manufacturing facility in Batu Caves near Kuala Lumpur, Malaysia, doubling production capacity and enabling faster delivery times to customers.

The site, which sits on 18 acres (7.3 ha), has been expanded to include a new Continuous Rubber Process (CRP2) facility, a new Banbury mixer to manufacture masticated dry rubber and additional rubber presses to support the growth within this area of the business.

The modern manufacturing facility features state-of-the-art equipment that produces Linatex rubber products, a leading rubber used to protect equipment in mining, minerals processing and industrial applications for the global Weir Minerals network. The £13 million ($14 million) investment enhances Weir Minerals’ position as a global supplier, enabling the company to meet the increasing demand for premium rubber products and support its worldwide customer base, it said.

The new facilities were inaugurated by the President of Weir Minerals, Ricardo Garib, Vice President Operations of Weir Minerals, Richard Hinsley, and Managing Director of Weir Minerals Malaysia, Stephen Frendt.

Frendt said: “Our site manufactures Linatex rubber sheet and moulded rubber products for process equipment used in mining and industrial applications. This expansion will allow us to service the growing demand in the market – not just now but for years to come.

“The investment in the CRP2 allows us to increase the production capacity for the high wear and abrasion resistant Linatex rubber sheet. The Rubber Mixing Process expansion, on the other hand, is an upstream vertical integration of the supply chain in which masticated dry rubber compounds such as R55 are manufactured and distributed worldwide from the facility here at Weir Minerals Malaysia.”

The investment is a testament to the company’s focus on material technology, it says, ensuring that Weir Minerals’ customers have access to the best elastomers and supporting continuous product development.

The CRP2 control room at Weir Minerals Malaysia

Garib added: “Linatex is a vulcanised natural gum rubber, which is produced through a unique liquid phase proprietary process. Manufactured from a renewable resource, the final product is 95% natural rubber made from the highest-quality latex. Our rubber manufacturing facility is
very significant to Malaysia and to Weir Minerals globally, and continues to showcase our dedication to the environment and sustainable practices.”

In line with Weir Minerals’ dedication to sustainable solutions and practices, the Linatex rubber manufacturing process already has the lowest energy consumption compared with other rubber suppliers to the industry, it claims. A new renewable solar energy system has been installed on site in Batu Caves to further lower the power used in the rubber production process. The solar panels will reduce greenhouse gas emissions by almost 900 t CO2e/y, the company estimates.

Weir Minerals says it is also committed to further sequestering carbon by planting new trees on site and ensuring the natural surroundings are rehabilitated and preserved. All-local tree species were selected for this project after consultation with the local town council.

Hinsley said: “Sustainability is an inherent part of Linatex production, starting with latex being a natural and renewable resource sourced directly from the Hevea Brasiliensis trees, to working with ‘green’ suppliers, to manufacturing. The Continuous Rubber Process has minimal waste, and even mixing requires less energy compared to other rubbers.

“Sustainability is also an important part of our supply chain: we have been investing in Malaysia for a long time, employing local workers, providing community support and partnering with local suppliers, some of whom have been with us for over 30 years.”

Metso Outotec expands O-Series wear parts offering for crushing equipment

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining services, , , , , , ,

Metso Outotec is expanding its O-Series wear parts offering from working wears to protective wears, with the new offering now commercially available.

“We are excited to announce that through the expansion of the offering, the customer can get a complete set of wear parts in a competitive price range from the O-Series offering,” Olli Heinonen, Director, Mid-Market Crusher Wears, Consumables business area, says. “Our O-Series is a fit for customers who want reliable wear parts that are designed for Metso Outotec crushers, and backed up by OEM warranty, quickly and flexibly.”

Metso Outotec O-Series crusher wears are available for Metso Outotec’s stationary and mobile crushers in mining and aggregates industries. The protective wears will include selection of wears for Nordberg HP Series and GP Series cone crushers and C-Series jaw crushers.

The O-Series wear parts will be featured at the Hillhead Quarry event 21-23 June in the UK.

The O-Series wear parts were originally launched in 2019 and have been sold to hundreds of customers since, the company says.

Alongside this expanded wear parts offering, Metso Outotec is launching Chamber Expert Service, a service that brings the company’s wide selection of crusher wear parts with crushing process-specific application instructions delivered to the customer’s crushing site, at Hillhead this week.

The service uses Metso Outotec’s online wear part product catalogue, and the unique Chamber Pro online simulation tool to select the optimal chamber geometry and crushing parameters that match the customer’s production targets and the specific crushing process, it says.

In aggregate processes, the optimal chamber geometry and crushing parameters improve process performance and reduce energy consumption and maintenance costs, yielding an increase in saleable products and a longer wear part life cycle.

Jarkko Leppänen, Vice President, Aggregates Crusher Wears at Metso Outotec, said: “The service has been developed in response to customers’ increasing demand for continuous improvements in process performance. The correct wear part and verified sizing make a clear and sustainable difference for the customer’s crushing process.”

Chamber Expert Service will get the crusher producing for our customers with:

  • Best performing chamber to match customer capacity and quality targets;
  • Ensured optimal chamber geometry and crushing parameters;
  • Improved process performance and lower energy consumption, bringing improved sustainability benefits;
  • Cost efficiency without a major investment in new equipment; and
  •  Verified wear part lifetime.

Weir Minerals’ Vulco rubber compound proves its mill lining worth

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining maintenance, Sustainable mining, , , , , ,

Close to four years after release, Weir Minerals Vulco® 67 rubber compound is providing exceptional wear life and reliability in mill lining systems, according to the OEM.

These abrasion- and impact-resistant rubber compounds have been developed with advanced technologies by the Weir Minerals’ team of expert engineers and material scientists who are continually refining Vulco rubber products to keep them at the forefront of mill lining systems technology, the company says.

Having identified a need for higher-wearing rubbers for mill lining systems, the material science experts commenced developing an industry leading, premium-grade rubber compound with superior wear life and performance in mill lining applications. The result was the Vulco R67 rubber – a material manufactured with proprietary new compounds and innovative methods of processing to deliver outstanding wear life and longer uptime, Weir Minerals says.

Extensive field research, compound testing and site trials were conducted to ensure it was not only able to withstand severe abrasion in typical mill system applications, but that it is best in class, the company said.

“In fact, it has been the most wear-resistant rubber compound that Weir Minerals has ever developed for mill lining applications,” Weir Minerals said. “The R67 compound boasts a high hardness, elongation, tensile and tear strength, and is suitable for lifter bars, head/shell plates and grates. When it’s utilised in conjunction with metal cap mill liners, the result is a versatile, economical and efficient product that weighs up to 50% less than steel alone.

“The added benefit is a lighter product that’s faster, easier and safer to install.”

Revolutionising wear lining

Since its launch in 2018, many mining operators from around the globe have implemented the R67 compound into their mill lining systems, according to Weir Minerals. They have reported as much as 20-40% improvement in wear life, which is resulting in fewer mill lining replacements and longer mill campaigns. This reduction in shutdowns has a dual benefit of increased cost savings and improved plant availability.

With a liner that can run significantly longer, operators have experienced a wide range of benefits including:

  • Improved wear life;
  • A measurable reduction in mill downtime;
  • Increased uptime and processing;
  • Easier and safer installations; and
  • Reduced maintenance costs.

In-field success

Extensive global trials and commercial installations in the market have resulted in several successful outcomes across a variety of different grinding applications.

As an example, a high-grade nickel and copper mining project in the US had a problem where the liners in one ball mill were wearing out too quickly, leading to continued downtime and reduced processing. The operation was looking for a product significantly superior to the elastomer it was using. Initially there was reluctance from the mine, as it had loyalty to its original mill supplier, however after Weir Minerals conducted a series of trajectory simulations and discrete modelling – to optimise the design and deliver the best process performance for the mill – it agreed to trial the R67 liners.

At the end of the trial, the R67 showed 30-40% better performance than the incumbent liners and the customer installed a full set of R67 liners in its mill.

Another trial in the US took place in an iron ore mine with several dozen ball mills in operation. Here, Vulco R67 liners delivered a 17% increase in life compared with the failed shell plates from the mine’s original mill lining system supplier. The company has since installed a complete shell liner in its ball mill.

Moving to Chile, a copper mine was keen to trial the R67 compound to see if it could improve the wear time of a competitor rubber liner. After a three-month trial, all liners were physically measured showing the Vulco R67 liners fully worn wear life projected from the actual wear would be 80% longer compared with the incumbent liners.

Another copper processing plant in Chile trialled R67 composite liners in its SAG mill against two other compounds commonly used in the industry. After 12 months, there was a 48% and 62% wear life improvement on the other liners – proving the R67 composite liners could withstand the highly abrasive environment.

Vulco R67 mill liners are made exclusively at Weir Minerals facilities in North and South America, Australia and South Africa, with plans to expand production into more regions in the future.

Metso Outotec embeds virtual reality into mill lining inspection process

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining maintenance, Mining services, Mining software, , , , , ,

Metso Outotec is launching a patented Virtual Inspection tool for horizontal grinding mill linings to, it says, take the benefits of 3D scanning to a new level.

The new tool enables the scanned mill linings to be viewed in virtual reality and offers an efficient and safe environment for technical discussions, according to the company.

“This innovation is a continuation of Metso Outotec’s pioneering role and its more than six decades of experience in engineering and manufacturing mill liners and grinding mills,” Metso Outotec said.

‘On-site’ mill lining inspections can be safely hosted while being off-site, thanks to the fully immersive virtual walkthroughs and the ability to comprehensively review any particular point of the mill lining. Features like remaining liner thickness measurements and profile review enable the users to make real-time assessments of the liners, while the colour-coded heatmap mode helps in analysing the wear patterns and in detecting problem areas, so that the mill lining design and performance can be improved.

The Virtual Inspection tool aligns with Metso Outotec’s aftermarket digital strategy by improving the efficiency and safety of its services through advanced wear-part analyses, it added.

Lars Furtenbach, Research and Technology Development Manager, Mill Lining Solutions, said: “Our patented MillMapper™ 3D scanning of mill linings has been the industry benchmark for years. The scans are used to understand the way the mill liners wear, to optimise the liner design, and to accurately predict the reline schedules. There is a growing need to find new ways to reach out to our customers and to discuss mill lining performance with them remotely. Our customers will benefit from our strong experience with over 8,000 mills worldwide combined with the market’s most comprehensive offering and the new software platform.”