Vulco® Rubber is renowned in the mining industry for its durability and reliability in mill liner systems. These abrasion and impact resistant rubber compounds have been developed with cutting-edge technology by Weir Minerals’ team of expert engineers and materials scientists who continually refine Vulco rubber products to keep them at the forefront. mill coating systems technology.
Having identified a need for higher wear rubbers for mill liner systems, materials science experts began to develop an industry-leading premium rubber compound with longer life and performance. superior in mill coating applications. The result was Vulco R67 rubber – an optimal material that is made with new proprietary compounds and innovative processing methods to deliver exceptional life and longer uptime.
Extensive field research, compound testing and on-site trials were conducted to ensure that it was not only capable of withstanding severe abrasion in typical factory system applications, but that it was best in class. In fact, it is the most wear-resistant rubber compound Weir Minerals has ever developed for mill liner applications. The R67 compound exhibits high hardness, elongation, tensile and tear strength, and is suitable for lift bars, head/shell plates and grids. When used in conjunction with metal plug 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, faster, easier and safer product to install.
Revolutionize the wear liner
Since its launch in 2018, many mine operators around the world have implemented the R67 compound in their mill liner systems. They reported a 20-40% improvement in life, which translates to fewer crusher liner replacements and longer crushing campaigns. This reduction in downtime has the dual benefit of increasing cost savings and improving plant availability.
What are the benefits for plant operators?
With a coating that can perform much longer, operators have enjoyed a wide range of benefits, including:
- Improved lifespan.
- A measurable reduction in plant downtime.
- Increased availability and processing.
- Easier and safer installations.
- Reduced maintenance costs.
In addition, the mines benefit from an experienced and dedicated team at Weir Minerals who custom design the liners to meet the unique requirements of each mill for optimum life.
The elastomeric compound R67 modifies the operation of factories. Extensive worldwide trials and commercial installations in the market have resulted in a number of positive results in a variety of different grinding applications. From mines in the United States to Chile, the R67 has consistently proven its exceptional performance.
For example, a high-grade nickel and copper mining project in the United States had an issue where the liners of a ball mill were wearing out too quickly, leading to continuous downtime and reduced processing. . They were looking for a product that was clearly superior to the elastomer they were using. Initially, the mine was reluctant, as it was loyal to its original factory supplier; however, after Weir Minerals conducted a series of trajectory simulations and discrete modeling – to optimize the design and provide the best process performance for the plant, they agreed to test the R67 liners. At the end of the trial, the R67 showed 30-40% better performance than the liners in place and the customer installed a full set of R67 liners in their factory.
Another trial in the United States took place in an iron ore mine with several dozen ball mills in operation. Here, Vulco R67 liners provided a 17% increase in life compared to the failing hull plates of the mine’s original crusher liner system supplier. The company was extremely impressed with the results and installed a full casing in their ball mill.
Moving to Chile, a copper mine wanted to test the R67 compound to see if it could improve the wear time of a competing rubber liner. After a three month trial, all liners were physically measured, showing that the life of fully worn Vulco R67 liners projected from actual wear would be 80% longer than that of the liners in place.
Another copper processing plant in Chile tested R67 composite liners in their SAG mill against two other compounds commonly used in the industry. After 12 months, there was a 48% and 62% improvement in the life of other liners, proving that R67 composite liners could withstand the highly abrasive environment.
Vulco R67 mill liners are manufactured exclusively at Weir Minerals facilities in North and South America, Australia and South Africa, with plans to expand production into other regions in the future.
Read the article online at: https://www.globalminingreview.com/product-news/19012022/the-benefits-of-mill-lining-rubber-compounds/