Vulco® R67 Grinder Lining Rubber Compound Revolutionizes Minesite Grinding Operations
Bernice J. Hicks
4 min read
Vulco® rubber is renowned in the mining industry for its exceptional life and reliability in crusher liner systems. These abrasion and impact resistant rubber compounds were developed with cutting-edge technologies by Weir Minerals’ team of expert engineers and materials scientists who continually refine Vulco® rubber products to keep them state-of-the-art mill coating systems.
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 manufactured 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 that Weir Minerals was never 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 to this, the mines benefit from an experienced and dedicated team at Weir Minerals who custom design the liners to meet each plant’s unique requirements for optimum life.
Global success on the pitch
The R67 elastomeric compound changes the way shredders work – with exceptional results. 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 mill supplier, but after Weir Minerals conducted a series of trajectory simulations and discrete modeling – to optimize the design and provide the best performance of process for the factory, they agreed to test the R67 shirts. 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 shell plates of the mine’s original crusher liner system supplier. The company was extremely impressed with the results and installed a complete 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 in-place liners.
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.
Help customers optimize their process
As a leader in materials technology, Weir Minerals continuously undertakes research and development to provide best-in-class products to mining customers, while helping them improve their bottom line. When using Vulco® R67 rubber compounds, our customers can rest assured that they are getting a market-leading product that is backed by decades of experience, expertise and proven effectiveness. This innovative rubber compound not only offers superior physical and viscoelastic properties, but is also a lighter and safer material to use.
