Weir Minerals has developed a custom-engineered mill lining system with Vulco R63 rubber liners for James Hardie Philippines (JHP), a regional manufacturing hub of James Hardie, the global leader in fibre cement production.
Due to a substantial increase in demand for its product and in order to increase overall throughput of the site, JHP wanted to increase the output of its ball mill, which was processing a mixture of coarse and fine silica.
The incumbent rubber mill liners were only lasting between six and nine months and contributed to a 25 per cent drop in output after just six months in operation.
Weir Minerals’ mill lining specialists, renowned for their expertise in mill lining systems and wear materials, conducted extensive testing and modelling scenarios to evaluate how optimisation of the ball mill charge volume and trajectories would result in an increased mill throughput.
Using state-of-the-art simulation technology and drawing on decades of expert knowledge, the team designed a customised mill lining system with the Vulco rubber mill liners. The custom-engineered shell liner design ensured correct lifter face-angle to facilitate optimum performance while also increasing the service life of the liners.
To complete the ball mill overhaul, Weir Minerals experts also recommended to increase the charge height, significantly improving the grinding process.
The custom-designed solution resulted in increased production and increased mill availability at JHP.
The Vulco mill liners improved wear life by up to 200 per cent, from six to 18 months, more than halving the reline time and associated maintenance costs, while the throughput was increased by up to 44 per cent.
The innovative designs of Vulco mill liners are tailored specifically for every customer and are manufactured to the highest industry standards for autogenous (AG) and semi-autogenous (SAG) mills, primary, secondary, and re-grind ball and rod mills.
The inherent characteristics of elasticity, high tensile strength and corrosion resistance found in the Vulco elastomer compounds position them as the preferred mill lining material over steel in many applications.
Key features and benefits:
· Lighter than conventional steel linings for increased handling safety
· Reduced noise due to rubber’s sound dampening effect
· Increased power draw due to reduction in lining weight, increasing filling volume
· Increased safety and decreased lining installation hours due to reduced component and lining mass
· Faster manufacturing lead times than metal liners
For more information about Vulco mill liners, visit here.