Dedicated to expanding its mineral processing offerings in Australia, Thejo Engineering is taking a client-first approach when supplying custom-designed solutions to the mining industry.
Thejo understands it is critical for every processing plant to have its mill running as efficiently as possible and the role innovation plays in ensuring this.
To help processing operations achieve optimal productivity, Thejo works in close contact with mining companies to design, manufacture, install, monitor and improvise mill liner performance for their operations.
Thejo chief operating officer Manoj Joseph Kallarackal says the company’s experts begin by analysing the operating conditions and the specific details of what its mining partners want.
“From this data we are able to gauge a rough idea of the direction we would take before finalising the designs,” Kallarackal says.
Thejo uses state-of-the-art engineering design and simulation software to create its designs. Operating out of its head office in Chennai, India, the company sends its design to each client based on the simulations and the operational feedback received from site.
Kallarackal says the first step of the process for Thejo is guiding its mining partners through the decision-making process and responding with alterations to the designs, if needed. The second step is identifying the optimised choice of material to be used for making the mill liners. Thejo offers mill liners in rubber, as well as composite of metal and rubber.
THOR – R mill liners are manufactured from specially formulated rubber compounds, which are a time tested superior blend of natural and synthetic rubbers.
The T800 rubber formulation series has proved its robustness over time, through installations across a wide range of minerals and sizes of mills.
In comparison, the THOR – M mill liners are manufactured from high-wear and abrasion resistant alloy castings or alloy steel plates integrally moulded with T800 rubber compounds.
The alloy steel takes the harsh operating impact and wear, while the rubber provides absorption of the impact energy, reduction of noise and weight compared with full metal liners.
With India being a leading producer of superior quality natural rubber, Kallarackal says THOR – R mill liners provide several benefits over metal alternatives.
“The fundamental challenges clients face with metal and composite mill liners is that they are very heavy, making it difficult to handle and install, consumes higher power, and is noisy during operations. Whereas, rubber liners are a lot lighter,” Kallarackal explains. “There are many advantages clients could derive, if they could consider rubber options, wherever possible.
“We have been working closely with three mines in Western Australia who previously used composite liners, but have today achieved extended wear life with THOR – R liners. It is a significant breakthrough in terms of economics and productivity.”
When it comes to sizing, Thejo provides trommels and screen panels under the branding of ‘GRATOR’, which are designed and engineered with decades of experience.
Kallarackal says the company’s objective is to provide reduced cost-per-hour tonnage in separation, reduction, sizing, washing and de-watering applications to clients. Clients are constantly on the lookout for extending the life of products.
“Through our continued R&D, we have achieved significant success for a very large mine in Western Australia, which required us to improve the wear life, efficiency, eliminate pegging and blinding issues of their screens,” Kallarackal explains.
“Our custom engineered rubber screen panels for a trommel of a SAG mill delivered 33 weeks of operational life as against 10 weeks achieved by competitors. This resulted in scheduling longer periods between shutdowns, thereby enhancing the grinding circuit availability, increasing productivity.
“We pride ourselves in doing this work and have dedicated personnel who spend time with the clients, take feedback, implement and monitor the improvements.”
For slurry handling operations, the company also offers WARDOG wet abrasion resistant sheeting, CERALINE flexible ceramic panels and ANAKONDA range of hoses and pipes.
The company’s range of HIPO filtration solutions are established globally as the preferred spares for Larox-Outotec, Metso, Diemme and Andritz Pressure Filter Presses. HIPO rubber diaphragms, plate pack seals, feed ports, pinch valve sleeves, PP plates, vats, grids and hoses are utilised by major clients such as BHP, Vale, Glencore, Karara, Tata’s, Accelor Mittal, Jindal, Molymet, Ingredion, Imerys across the globe, through both a direct and distribution network.
With its modern manufacturing, research and development facilities, Thejo is established as a specialist manufacturer of engineered polymer products.
“Thejo products are subject to stringent process and quality control parameters,” Kallarackal says. “They are designed to deliver superior properties of resilience, wet abrasion resistance, tear and tensile strength, cut and tear resistance of the highest standards.”
Kallarackal says Thejo’s team is constantly searching for new technological improvements, ideas and products that complement operations in the mining industry.
“We are proud to say that our products are comparable with the best in the world,” he says. “One of the latest product options we now offer is called Sustainable Synergetic Solutions (SSS).”
SSS provides safe work environments, focussing on quality, reliability and cost effective engineering solutions that ensure Thejo’s products and services perform above and beyond the expectations of customers to increase efficiency and productivity.
By continued presence and growth in Australia, backed by high-quality products and service, Thejo has its eyes set on becoming the go-to company for minerals processing solutions.
This story also appears in the April issue of Australian Mining.