MAINTENANCE
factor of up to 15 times compared with traditional wear solutions, depending on the ore type and application. This allows mineral processing plants to achieve a total cost of ownership less than half that of other liners.”
Depending on ore type and application FerroCer increases wear resistance up to 1,200 % says FLSmidth and FerroCer Impact is effective in temperatures down to-40 ° C and has been tested in harsh Australian mining sites where ambient temperatures can climb to 50 ° C.
FerroCer Impact consists of panels that are lighter and less bulky than metallic liners. Each panel comprises a number of ceramic inserts enclosed within a matrix of cast metal. The matrix protects the more vulnerable side faces of the inserts and ensures that only the wear face of the ceramic is exposed to material impact. Tapers on the sides of the inserts and corresponding holes within the matrix act to wedge the ceramic inserts within the matrix and prevent material particles and fluids from causing the inserts to be ejected from the matrix. The matrix protects the more vulnerable side faces of the inserts and prevents them from being prised away from the wall of the chute. The inserts and matrix holes are tapered to ensure positive location.
“ The tapered geometry of each ceramic insert enables its remaining wear life to be visually assessed. As the exposed surface of the insert is progressively worn away, its area and face width increase. There is a direct correlation between an insert’ s face width and height so that the one can be readily calculated from the other.” The panels’ low weight( approximately 5 kg) and compact shape make them quick and easy to install using standard hand tools. They are also compliant with the manual handling requirements of occupational health and safety organisations. Each panel is attached using a single countersunk bolt. The mounting hole for the bolt is then closed using an adhesive coated ceramic plug.
An entire chute can be lined with just two different types of FerroCer Impact panel. The“ Standard” panel is installed over most of a chute’ s surface, while the“ Edge” panel has an elongated end of solid metal and can be installed at the chute’ s entry and exit points. It can also be trimmed to a specific length or angle to accommodate chutes with irregular shapes or corners.
In one nickel processing plant, the FerroCer panels were installed in a conveyor discharge chute, downline from the primary crusher unit where the material drops 6 m from one conveyor belt down to another one, where it is transported onwards to the secondary crusher. The hardness of the nickel ore is approximately 5 on the Mohs scale. After installation, the plant operated for 270 days, and it operated at full production of
900 t / h with lump sizes of up to 250 mm in diameter. This was a big step up from the previous liner, which had lasted less than three weeks on average.
In another gold processing plant, FerroCer panels were installed in a chute downstream from the primary crusher where the drop height is 2 m and the lump size up to 400 mm in diameter. The previous liner type, consisting of heavy-duty rubber and steel bars, typically lasted no longer than six weeks. After the first 17 weeks in operation, the wear measurements taken on site indicate that the new FerroCer panels will last at least another 80 weeks, making them at least 10 times better than the previous liner solution.“ FerroCer Impact answers an important need in the minerals processing industry. It combines long wear life, ease of installation and affordable pricing to achieve a total cost of ownership which is less than half that of other liners. Its low replacement rate results in greatly reduced lost production time for mines.”
Conveyor belt maintenance
Flexco recently released the newest cleaner in its line of belt conveyor products, the MXP Extreme Duty Precleaner. Available for use with belts ranging from 1,050 mm to 3,000 mm wide, pulley diameters 1,200 mm and up, and belt speeds up to 10 m / s, the MXP is the largest, most rugged
Flexco recently released the newest cleaner in its line of belt conveyor products, the MXP Extreme Duty Precleaner
Under the Forever Belt Cleaner Guarantee, Martin Engineering will provide replacement parts as required, for all cleaner assemblies using its urethane belt scrapers, regardless of model or blade type
cleaner in the Flexco offering. The new MXP is described as ideal for use in copper, coal, iron and oil sands applications and is designed for easy installation. Designed with heavy-duty construction throughout, the MXP boasts an oversized 200 mm diameter centre pole and 490 mm blade height, ensuring optimal cleaning on large pulleys and wide belts.
“ One of the big advantages to the MXP Extreme Duty Precleaner is that it is designed with a three-piece pole, making it easier to transport to the head pulley and install,” said Kevin Fales, Product Manager at Flexco.“ Instead of trying to lift one large pole into place, the cleaner can be placed in sections and assembled on site.” The MXP is available with 150 mm and 300 mm wide blade segments for varied material paths and easy replacement.
The spring tensioner on the MXP makes the cleaner compatible with mechanical splices, allowing the blade to move away from the belt when a splice passes.
Flexco says:“ the MXP Extreme Duty Precleaner is a Mineline ® – endorsed cleaner – designed and engineered to work – day in and day out – in some of the toughest applications in the world.”
In what it says is“ a first for the bulk material handling industry”, a global manufacturer of conveyor belt cleaning systems is offering lifetime no-cost replacement of tensioners and mainframes for belt cleaners that are fitted exclusively with the company’ s cleaner blades. Under the Forever Belt Cleaner Guarantee, Martin
22 International Mining | JANUARY 2017