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Lining and Molded

Products
Webinar 2016
Presented by
Robert Frey Wear Products
Molded Lining Systems

Weir Minerals – Linatex offers a number of abrasion


resistant solutions for a variety of application needs.

Plate-Backed Rubber/Ceramic Liners

Urethane Liners

Plate-Backed Rubber Liners

Modular Style Panels (MAP)

Profile Type Impact Liners

Impact Idler Bars and Assemblies

Molded parts
Lining Applications

Used in industries such as Mining, Aggregate, Concrete,


Grain, Foundries, Power plants, anywhere abrasion and
wear occurs.

Chute lining (Screen undersize, ore feed bins, etc)


Screen box feed boxes and discharge lip liners
Screen box impact liners above the screen or back walls off the
discharge end
Feeder liners (Vibratory feeders)
Conveyor transfer points
Feed and discharge liners (mainframe liners) for various types of
milling and crushing operations
Mixing devices
Slurry flumes
Conveyor skirting/ canoe liners
Information needed to decide the right type of liner

TYPE OF PRODUCT PRODUCING:


DESCRIPTION OF INSTALLATION
PARTICLE SIZE: LARGEST: SMALLEST:
PARTICLE SHAPE (ROUND, ANGULAR/ CRUSHED):
DROP DISTANCE:
WET OR DRY: % MOISTURE TEMP ° F
VELOCITY:
ANGLE OF IMPINGEMENT (What angle is material hitting the liner at?):
TONNAGE PASSING: TONS/HR. HRS / WEEK
HEALTH AND SAFETY CONSIDERATIONS (Liner Weight)
ECONOMICS (Present wear life versus expectations)
OBSTACLES TO ATTACHING LINERS
Getting application information is important!
Liners

Lining systems made of either steel,


ceramics, rubber, or polyurethane will help
to provide maintainable protection in
these vulnerable areas of the process.
Shape, attachment style, and thickness of
wear material are typically customized to
suit the application requirements.
Liner Options

Polyurethane
▪ Plain sheet
▪ Plain sheet with expanded metal backing
▪ Weld plate style sheets or made-to-size

Rubber/Ceramic- Made-to-size preferably


▪ Bolt-in or weld-in with counterbored holes and plugs
▪ Bolt-in with welded steel studs

Rubber Liners
▪ Plain Sheet
▪ Bolt-in or weld-in with counter bored holes and plugs- steel backed
▪ Bolt-in with welded steel studs- steel backed
Custom Designs

Can be made to client specifications


Or custom layout (for all liner types)
Application Principles Impact vs. Sliding Abrasion

Ceramics are good for sliding


applications

Rubber is good for impact
applications 90°

Rubber/ceramic is good for


combination applications 45°

*Particle size and drop distance must


be considered for all applications
Ceramic application chart
19.00
18.00
17.00
16.00
15.00
14.00
13.00
Material Size (inches)

12.00
11.00
10.00
9.00
2" or 2-1/2" R/C Impact Style
8.00
7.00
6.00
5.00 2" or 2-1/2" R/C
4.00
3.00
1-3/8" R/C
2.00
1.00 Ceramic Tile

0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Drop Distance (feet)
Cylinder grouping – Standard design

Standard for most applications


Direction of ceramic pattern is
important
Material Ceramic are packed tightly against
Flow
one another
Cylinder grouping – Impact design

• Extends the application limits of


2” thick ceramic liners
• Straight rows of ceramic
cylinders are separated by rubber
(typically 3/8”)
• Extra rubber helps to absorb
angular impact
Rubber/Ceramic Liners

Plate Backed
▪ Standard thicknesses: 0.75”, 1.00”, 1.50”, 2.00”, 2.50”
▪ 3/16” standard steel backing plate
▪ Four different fastening styles
▪ Counter bored bolt holes (Can be used for bolting or plug welding)
▪ Welded stud
▪ Exposed steel edge (for welding)
▪ T-track style (Adjustable)
▪ Molded part sizes up to 96” long, maximum size = 20 ft² depending on thickness
Variety of ceramic shapes and sizes available (0.812” & 1.25” cylinders are std.)
Standard rubber material is HD-70 but all Linatex compounds are available
Custom and curved shapes are possible
Chrome-White Iron (CWI) Liners

Combines highly abrasion resistant cast steel tiles with resilient rubber backing
Can be used in higher impact / higher load applications than rubber/ceramic
Good for applications where material is “sticky”
Custom molded to any (flat) shape (CWI tiles are plasma cut to suit)
Mounting styles similar to rubber/ceramic
Liner thickness ranges from 1” to 3”
CWI tile thickness available: 0.50”, 0.75”, 1.50”

CWI Tile Spec: ASTM-A532


Class II Type B
625 – 700 Bhn
Understanding Urethane Formulations

• Cannot just say


“Give me the 90 durometer, red stuff”
• Durometer doesn’t tell the whole story.
• Esters, Ethers, MDI, TDI, PPDI, NDI ????

• Rely on Linatex to choose the


right material for the
application!
HARDNESS RANGES
Various Elastomers and Plastics
CAST
POLYURETHANE
PLASTICS
RUBBERS

CAST POLYURETHANE ELASTOMERS

PLASTICS

Fluorocarbons
20 30 40 50 60 70 80 90 95

Polypropylene
DUROMETER A

Polystyrene

Phenolics
Acrylics
Nylons
Rubber 45 55 65 75 85
Band
Auto DUROMETER D
Tire
Tread
Mens'
Shoe Heel
50 70 90 100 110 120 130 140 150

ROCKWELL R
OCN- -CH2- -NCO + HO OH

Isocyanate Polyol/ Curatives

- -NHCO2 O2CHN- -

Polyurethane
Main types used in screening and lining

Isocyanate Types Polyol Types Curatives


MDI PTMEG Premium Ether Diamine (MOCA)
TDI PPG Low-cost Ether Diols
Polyester Triols
Additives
Pigments (color), Fillers, Plasticizers (softeners), Catalysts, others
General structure of polyol chains
O

-C - C - C - -C-O-C-
Ester based urethane Ether based urethane

Double bonded oxygen in esters causes higher tear resistance


but less rebound.
Linear oxygen in ether allows for higher rebound but easier to
tear.

C = Carbon O= oxygen Hydrogen atoms not shown but are attached


to the carbon atoms
Limitations of Polyurethane
High temperature service. Durex urethanes usually handle up to 170 degrees F. with a periodic
spike up to 210 deg. F. This will vary with different formulas. Some urethanes are made to handle
higher temperatures but they usually sacrifice wear life due to poorer abrasion and tear resistance
once they are at ambient temperature.

Moist hot environments. Ether-based urethanes are much better in hot humid conditions than ester-
based urethanes, in particular, the southern states. Ester-based materials can handle hot humid
situations as long as they are in constant use. Once they are taken out of use or if they sit around
waiting to be used, they will degrade over a shorter life than normal.

Certain Chemical environments. The ether-based materials are best for submerged water
situations and for weak acids and bases. Before putting a urethane material in this type of
environment, be sure to put a sample in the solution for several days. Some materials will crumble
away and some will bloat. When the material is removed from the solution, it can go back to normal.
Be sure that you see what the results are in solution. Ester-based materials are better for oils and
solvents. Strong solvents will destroy any urethane though.
Hydrolysis on
Ester based
liners

Back of the liners next to the


hot steel are destroyed
Urethane Sheet Liners

Standard thicknesses: 0.25”, 0.375”, 0.50”, 0.75”, 1.00”, 1.25”


Available in Standard urethane materials: #101 (90A), #183 (83A)
Three different styles
▪ Plain sheet
▪ Plain sheet with expanded metal backing
▪ Weld plate attachment

Molded part sizes up to 60” wide x 144” long, Maximum weight = 300 lbs.Weld Plate Style
w/ plug
Available in standard sheet sizes (48” x 96”), (48” x 120”), (60” x 120”)
Can be cut to size on site
Also available in pre-cast custom sizes or shapes
Bolt-in urethane liner products

Standard polyurethane sheet provided in standard sizes can be


custom cut on site to suit shapes needed
Counterbore / drilling tool is used to cut custom hole patterns on
site
Urethane covered bolts are used to secure the panels in place
Using urethane 4 X 10 sheets for bolted in made-to-size- liners

Measure and cut to size Layout the hole pattern and drill the holes

Install with urethane


coated bolts
Weldable or Plain Liners

A common size of bin, scale, or hopper liner can be designed


to fit various angles and obstructions. Weld plates can be
placed at various spacing- more around the edges and less
in the high wear spots.
Polyurethane plug weldable liners being installed

Liners are designed in a “kit” for


a complete liner project

Liners are installed via plug


welding at each weld plate
location.
Liners for a mixing drum

Typical completed drum lining


Molded Rubber Liners

Plate Backed
▪ Thickness range: 1/2” to 6”

▪ Steel backing plate from 1/8” to 1/2”


thick

▪ Four different fastening styles


▪ Counterbored bolt holes
▪ (Can be used for bolting or plug
welding)
▪ Welded stud
▪ Exposed steel edge (for welding)
▪ T-track style (Adjustable)

▪ Molded part sizes up to 54” wide x


120” long
Variety of Common Rubber Formulations

Category STANDARD RUBBER SPECIALTY RUBBER


Designation Linard 60 Linard HDS Linard HD-60 Linard HD-70 Linatex 240 660 Linagard OSR

Polymer Type NR NR/Synthetic NR/Synthetic NR/Synthetic NR NR EPDM Neoprene


Hardness Shore 58A 70A 60A 70A 38A 40A 60A 55A
Color RED RED BLACK BLACK RED BLACK BLACK BLACK

Anti- Higher Oil Sands -


Typical Dry Wet / Dry Wet
Anti-cutting Dry Abrasion Plugging / Temp. Oil/Chemical
Application Abrasion Abrasion Abrasion
Blinding Wet/Dry Resistant
Table for choosing rubber liners
Rubber liners
Rubber liners
MAP – Modular Wear Panel

Molded Product
Available in 1’ x 1’ units
Thicknesses in 25mm, 40mm, and
50mm
Rigid Rubber backing (to eliminate
steel)
Easy to “cut to fit” in chutes
No adhesives required
12mm bolt attachment
Available as Rubber/Ceramic
MAP Panel Installation
Strapbak
Steel backing strips bonded to the rubber liners
Other Rubber Liners

Tensions Rails
Eccentric Shaft Covers

Cross Support Protectors


Profile Liner Slabs – Importance of Angle of Impact
Particle hitting rubber at sharp angles leads to premature failure.
Rubber cannot perform as intended.

Sliding abrasion or 90 degree impact are ideal and 20-50 Degree


Angle is to be avoided.

Profile Slabs resolve this issue.


Linard Profile Slab

Key considerations impact angle, velocity and hardness


Molded Rubber Liners
Conveyance Wear Problems
Impact Assembly
Impact Idlers under loading areas

Replaces idler rollers that get destroyed due to high impact


Other Molded Products

Sand Classifier Parts


• Screw Shoes
• Down Spouts
• Valves and Seats
• Flume liners
• Level indicators
Urethane Parts for Screen Decks
Spray pipe seals and covers
Spray Deflectors
Miscellaneous Custom Products
Urethane Parts used in
sand and gravel
operations
Screen Underpan

Linatex rubber used in


these locations
Classifier Tank flumes
Linatex – High Performance Truck Bed Liner

Large panel size, makes for


quick installation and fewer
joints.
Fewer exposed joints
reduces material buildup
between and under panels.
Liners are made-to-size as a
‘kit’ to eliminate field cutting.
Liners can be bolted into
place with stud welding so
drilling or full welding is
unnecessary.
Molded Rubber at mines

Scrubber
Liners
The Weir Group PLC
3459 South 700 West
Questions?
Salt Lake City UT
112 West First Avenue
Luck WI

T 715-483-9611 in WI
F 715-483-1448 in WI

www.weirminerals.com
Follow us on Twitter
@weirgroup