Typical application of industry standard supply snap lock liners is to resist the effect of abrasion and to absorb medium to high, direct or angular impact caused during mineral processing. These types of liners can be widely seen in screens and feeders where impact would be a significant factor along with abrasion.
The polyurethane being relatively harder compound, has excellent abrasion resistant property and is used as a base compound for the snap lock system. Majority of snap lock impact liners supplied in Australia consist of ceramic tiles moulded in polyurethane backed by an anchoring arrangement enabling it to arrest to the locking arrangement. Parent metal or the surface that needs to be protected from impact and abrasion comprise of a tubular rail which acts as an engaging arrangement for the locking system of the impact liners.
With its outstanding tear resistance and abrasion resistance properties, the polyurethane system is well suited for the designed application. However, the major issue of existing polyurethane system is repetitive encounters of ceramic tiles bursting off the polyurethane mould due to impact of ore material on the liner. Polyurethane has higher likelihood of giving away its bonding to ceramic tiles in a high dynamic stress environment. The impact coupled with polyurethane’s resilience properties, cause premature failure of the system well before the life expectancy of the system. Subsequently, abrasion of the material cause polyurethane to wear faster resulting in damage to the parent metal. This leads to unexpected maintenance along with high replacement costs.
WENCO Mining was given the opportunity to work on improvising such system to fit the application. WENCO Mining engineering team in Australia, after analyzing the root causes of the issue, suggested and carried out modifications to the coherence of the material arrangement in existing product without altering the foot print of the system.
- WENCO Mining replaced polyurethane with specially engineered rubber compound of suitable duro as rubber compound perform better than polyurethane in a dynamic stress environment and to match the impact absorption required for the application.
- WENCO Mining replaced cylindrical tiles with rectangular tiles to allow maximum tile coverage of the liner consequently reducing the exposure of rubber compound.
- WENCO Mining reduced the thickness of the ceramic tile to introduce a thicker layer of rubber to compensate the impact.
- The locking arrangement was made of suitable duro material normally higher than the compound used to achieve rigid locking.
The product was a lock on base liner with significant increase in life expectancy without any compromise on the reliability aspects. The fact that the footprint of system remained unaltered meant minimal capital cost was involved in adopting the new and improved system. The new snap lock system is continuously monitored and have already outlasted the polyurethane system.