Multotec offers a comprehensive range of wear linings for any materials handling application

Multotec Wear Linings offers a comprehensive range of wear lining materials, including high alumina ceramics and basalt, in addition to a range of composite wear linings that includes steel/ceramic, rubber/ceramic and polyurethane/ceramic. “The selection of the most appropriate wear lining depends on application requirements, and this is where the expertise and experience of Multotec comes to the fore,” Mike Dexter, Managing Director of Multotec Wear Linings, says.

A major differentiator for Multotec in the marketplace is the dedicated engineering service it is able to offer its customers. “Our team has the necessary experience in terms of designing the entire transfer point, with the appropriate selection of wear linings for the application in question. Our engineers are able to assess any materials handling situation, which then gives them the necessary information to be able to provide a total solution that is not only cost effective, but which also achieves the throughput tonnages required,” Dexter explains.

Wear is defined as the progressive loss of material from the operating surface of a body due to relative motion at the surface. This means that in the course of processing material through the process plant, the ore or material will wear out all the working surfaces that it comes into contact with. This calls for the use of replaceable protective layers in all areas subject to wear. However, the current trend in mineral processing plants is to deploy total wear solutions that go beyond the sacrificial surfaces.

Three elements need to be considered when selecting a wear solution, namely the material being handled, the wear lining material that is selected and the system design. “A successful total solution combines all three elements,” Dexter comments. A wide range of materials is available to resist wear. All have different properties and therefore different applications. The ore or material causing the wear needs to be considered in terms of density, hardness, sharpness and the size of the abrasive particles. The ratio between the hardness of the material causing the wear and the hardness of the wear lining material itself needs to be taken into account when selecting an appropriate wear lining material.

“Multotec, as a leading manufacturer and supplier of wear-resistant products and systems, has developed a range of wear-resistant materials that can be customised for specific application requirements,” Dexter says. Wear-resistant ceramic is formed using modern uniaxial and isostatic pressing, slip casting, extrusion and/or pressure casting methods.

The various components are shaped and then sintered at high temperature. Dexter says that ceramics are used extensively in the materials industry due to its high compressive strength of 2 450 MPa and bulk density of 3.6. Multotec has also developed a range of specially formulated high temperature and standard adhesives for use in various applications.

Multotec also offers cast basalt wear-resistant materials in both pipe and tile form. This provides an extremely hard wearing surface for the handling of wet abrasive or corrosive media in particular. MultoSlipF™ is an ultra high molecular weight polyethylene (UHMWPE) low friction liner for use where product does not flow properly or gets ‘hung up’ due to its inherent stickiness.

Dexter explains that Multotec’s total solutions approach to improved plant availability and reduced maintenance costs, based on the implementation of an engineered wear lining, begins with a thorough wear audit. This involves a comprehensive on-site inspection from the start of the process to the final delivery of product and any associated waste.

“These wear audits are conducted by our wear specialists in conjunction with the client. For example, it includes photographic documentation of specific issues such as chutes with less than optimum designs or areas where the wear lining material applied is underrated for the application in question,” Dexter says.

Once the inspection data has been collated and analysed, a comprehensive report is compiled detailing suggested improvements in order of priority. The report also includes a detailed budget stipulating the full costs associated with the suggested improvements and upgrades. “We then agree upon a refurbishment programme in conjunction with the client, including the timeframe for the full implementation and other factors such as plant shutdowns, for example.” A phased approach can be adopted for such implementation, including ongoing assessments.

“Following Phase One implementation, it is recommended that the initial wear audit be reassessed to ensure that the original priorities are being adhered to. This is mainly due to the fact that there may have been process changes in the plant during this period, or that applied solutions might have resulted in a migration of the wear issue to another critical area, which will necessitate a revision of priorities,” Dexter comments.

During capital refurbishment projects it is also important to take cognisance of upgraded sections of the plant and to undertake a wear areas assessment based on historical data. “Therefore it is often recommended that a wear-resistant linings maintenance contract be implemented,” Dexter says. Such a maintenance contract is tailor-made for a specific client and application.

It includes regular inspections and reporting on wear areas by Multotec experts and also providing the necessary personnel to affect any repairs needed. “It is vital that critical areas be monitored on a regular basis as this will allow for predictive maintenance. Thus wear audits go hand in hand with lifecycle planning to produce considerable cost savings for the client at the end of the day,” Dexter concludes.