FLSmidth has launched redesigned mill lining components engineered to suit the specific functions and differing operating environments of the mining industry. The new mill liners will increase the throughput of SAG mills and substantially increase the wear life of liners.
Delivering on a promise to provide increased productivity to the mining industry, the composite materials incorporated in FLSmidth new mill liners ensure users can take advantage of the wear characteristics of multiple materials, while extending the liners’ wear life.
With lighter weight mill liners, installation is faster and safer as each liner is easier to manipulate. There are also fewer parts, and hence fewer movements are required to perform a reline resulting in a significant decrease in scheduled downtime. The composite nature of the liner reduces its weight by almost 50%, allowing the plant to increase its ball charge level without increasing the total weight of the mill. This higher ball charge further contributes to the higher throughput.
The lighter weight of these liners has an important impact on size, design and installation time. Each liner can now be larger – subject to the size of the mill opening – and the mill can be lined with fewer of them, reducing the downtime required to conduct replacement. A lighter liner means fewer bolts to hold it in place, a factor further reduces installation time. The shorter downtime means less time for contractors inside the mills, leading to faster and safer liner changeout.
Another important benefit of the composite material used in many of FLSmidth’s redesigned liners is it is not necessary to torch the liners, as is sometimes required when removing old steel liners. This torching process in the mill is best avoided, as it can cause costly damage to the mill shell. Finally, there has also been the development of composite material shell liners that are bolted from the outside of the mill, speeding up installation and reducing risk.
“As mines increasingly recognise the positive financial impact derived from just a few more percentage points in throughput improvement, many are looking beyond conventional steel cast liners for mills. FLSmidth’s innovations, based on combinations of steel, rubber and ceramic components, allow the liners to be thinner, resulting in a larger volume inside the mill, making higher charge levels possible,” comments Jack Meegan, Product Line Manager for Comminution at FLSmidth.
“Responding to the continuous assessment of customer needs, FLSmidth has launched a mill liner solution based on extensive data on mill operations, shutdowns, wear profiles and other factors. These have been used to develop a high-end technical and financial solution. Following installation, an ongoing measurement of actual wear, tonnage processed and estimated wear life is conducted so further recommendations can be made to improve performance,” concludes Meegan.
The depth of technical and operational expertise within FLSmidth allows a high level of process support for customers assisting in mill operation and metallurgy. This is vital to the company’s strategic mission of helping customers achieve higher production and recovery rates. FLSmidth is also on hand with technical advisory services to assist with installation, so scheduled downtime is minimised and uptime optimised.