Selection of the most suitable mill liners to suit different applications can be a tricky business, particularly when evaluating new materials against old “tried and tested” liners that have been used on certain operations for decades.
Most commonly engineers may be tempted to stick to what they know and use liners that have been used before as they have a track record and there is a track record whereby lifespan and performance is known and can be measured.
Yet, according to Tega Industries marketing and business development manager Vishal Gautam, new liners are continuously being developed using ever-stronger and more efficient materials that can outperform and outlast older generation liners. In certain instances combinations of different liners may provide additional benefits as the best materials can be selected for each section of the milling process to combat wear, absorb impacts, increase flow rates etc.
Team of specialists
“With such a wide range available nowadays it is best to have a specialist mill lining company come and assess the requirements and design a mill lining that is best suited to the operation’s requirements. In these circumstances it is usually better to consult with a supplier that is able to provide different types of liners rather than a single type, as these may feel the need to adapt the process to suit their product rather than provide the right solution for the application.
“Tega Industries has years of local experience, as well as far-reaching global expertise that allows us to perform full-function design and development of mill liners on behalf of clients. We also work with the mine’s engineers to compare “old type” linings and see if there are better materials available and provide them with data on the durability and performance of these materials that is either simulated on our advanced software, or is gathered from global operations with similar applications.
“In this way we are able to work with them to find solutions that work and allow them to meet the previous milestone relating to mill efficiency. Once we have the operating parameters of a mill depending on requirement relating to throughput or sizing of materials and type of material then the Tega design office springs into action,” says Vishal.
Drawing from experience
He explains that based on past experience worldwide as well as experience gain in the field in Africa they look at similar operations where similar criteria was required. This global experience means that they can call on parameters from more than 500 Tega lined-mills around the world to compare and calculate requirements that will work best with the existing infrastructure.
Many other factors also need to be taken into consideration such as movement lengthwise through the mill, as well as greater or lesser retention time. Also rotation needs to see that the balls are landing in the right place in the mill – height to angle, ball size, speed and charge volume play a role and need to be factored in.
“If done correctly the calculation will result in the required throughput or it will highlight any shortcomings which can then be addressed separately,” says Vishal. “At this point our team works closely with the client to ensure all the requirements are met and we use technical expertise to guide and assist clients to making the right decision for the best liner that fits their requirements and budget.
“Our locally manufactured liners are made to international standards and are carefully installed to ensure trouble-free operation. To ensure it continues to work flawlessly our after sales service team will continue to be actively involved with the client to ensure the maximum service life is achieved and that the process continues to operate as designed.
“Our technical support includes monthly wear reports, highlight high wear areas and provides plans for maintenance and shut down I future. They also work continuously to develop and improve the mill performance throughout the duration of their involvement,” say Vishal.
Better all-round performance
He concludes that the importance of partnering with a technically adept and service orientated company is of paramount importance to ensure that the mill runs efficiently and reliably for years to come. With the right type of liner in place it is even possible to dramatically increase throughputs while significantly increasing times between maintenance and repairs.”