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

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 Rubber/ceramic is good for combination applications 0 90 45 *Particle size and drop distance must be considered for all applications

Ceramic application chart Material Size (inches) 19.00 18.00 17.00 16.00 15.00 14.00 13.00 12.00 11.00 10.00 9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 2" or 2-1/2" R/C Impact Style 2" or 2-1/2" R/C 1-3/8" R/C Ceramic Tile 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 Flow Ceramic are packed tightly against 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!

RUBBERS HARDNESS RANGES Various Elastomers and Plastics CAST POLYURETHANE PLASTICS 20 30 40 50 60 70 80 90 95 Rubber Band DUROMETER A Auto Tire Tread CAST POLYURETHANE ELASTOMERS Mens' Shoe Heel Fluorocarbons Polypropylene 45 55 65 75 85 DUROMETER D PLASTICS Polystyrene 50 70 90 100 110 120 130 140 150 ROCKWELL R Nylons Acrylics Phenolics

OCN- -CH 2 - -NCO + HO OH Isocyanate Polyol/ Curatives - -NHCO 2 O 2 CHN- - 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 esterbased 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. 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 Weld Plate Style w/ plug

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 Typical Application Dry Abrasion Anti-cutting Wet / Dry Abrasion Dry Abrasion Wet Abrasion Anti- Plugging / Blinding Higher Temp. Wet/Dry Oil Sands - Oil/Chemical 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 Classifier Tank flumes Linatex rubber used in these locations

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 Salt Lake City UT 112 West First Avenue Luck WI Questions? T 715-483-9611 in WI F 715-483-1448 in WI www.weirminerals.com Follow us on Twitter @weirgroup