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A Quick Guide to Wear Plates in the Mining Industry and how they compare with ROXDUR

Conveyor systems work with a wide range of raw materials. And these are often not very easy to handle. They are hard, abrasive and move at high velocities causing wear and tear. At the very least, this wear and tear can become a source of constant maintenance. In the worst-case scenario, it can cause a complete failure of the conveyor system and lead to massive amounts of spillage.

The nature and properties of the raw material can be changed to a certain extent to make the interaction between the aggregate and the system more harmonious. For instance, we can ensure a smaller lump size. However, it is just not enough in high-tonnage, high-speed systems. Crushers, buckets, hoppers, transfer points, chutes, screens and feeders have critical points that are vulnerable to abrasion and impact damage in such situations. An effective strategy to prevent such damage and increase component lifespan is to make the system more wear-resistant. This is where wear plates play a key role.

What is a wear plate?

Wear plates are sacrificial plates that function as an intermediary between the raw materials and conveyor system components. They are fixed onto components such as chutes to guard them against the abrasive nature of raw materials. The entire area where the raw materials interact with the system at high relative speeds is covered with these wear plates.

The wear damage now occurs on these wear plates instead of on the expensive component. Over time, these plates erode and are replaced with new ones. Using wear plates is a very effective method of minimizing permanent wear damage to conveyor system components.

What is a wear plate made of?

Over the years, engineers have experimented with a variety of materials to create wear plates for various aggressive bulk powders and aggregates. These include.

• Rubber
  • Low cost solution, not suitable in heavy duty environments
• Ultra-high-molecular-weight (UHMW) Polyethylene
  • A dependable material for uninterrupted raw material flow. Low heat resistance (unless treated), surface hardness, rigidity and creep resistance are common issues associated with polyethylene.
• Polyurethane
  • Lightweight and easy to install, but low impact absorption
• Abrasion-resistant steel
  • Popular solution for mining and high-wear applications. Poor performance in terms of abrasive resistance
• White iron
  • Ideal in wear resistance and abrasion resistance applications. Its hardness can be a limiting factor

The introduction of composite wear plates

Composite wear plates consist of two different materials in a matrix, each of which retains its properties. Many composite wear plates are available in the market to choose from. These materials typically outperform single material wear plates. An example of such a wear plate is when hardened steel is embedded in a rubber matrix. Composite materials combine the best properties of the two constituent materials.

A brilliant example of composite wear products outperforming conventional alternatives is that of ROXDUR products from Roxon. Roxon performed several comparative studies at different locations to verify the effectiveness of ROXDUR products. We will take a look at the results of these studies, but before that let us learn about the material used in the production of ROXDUR wear products.

Composite wear plates from ROXDUR

ROXDUR wear products are made from a composite material consisting of cemented carbide in an iron matrix. It has excellent wear and impact resistance properties that enable it to last up to 20 times longer than conventional wear plates for mining.

Under testing, it outperformed different grades of carbon steel, abrasion-resistant steel, manganese alloys, ceramics and even white iron by a huge margin. This degree of resistance contributes to its long life, significantly increasing the interval between plate replacements. This, in turn, reduces downtime and maintenance costs for medium, heavy and light duty applications.

ROXDUR wear products outperform traditional wear plates at multiple client locations

Roxon&#;s engineers were able to evaluate the quality of ROXDUR wear products in operation through three distinct case studies. These studies were carried out at client sites where ROXDUR products had recently been installed. The testing focused on various parameters that are of great significance in any mining operation These parameters are:

• Harsh working environment
• Service life
• Tonnage

Harsh working environment

The first case study took place at an iron ore mining facility in Sweden. The facility had a capacity of t/hr and lump size of 300 mm.

ROXDUR skirt liners were installed to improve ore containment on the first conveyor right after the primary crusher. The setup was observed for 183 days. During the duration of the study, the weather conditions were between 0°C and 25°C.

When the study concluded in October , it showed that ROXDUR skirt liners lasted six times longer than the white iron wear plates before them. The liners are still in operation as of April .

Service life

One of the most significant benefits of ROXDUR wear products is their unrivaled service life. For the second case study, the engineers selected a copper ore mining facility in Peru. The capacity of the system was t/hr and the material size was between 250 and 350 mm.

In this system, ROXDUR skirt liners were installed on a belt feeder after the primary crusher. Critical points on the feeder that were most vulnerable to heavy wear damage were fitted with these liners. Prior to this, white iron plates were in use at these locations and they lasted only one month.

The performance of ROXDUR liners was evaluated for 160 days until the study concluded in September . However, at the end of three months itself, the client was happy with ROXDUR performance and decided to continue with them. The liners have been running for seven months by now showing an improvement of at least a six times longer service life.

If you want to learn more, please visit our website wearplate.

Tonnage

The third case study took place at another iron ore facility based in Sweden. This facility had a capacity of t/hr with a material size of 200 mm. ROXDUR chute liners were installed at a critical chute after the primary crusher. With the previous wear plate, a replacement would be in order after every 500 ktons.

ROXDUR chute liners, however, have so far lasted ktons and are still going strong. Even if we consider ktons as the provided tonnage, that is eight times as much tonnage as the previous wear material making it a very beneficial investment.

Summary

Every mining operation is different. Every raw material has its own characteristics. But there are certain qualities expected of wear-resistant materials that are invariable for an efficient mining operation. These include qualities such as low friction, noise damping, high abrasion and impact resistance, easy installation and replacement and a long service life. ROXDUR products have all of these qualities and more.

If your plant is experiencing wear-related problems at bunkers, transfer points, chutes, hoppers screens and feeders, reach out to us today for a reliable solution. At ROXON, we undertake chute manufacturing and installation as well. First-time customers who invest in a ROXDUR installation can also be supported with a performance guarantee.

To find our more about ROXDUR visit www.roxon.com/roxdur

Overall, abrasion resistant wear plates have become a staple in the mining industry, with most businesses finding that they have become an indispensable part of their day-to-day operations.  Although they come with a slightly higher investment upfront, the benefits far outweigh the costs associated with upgrading to abrasion resistant plates. 

What are the Most Common Applications of Wear Plates in the Mining Industry?

Below, we&#;ve put together a list of the six most common areas we see our clients using Tri-Braze ® alloyed abrasion resistant plates, and why they choose to use them.

1. Conveyor Systems:

   Conveyor systems are one of the most pivotal parts of a mining operation.  Since they&#;re designed to move material without the constant oversight of an operator, it&#;s important that conveyors stay online for as long as possible. Tri-Braze® skirt boards and pan liners can help keep your conveyors up and running with less down time by acting as a sacrificial layer, allowing a much longer lifecycle for your system.

2. Crushers:

   Breaking down large rock and ore into more manageable sizes is not an easy job, which means that crushers see some of the most intense wear and tear out of all of the equipment at a mine.  When implemented correctly, abrasion resistant liners and screens can help extend the amount of time between repairs and maintenance, allowing your operation to stay running longer.  

3. Excavator/Loader Buckets and Dozer Blades:

   Tri-Braze® and Super-C® wear plates are also very useful when it comes to earth-moving equipment like excavators, loaders, and dozers. The constant moving of materials can wear down these pivotal pieces of equipment quickly. Bed liners, bucket liners and dozer blades fabricated from Tri-Braze allow you to go longer periods of time without having to swap out buckets, leading to higher efficiency and an overall safer workplace for your employees.

4. Hoppers and Chutes:

   Hoppers and chutes are a literal bottleneck in your operation, holding large quantities of material.  These pieces of equipment can also experience incredible levels of abrasion thanks to the considerable weight of the material and its abrasive nature. This makes hoppers and chutes both prime targets for abrasive wear. Using Tri-Braze® alloyed wear plates in hoppers and chutes can help cut down the frequency of replacing parts, leading to a smoother operation.

5. Truck Beds:

   Haul trucks that work within mines are subjected to some of the harshest and most abrasive conditions in a mining operation. The combination of impact from loading and abrasion from dumping causes a considerable amount of wear and tear to their beds. Tri-Braze® wear plates can help extend the lifespan of the truck beds when compared to the same thickness AR wear plates, giving the same service life with thinner liners, leading to less carry-back weight, longer tire life, and better fuel economy.

6. Ball Mill Liners
   

   Ball mills are used to grind materials and crush them into smaller pieces for further processing to separate the desired ore from its surrounding material. The grinding operation creates a huge amount of abrasion, both from the ore-laden material and the grinding balls in the mill. Tri-Braze® and Super-C® wear plates have been proven to outlast traditional AR wear plates, enhancing uptime and mill throughput. 

Tricon Wear Solutions: A Trusted Partner in the Mining Industry

The mining industry relies on some of the most sturdy, reliable, and complex equipment in the field. Wear plates not only play a pivotal role in helping protect your company&#;s equipment from everyday wear and tear, but they also play an important role in employee safety. After all, when your equipment requires less maintenance, your production lines can stay up and running for longer and your employees will find themselves in hazardous positions less often.  

Tri-Braze® alloyed, abrasion-resistant wear plates provide critical protection to some of the most important pieces of machinery experiencing the highest levels of wear and tear.  By investing in the highest quality wear plates from Tricon Wear Solutions, you can enhance both the profitability and safety of your operation.  

Learn more about Tri-Braze®

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