Superior mill liners, service and support combine to improve mine’s success

Background and objective

With a production capacity of 22,000 tonnes per day, this gold and copper mine depends on their 24’ x 14.5’ SAG mill to continuously operate at peak efficiency. They know dependable mill liners not only boost their mill’s reliability and performance, they protect it from the intense wear and tear that comes from constant grinding of hard, raw materials. They also know dependable mill liners boost their operation’s productivity, whether by reducing downtime or increasing tonnes milled.

With the aim being to increase throughput and milling efficiency, and to reduce downtime, the mine sought to compare the performance of composite mill liners from a new supplier against composite mill liners from their current supplier. The new supplier was FLSmidth.

Defining the project

Shell liner life is a crucial component in a mine’s up-time, efficiency and output, and this mine owner knows that not all mill liners are created equal.

In order to accurately compare the wear life of two different suppliers’ composite mill liners, it was determined that a side-by-side test of the liners would be undertaken. 

Side-by-side testing allowed both suppliers’ liners to be exposed to exactly the same mill conditions, at exactly the same time.

FLSmidth proposed to the mine that they trial the PulpMax Composite Shell Mill Liners. FLSmidth anticipated that the liners would last 120 days, reduce the total weight, avoid cracks and allow a higher ball charge level without increasing the stress on the mill.

The solution

FLSmidth installed their PulpMax Composite Shell Mill Liners in the mine’s 24’ x 14.5’ SAG mill. The installation comprised three FE Shell Lifters and three FE Shell Liner Plates. The competitor also installed their liners in the same mill. The trial protocol was established, and it was determined that technical reports would be presented at the time of installation and during the mid-campaign shutdown. A final report would also be delivered.

In addition to supplying high-performance, lightweight composite mill liners, FLSmidth made frequent site visits to provide any needed services, checks or adjustments.

The mid-campaign inspection revealed the PulpMax Composite Shell Mill Liners displayed wear patterns and wear ratios as initially expected. Most importantly, there were no cracks or adherence problems between the rubber matrix and the steel inserts. Additionally, based on the wear patterns and wear ratios, liner life was forecast to exceed the expected 120 days.

At the final inspection, FLSmidth used 3D scanning technology to examine the liners. Then, they removed the liners for further analysis.

The results

FLSmidth’s PulpMax Composite Shell Mill Liners lasted 124 days. The continued use of these liner types would result in decreased down time and improved wear life.

While the mine found the PulpMax liners outperformed the competing supplier’s liners, they particularly valued the exceptional tailored service and support they received from FLSmidth during the trial period. It was far superior to what they received from the competing supplier and FLSmidth’s support helped the mine’s operations to run more efficiently.

At the end of the trial, the mine’s choice was obvious. The superior performance of FLSmidth’s PulpMax Composite Shell Mill Liners and FLSmidth’s outstanding service and support helped the mine to meet their objective of increased productivity and milling efficiency, and reduced downtime.

A full set of FLSmidth PulpMax Composite Shell Mill Liners is now in place in the mine’s 24’ x 14.5’ SAG mill and FLSmidth has continued to support their use.