How liners can reduce operating costs

By Greg Donecker| February 28, 2023

This scalping screen was fitted with rubber discharge lips, and the custom-designed chute handling large jaw crusher discharge rock was lined with rubber on the floor and sidewalls of the chute. The rubber lasted three times longer than AR steel, according to Kemper Equipment’s Greg Donecker. Photo: Greg Donecker

Today’s aggregate producers are seeking out a myriad of solutions to mitigate increasing costs.

Processing plants and wear parts are being purchased with the ultimate goal of reducing costs. Similarly, engineered wear-lining systems constructed of rubber, ceramic rubber and urethane are being installed to extend the time between maintenance.

While producers want to put more time between maintenance intervals, they’re also focused on the safety and health of their employees. One way they’re prioritizing safety and health in this area is by implementing more linings.

As materials are transported in a mine – both in the pit and through the processing plant – wear and damage are done to assets. This occurs in mobile equipment truck beds; in hoppers, bins and silos; in slurry boxes and sump tanks; in feed boxes and transfer chutes; on conveyors and belt feeders; and with crushers, screens and other processing machinery.

All of these areas can be protected with liners, but the type selected and the specification of a lining material is application driven. The material’s characteristics must be factored in – including the size, weight, density, shape, clay content, moisture and temperature.

One important factor that’s often overlooked, for instance, is travel distance. The drop height and travel speed of aggregates also matter. After determining the fall distance, the angle of the travel impact against the surface should be reviewed.

Other considerations

The bolt-in urethane liners in this slurry sand chute assist in lowering the plant’s maintenance costs. Photo: Greg Donecker

Consider, too, that multiple types of wear lining materials are often needed.

Additionally, a properly applied material along with a well-designed system can result in up to 150 percent liner life. Not having proper liners negatively influences costs and downtime. Plus, a reduction in production capacity and out-of-spec products may occur.

Producers must also protect employees – and lining systems play a role. Lining systems reduce a plant’s noise and dust levels. They also reduce how frequently liners are replaced in confined spaces while reducing plugged chutes and transfers.

Greg Donecker is president of Kemper Equipment, an equipment dealer and a supplier of parts, service and engineered systems for aggregate and mineral processing plants. The company is based in Honey Brook, Pennsylvania.