Maximizing Equipment Lifespan and Efficiency with Advanced Wear-Resistant Ceramics

The Evolution of Wear-Resistant Materials in Mineral Processing

In the realm of mineral processing, the seamless conveyance of bulk materials between stations poses a challenge, pushing processing equipment to its limits. One critical issue faced is the severe wear and tear experienced by components, notably chutes and hoppers. The cost of replacing worn-out equipment significantly inflates maintenance expenses. Therefore, any measures that mitigate wear and enhance equipment lifespan hold paramount importance.

Redefining Durability: Choosing the Right Wear-Resistant Materials

As demands escalate for reducing maintenance costs and augmenting output, the quest for longer-lasting wear-resistant materials intensifies. Embracing lighter, more durable wear-resistant materials has emerged as a prevailing trend.

Traditional wear-resistant steel plates, while robust, exhibit high density and weight—1.4 times heavier than ceramics. High-quality, high-hardness wear-resistant steel liners come with a hefty price tag, intricate processing, and usage limitations. Under extreme temperature conditions, these materials witness fluctuations in hardness, rendering them susceptible to brittleness at low temperatures and reduced hardness at high temperatures.

In contrast, wear-resistant ceramic liners outshine traditional wear-resistant steel plates in terms of weight and durability.

The Innovation: Ceramic Rubber Vulcanization Liners

Enter the realm of wear-resistant ceramic liners crafted through specialized plate vulcanization processes. This technique amalgamates ceramics, rubber, and steel plates through heat vulcanization, resulting in a seamless integration. These liners boast exceptional wear resistance owing to ceramics while exhibiting a level of impact resistance—attributed to the rubber layer's effective cushioning throughout the liner's usage. This fortified impact resistance adeptly handles the high-intensity impacts during material conveyance processes.

In an illustrative case at a steel plant, the application of Precision City's wear-resistant ceramic liners within the secondary crusher's belt discharge chute, accommodating materials dropped from a height of 5 meters (transitioning from one conveyor belt to another), demonstrated outstanding results. Considering the typical hardness of iron ore at 7 on the Mohs scale, the site utilized these liners for 329 days (and still operational), consistently operating at full capacity (900 tons per hour). These liners effectively handle block materials of up to 200mm in diameter, marking a significant leap from the previous wear-resistant steel liners that barely lasted an average of 8 weeks.

Sanxin New Materials Co., Ltd., dedicatedly specializes in ceramic milling balls, nanoparticles, nanopowders, as well as wear-resistant and abrasion-resistant ceramics, offering groundbreaking solutions to the challenges encountered in mineral processing.