In the demanding, rough-and-tumble world of mining, equipment durability and efficiency are critical to operational success. At Copps Industries, we understand the challenges mining professionals face, and we provide advanced wear-resistant products that enhance the longevity and performance of your essential mining equipment.
Here, we’re highlighting two key applications where our innovative K-038 ArmorPlate Ceramic FC has made a significant impact: Overflow Ball Mill Outlet Boxes and Hydro-Cyclone Launders.
Application #1: Overflow Ball Mill Outlet Box
The overflow ball mill box plays a crucial role in grinding operations and is designed to overflow and discharge materials from the trunnion on the outlet side. Typically combined with a mechanical classifier or wet-processing cyclone, this setup is used for fine grinding in closed circuits or special applications such as regrinding in open circuits. However, the highly abrasive nature of the ore often leads to rapid wear and tear of the outlet box lining.
The overflow mill has a discharge steel box that is usually rubber-lined or ceramic-lined to resist high abrasion. These rubber linings typically wear out within 3-6 months, leading to frequent maintenance and downtime. To address this issue, Copps Industries introduced K-038 ArmorPlate Ceramic FC to replace the rubber lining.
Here are the benefits of using K-038 ArmorPlate Ceramic FC:
- Fast Cure Material: Minimizes equipment downtime by curing quickly.
- On-Site Repairs: Allows repairs to be made without dismounting the equipment.
- Easy Mixing and Application: Can be applied easily without specialized tools.
- Versatile Application: The paste can be applied vertically without sagging, unlike some competitor products.
- Superior Abrasion Resistance: With K-038, the anti-wear material lasts 9-12 months, effectively doubling equipment lifespan compared to rubber linings.
Application #2: Hydro-Cyclone Launders
Hydro-cyclones separate coarse materials from fine particles, operating through a vortex cone fed at the top by a pump. The launders are made of carbon steel and house a battery of three cyclones. The extreme abrasion in these launders necessitates the use of protective lining plates to prevent equipment damage.
Working with one customer, we saw these lining plates were coated with competitors’ ceramic beaded epoxy, which required up to two preventive maintenance schedules per year to keep the equipment running without failure. The downtime and maintenance frequency were significant challenges.
By introducing K-038 ArmorPlate Ceramic FC, we provided a solution that exceeded the customers’ expectations and reduced maintenance. Coating the lining plates with K-038 significantly improved the durability and abrasion resistance of the launders and reduced maintenance to just once a year.
Consider these advantages of K-038 for Hydro-Cyclone Launders:
- Proprietary Formulation: Developed over 35 years to address the unique challenges of the mining industry.
- Enhanced Performance: Outperforms competitors’ materials in both durability and abrasion resistance.
- Reduced Downtime: Minimizes the frequency of maintenance, ensuring continuous operation.
- Quick Cure Time: Allows for faster turnaround and less downtime during maintenance.
Wear-Resistant Products from Copps Industries
At Copps Industries, we’re proud to support the mining community with products that empower excellence and drive success. With the superior properties of K-038 ArmorPlate Ceramic FC, we’ve enabled mining operations to achieve greater efficiency, less downtime, and longer equipment life.
Our line of wear-resistant products was specially formulated with the mining industry’s unique needs in mind, and our commitment to excellence ensures that we continue to meet the industry’s evolving needs. For more information on our wear-resistant solutions and how they can benefit your operations, contact us or request a quote today.
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