Custom Designed and Engineered for Each Individual Mill
At Weir, we provide market-leading rubber and composite mill liner solutions that are personalised and tailored to suit each individual customer's needs and site.
Vulco® mill linings are custom-designed to fit the specific geometry and operating conditions for each grinding application, with consideration given to available mill power, trunnion bearing loads, mill weight restrictions, grinding media charge volume and service life.
By employing designs to suit a specific application, our mill lining systems can increase mill volumes and provide a longer period of effective grind recovery and optimisation.
Optimal Performance
Our team use the most up-to-date technologies and design tools to ensure optimum system design and accurate liner fit.
After the careful review of all available data, our expert team will help you to select the most appropriate grinding mill liner design and materials to deliver optimal performance and lower total ownership cost.
Some of the advanced technologies and design tools we use include:
- Finite Element Analysis (FEA)
- Discrete Element Modelling (DEM)
- Fluid Dynamic Modelling (FDM)
- Scaled Laboratory Models
- Single Particle Hydrodynamics (SPH)
- Unigraphics CAD systems and
- 3D visualisation with computer-aided modelling.
Fast Installation and Long Wear Life Assured by Strict Quality Control
Vulco® mill lining products are quality checked at every step of the process to provide high quality, correct fitment and fast installation.
With our own internal rubber mixing facilities, we are able to ensure that our compounds are properly mixed to meet stringent specifications. They are also supported by internal quality standards to ensure that Vulco® mill lining products are manufactured to the highest quality.
Additionally, our internal quality control procedures, which include comprehensive raw material checks, visual, electronic, chemical and physical testing procedures, ensure that Vulco® products meet strict design and quality expectations.
Efficient Milling Operations
With advanced materials and state-of-the-art design, Vulco® wear-resistant rubber and composite mill liners are specially formulated for maximum tear resistance, resilience, efficiency, increased wear life and reduced downtime between relines.
Vulco® rubber compounds maintain their original design profiles for longer periods of time compared to other compounds, ensuring more efficient milling operations. They also conform to the mill’s internal surface, creating a seal that helps prevent leakage, slurry erosion of the mill shell and precious metal lockup under the liners.
The available combinations of lifter height and width with an optimal leading-edge face angle design ensure that the available power is converted into the most efficient particle size reduction.
Lower Total Cost Of Ownership
Compared to traditional metal liners, Vulco® rubber liners effectively reduce the total cost of ownership as the longer wear life leads to fewer replacements, less downtime and longer periods of productivity.
Additionally, by balancing the high- and low- wear zones within the mill, similar service life can be achieved across all zones.
Vulco® R67 rubber mill lining systems are particularly renowned for lasting longer than other rubber compounds. This means that operators experience a measurable reduction in mill downtime, installation and maintenance costs.
Multiple trials spanning various continents revealed that Vulco® R67 rubber provided significant wear life improvements, and in some cases up to a 50% increase. We are confident that the latest R67 rubber technology will help you get the most out of your mill.
You can read more about the results from our case studies below:
- Saving an estimated 25% in maintenance costs with Vulco® R67 mill liner
- Liner life extended by 167% and mill throughput up by 97%
- Vulco® mill lining system improves P80 and increases throughput capacity by 13%
- Capstone Pinto Valley Copper Mine discovered additional safety benefits of using R67 liners
Safe and Easy Installation
Since rubber and composite mill liners weigh 35-40% less than steel, they are faster, easier and safer to install.
We also help to lower installation costs by providing correct dimensional components, on-time and fully labelled packaging and certified lifting points. You will also have access to trained personnel to assist with risk and hazard management strategies.
Increased Chamber Capacity
Reducing the mass of grinding mill lining systems can help to increase mill chamber capacity, enabling more materials to be processed. This allows additional feed material to be added without overloading the mill support bearing and shell structural design.
Lower Maintenance Requirements
The low-profile T-track system eliminates the need for frequent inspections, repair and bolt tightening. Longer wear life, faster change-outs and fewer maintenance interruptions result in greater mill availability, performance and production.
Improved Health and Safety On Site
Converting from metal to Vulco® rubber mill lining helps to improve health and safety on site by reducing the:
- Transmitted sound levels associated with grinding processes, e.g. noise pollution
- Risk of strain injuries during installation as the rubber liners are lighter in weight
- Number of components to be handled, thereby decreasing the potential for injuries to fingers, hands and limbs