Sandvik WT6000 primary hopper lining at Hanson’s J. Riera S.A. Quarry in Spain
Monday, June 28th, 2010
In June 2009, Sandvik Española – through Sandvik’s dealer for conveyor components, screening media and wear protection products in Catalonia, Comercial Dyser – was contracted to line the Hanson group’s primary hopper with wear protection located at their Llinar del Valles quarry. The original turn-key plant was delivered at the beginning of 2009.
The primary hopper is the first structure to receive feed material in the plant. The processed material is blasted granite, with a high abrasive index and possessing a maximum size of 2000 mm. The material is directly discharged by a dumper truck into the 90 m3 hopper, with the hopper dimensions being 6623 x 7575 x 3887 mm.
Due to the all encompassing nature of a project of this nature several factors must first be considered when selecting lining material for the hopper. These include the characteristics of the processed material, including the size, as well as the physical discharge conditions. Additionally, the installation method was a key factor that had to be taken into the complex equation.
Once the process operation had been fully assessed, Sandvik chose the WT6000 encompassing 60 shore rubber wear plates with full 5 mm steel backing, and a total thickness of 125 mm. Stud welding was used to set up the facilities.
The WT6000 installation extends equipment life by reducing vibration through the dampening of the impact forces on the hopper structure. Provided that the correct rubber thickness has been selected, the inherent flexibility of the WT6000 rubber allows it to move away, preventing cracking and surface deformation. Since the rubber isn’t affected by corrosion, it has an additional longevity benefit compared to steel linings.
Another great advantage for the WT6000 is the on-site noise reduction that enhances the work environment. Additionally, the stud welding system avoids drilling the hopper, making the installation easy and secure. The stud welding allows for easy and economical maintenance, as any damaged modules can be replaced without welding or drilling works.
The hopper lining design process was carried out following the hopper specifications which were made by the Sandvik technical department in Svedala. Once all the material was ready to be installed on site, a Sandvik service team, supported by Dyser technicians, started the installation work during the last week of June 2009.
The lining process began with the set up of the stud weld, which followed the assembly pattern provided by the Sandvik design department. The next step was to place the WT6000 rubber plates; these had been cut and drilled previously following the same pattern. The drilled holes in the rubber plates were covered with a rubber plug, which protects the fastening elements against wear and tear.
Six months after installing the lining, Mr. Javier Moyano, plant manager at J. Riera S.A, provided his feedback regarding the work undertaken. From his point of view, the biggest advantage was enhancing the work environment thanks to noise reduction, through the installing of the Sandvik WT6000 rubber plates. Prior to this installation, every time material was discharged in the hopper the resulting noise was audible in the entire locality. Now however the discharges are made without disturbing the workers or the others in the vicinity of the quarry.
Furthermore, there has been a significant reduction in downtime and maintenance cost. After six months, and more than 250.000 processed tons, the lining is still in perfect operating condition, and no maintenance has been required. The installation of the Sandvik WT6000 rubber plates with full steel backing has been a great success that has not only improved the working environment, but has improved the economic operation thanks to the substantial decrease in maintenance costs.
WT6000 – Products Highlights
• 60 shore rubber
• 13 mm – 150 mm thickness
• 3-5 mm steel backing
• Easy and secure fastening
• Enhanced work environment
• Impact absorption
• Long wear life
• Less maintenance
• Lower cost
• Noise reduction