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Proprietary abrasion- and impact-resistant compounds, combined with a ball mill overhaul, deliver optimised performance with increased mill availability and improvements in production levels.

Melbourne, Australia – Weir Minerals has developed a custom-engineered mill lining system with Vulco® R63 rubber liners for James Hardie Philippines (JHP), a regional manufacturing hub of the global leader in fibre cement production, James Hardie™.

Due to a substantial increase in demand for their product and in order to increase overall throughput of the site, JHP wanted to increase the output of their ball mill which was processing a mixture of coarse and fine silica. The incumbent rubber mill liners were only lasting between six and nine months and contributed to a 25% drop in output after just six months in operation.

Weir Minerals mill lining specialists, renowned for their expertise in mill lining systems and wear materials, conducted extensive testing and modelling scenarios to evaluate how optimisation of the ball mill charge volume and trajectories would result in an increased mill throughput.

Using state-of-the-art simulation technology and drawing on decades of expert knowledge, Weir Minerals specialists designed a customised mill lining system with Vulco® R63 rubber mill liners. The custom-engineered shell liner design ensured correct lifter face-angle to facilitate optimum performance while also increasing the service life of the Vulco® mill liners. To complete the ball mill overhaul, Weir Minerals experts also recommended to increase the charge height, significantly improving the grinding process.

Exceptional wear life and results

The custom-designed solution resulted in increased production and increased mill availability at JHP. The Vulco® R63 mill liners improved wear life by up to 200%, from six to 18 months, more than halving the reline time and associated maintenance costs. As a result of the ball mill overhaul -designed and executed by Weir Minerals experts in partnership with JHP, the throughput was increased by up to 44%.

Vulco Mill Lining Systems

The innovative designs of Vulco® mill liners are tailored specifically for every customer and are manufactured to the highest industry standards for autogenous (AG) and semi-autogenous (SAG) mills, primary, secondary, and re-grind ball and rod mills. The inherent characteristics of elasticity, high tensile strength and corrosion resistance found in the Vulco® elastomer compounds position them as the preferred mill lining material over steel in many applications.

Key features and benefits:

  • Lighter than conventional steel linings for increased handling safety
  • Reduced noise due to rubber’s sound dampening effect
  • Facilitate increased power draw due to reduction in lining weight, increasing filling volume
  • Increased safety and decreased lining installation hours due to reduced component and lining mass
  • Faster manufacturing lead times than metal liners