Ball Mill and Crusher Liner Rebuild
Worn mill liner backing and crusher transfer points rebuilt so the plates sit on a solid seat and the shell is protected from impact.
The challenge
The liner backing and feed-end housing of a mill had worn through behind the plates, so the wear plates no longer sat on solid metal. With the backing gone, every impact worked the bolts loose instead of being carried by the shell, and the play kept getting worse between repairs. At the crusher transfer points the metal had ground down thin enough that impact was starting to reach the shell directly. Left alone, the loose plates and the thinning shell put the mill at risk of a failure that would pull it out of service on no notice.
Our approach
We start by cleaning the backing and feed-end housing areas back to sound metal so the rebuild has something to key to. Then we rebuild the worn shell metal and the housing back to profile so the wear plates bed on a solid seat instead of bridging a void, which lets the impact be carried by the shell rather than working the bolts loose. At the transfer points we blast the thinned metal and apply an abrasion-resistant lining keyed to the duty, protecting the shell and giving the liners a sound surface to ride against through the grinding cycle. Where a face flexes or takes repeated impact, we use a cold-applied elastomer instead.
- Assess backing and transfer pointsWe inspect the liner backing, feed-end housing, and crusher transfer points to find where the metal has worn through and where the plates have lost their seat.
- Clean and prepWe clean and blast the backing, housing, and transfer-point metal back to a sound, profiled surface so the rebuild and lining bond properly.
- Rebuild the shell and seatWe rebuild the worn shell metal and housing back to profile so the wear plates bed on a solid seat instead of bridging a void.
- Bed plates and line wear facesWe bed the wear plates back down on the rebuilt seat and line the transfer points with an abrasion-resistant system keyed to the duty, using a cold-applied elastomer where a face flexes or takes repeated impact.
- Return to serviceWe cure and check the rebuilt areas, then hand the mill back ready to run through the grinding cycle.
The result
- Worn liner backing and shell metal rebuilt in place so the wear plates bed on a solid seat
- Impact carried by the shell instead of working the liner bolts loose
- Crusher transfer points lined and protected so the shell rides against a sound wear face
- Mill returned to service by factory-trained and factory-certified Belzona applicators
Belzona systems used
In the field
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