How to choose wear-resistant materials for mineral equipment? Comparison of ceramic rubber liner/nylon products/glue wood shingles parameters
Categories: Company News Views: 588
Excerpt:
In the mineral industry, high-performance non-metallic materials such as ceramic rubber liners, nylon dust rings/nylon plates, and gum wood shingles are widely used due to their unique physicochemical properties, and the following is an analysis of their typical application scenarios and advantages
InMineral industryMiddle.Ceramic Rubber Liner,Nylon Dust Ring/Nylon plate,Gluewood shinglesHigh-performance non-metallic materials are widely used due to their unique physicochemical properties, and the following is an analysis of their typical application scenarios and advantages:
1. Ceramic Rubber Composite Liner
application scenario
- Ore Crushing and Conveying Systems: It is used as the lining of ball mill, crusher, vibrating screen, chute, silo and other equipments to resist the high intensity impact and abrasion of ore and slag.
- Mineral processing equipment: Laying on the inner wall of the cyclone and classifier to reduce slurry scouring wear.
- Wear-resistant pipes: Used for lining of slurry conveying pipes to prevent rapid perforation of pipes due to particle friction.
dominance
- Dual characteristics of impact + abrasion resistance: the rubber layer absorbs the impact energy and the ceramic sheet (e.g.aluminum oxide) provides ultra-high hardness (Mohs ≥ 9), life ismanganese steellinerof 3-5 times.
- anti-clogging material: The elasticity of rubber reduces material sticking and is particularly suitable for wet sticky ores.
- noise reduction and damping: The rubber layer reduces the noise of equipment operation (10-15dB) and improves the working environment.
2. Nylon dust ring/nylon plate
application scenario
- Hydraulic and pneumatic systems: formines(old) cunning（Sealing of piston rods (e.g. hydraulic pillars, rock drills) to prevent dust intrusion.
- sliding part: As wear-resistant pads for screen machine guide rails and conveyor belt rollers, replacing metal to reduce friction.
- Corrosive environments: for flotation cells, wetsmelt metalProtective liner for equipment, resistant to acid and alkali corrosion.
dominance
- Self-lubricatingsuffix forming noun from adjective, corresponding -ness or -ity: Nylon (e.g. MC901 modified nylon) has a low coefficient of friction (0.1-0.3) and requires no additional lubrication, making it suitable for dusty environments.
- lightweighting: 1/7th the density of steel, reducing equipment loads.
- chemical resistance: Better tolerance to salts and weak acids/alkalis in the slurry than common metals.
3. Bakelite shingles (phenolic resin laminates)
application scenario
- Heavy Duty Low Speed Bearings: Used for sliding bearings in ball mills and rotary kilns in mines to withstand high radial loads.
- Water lubricated environment: Replacement of metal in bearings of mining pumps and water turbines to avoid rusting.
dominance
- Extreme Pressure Performance: Phenolic resin + fiber reinforced structure can work under 50MPa pressure with PV value up to 3MPa-m/s.
- waterproofWater absorption <0.5%, long-term water immersion still maintains dimensional stability.
- Low-cost maintenance: Easy to replace after wear, lower overall cost than copper shingles 30%-50%.
| parameters | Ceramic Rubber Liner | Nylon dust ring/nylon plate | Gumwood shingles (phenolic resin) |
|---|---|---|---|
| staple | Aluminum oxide ceramic (Al₂O₃≥92%) + natural/synthetic rubber | MC901 modified nylon (PA6/PA66) | Phenolic resin + cotton/fiber reinforced laminate |
| Density (g/cm³) | 3.6-3.9 (ceramic layer) / 1.2-1.4 (rubber layer) | 1.12-1.15 | 1.3-1.4 |
| durometer | Ceramic layer: Mohs hardness ≥ 9 / Rubber layer: Shore A 60-80 | Rockwell hardness R110-R120 | Brinell hardness HB30-40 |
| abrasion resistance | Volume wear rate ≤ 0.02cm³/1.61km (ASTM G65) | Abrasion ≤ 50mg (CS-17 wheel, 1kg load) | Line wear rate ≤ 0.1mm/1000h (20MPa load) |
| Compressive strength (MPa) | Ceramic layer ≥ 850 / Rubber layer ≥ 15 | 80-100 | 100-150 (layerwise) |
| coefficient of friction | Dynamic 0.4-0.6 (rubber to steel) | 0.1-0.3 (dry friction) | 0.08-0.15 (water lubrication) |
| Temperature range (°C) | -40~+150 (rubber resistance limit) / ceramic resistance≥1600 | -40~+120 (short-term +150) | -30~+120 (instantaneous +150) |
| corrosion resistance | Acid and alkali resistant (except HF and strong alkalis) | Resistant to weak acids/alkalis and salt spray | Resistant to acids, alkalis, and organic solvents (except strong oxidizers) |
| Typical application equipment | Ball mills, chutes, slurry pipelines | Hydraulic cylinder seals, screening machine guide rails | Ball mill bearings, mining pumpsaxle tile |
| Lifespan comparison | 3-5 times longer than manganese steel liners | 2-3 times longer than metal backing plates | 1.5-2 times longer than copper bushings (water-lubricated conditions) |
| Key advantages | Combined impact resistance + wear resistance | Self-lubricating, lightweight | Extreme-pressure water resistance, low-cost maintenance |
Industry application trends
- Lightweighting and energy efficiency: Materials like nylon and bakelite reduce equipment weight and energy consumption (e.g., ball mill liner weight reduction can save 5%-8% in electricity).
- Smart compatibility: Ceramic-rubber liners can integrate wear sensors for real-time thickness monitoring.
- environmental demand: Non-metallic materials prevent lubricant contamination, complying with green mining standards.
Selection recommendations
- High-impact scenarios: Choose ceramic-rubber liners (larger ceramic blocks enhance impact resistance).
- Corrosive environments: Prefer nylon 12 or PTFE-modified nylon.
- Heavy-duty bearings: Bakelite bushings require graphite lubrication grooves to extend lifespan.
The application of these materials significantly reduces downtime maintenance frequency in the mining industry, improving overall equipment effectiveness (OEE), making them a core component of modern mining wear-and-corrosion-resistant solutions.
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