ROITECH interstage relining: synchronizing mill relining at different stages
Due to differences in the mileage of the lining in mills of different grinding stages, the timing of its replacement may not coincide. This requires a more precise approach to relining planning and has the potential to reduce the total number of stops.
ROITECH’s inter-stage approach allows you to synchronize relining cycles and build the entire grinding chain as a single system.
From a single mill to a system
ROITECH solves the challenge of synchronizing relining times across mills with inter-stage relining, an approach that considers the entire grinding chain rather than a single mill.
This approach involves an analysis of the entire chain: mill operating modes, mill loads and wear patterns at each stage and in each zone of the individual mill. Based on these data, materials and lining design are selected so that its service life at different stages is optimal and multiple.
Why do non-synchronous stops occur?
At enterprises, mills of different stages work with different intensity, so the timing of lining replacement does not coincide.
For example, a first-stage mill may require relining every 7 to 8 months, while the next stage continues to run for up to 12 months. In addition, wear occurs unevenly within the same mill – in different zones, the lining is changed at different intervals.
If the replacement intervals are not multiples, the stops fall on different periods. This increases the total number of repairs and complicates work planning.
Interstage relining allows these cycles to be synchronized. ROITECH is configured so that the service life of the lining at different stages and in different zones of the same mill is a multiple – for example, 6 or 12 months. In this case, maintenance is optimized: after a year, both mills are stopped at the same time and the work is carried out at the same interval.
This is especially important given the cost of downtime: the shutdown of one large mill with a diameter of 10-12 meters can cost the enterprise 300-400 thousand dollars per day. Synchronization reduces the number of shutdowns and makes equipment operation more efficient, predictable and manageable.
How to synchronize replacement dates
Let’s consider a typical configuration: the MSI mill with a diameter of 9 m and the MSh mill with a diameter of 6 m operate with a lining capacity of 6–10 and 10–12 months, respectively. At such intervals, the timing of lining replacement does not coincide and the work is carried out in different periods.
As part of the inter-stage approach, ROITECH proposes to change the configuration of the lining so that the service life is a multiple of 6 months. For MSI, the mileage of the elements is increased and partial replacement in the PPR is used, for the MC, a solution is developed with an extended service life of up to 24 months.
As a result, replacement times are equalized (for example, up to 12 or 24 months), and stops can be combined in single intervals instead of several separate ones.
Engineering Approach to Liner Life Management
Interstage relining is an engineering tool for controlling a grinding system.
ROITECH experts analyze the operation of several mills at the same time, select a combination of materials and form a single replacement plan that allows you to synchronize repairs and ensure stable operation of the equipment in the long term.
ROITECH mill lining is a high-tech product for mining companies. In-house design and a full cycle of preparation of design documentation allow us to create products for specific operating conditions.
ROITECH offers a full range of wear protection solutions for grinding and beneficiation equipment – for mills of all types and sizes. Modern materials are used in production, including metal, rubber and combined linings, to optimize performance and reduce operating costs.
The ROITECH portfolio includes:
- lining for AG, SAG, ball, rod, ore and multi-chamber mills;
- metal, rubber, rubber-metal and magnetic linings;
- Lining for vertical mills, loading and discharging trunnions, modular butars.
ROITECH specialists also carry out reengineering and modernization, developing individual solutions to increase the life of equipment and improve the efficiency of the entire grinding chain.
