Elastomer Mill Liner with Steel Inserts for Crack Resistance
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Solution Overview
Problem
Conventional grinding mill liners made of steel are prone to cracking and wear, requiring costly and difficult replacement, leading to operational downtime and safety hazards, while elastomer liners have limitations in service life and construction costs.
Innovation Solution
A mill liner element composed of an elongated elastomer member with non-elastomeric inserts, providing a durable and lightweight solution that reduces cracking and facilitates easier handling and replacement, combining the benefits of both materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel mill liner components are used, then strength and durability are improved, but weight increases and replacement difficulty increases
Solution Approach 1:
The patent applies composite materials by combining elastomer (for weight reduction and impact absorption) with steel inserts (for strength and durability). The steel inserts are embedded within the elastomer matrix to create a composite liner that achieves both lightweight properties and structural integrity, resolving the contradiction between strength and weight.
2Strength
If steel mill liner components are used, then strength is improved, but ease of repair deteriorates
Solution Approach 1:
The patent segments the liner into modular components with steel inserts embedded in elastomer sections. This segmentation allows individual worn or damaged sections to be replaced independently without replacing the entire liner, improving ease of repair while maintaining the strength benefits of steel reinforcement.
Solution Approach 2:
The composite structure of elastomer with embedded steel inserts enables easier repair compared to solid steel liners. The elastomer matrix can be replaced or repaired more easily than solid steel, while the steel inserts provide necessary strength, thus improving ease of repair without sacrificing strength.
3Strength
If steel mill liner components are used, then strength is improved, but loss of time increases
Solution Approach 1:
The segmented modular design allows for quicker replacement of worn sections compared to solid steel liners. Damaged elastomer sections with embedded steel inserts can be removed and replaced as modular units, reducing the time required for liner replacement and minimizing mill downtime.
4Strength
If conventional steel liners are used, then strength is improved, but object-generated harmful factors increase
Solution Approach 1:
The elastomer-steel composite structure reduces noise generation compared to solid steel liners, as the elastomer matrix dampens vibrations and impacts. The embedded steel inserts provide necessary strength while the elastomer component reduces harmful noise and reduces safety hazards associated with heavy steel components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The elastomer-based mill liner elements offer extended service life, reduced downtime, lower repair costs, improved safety, and simplified assembly, while reducing weight and noise, thus enhancing operational efficiency and worker safety.
Implementation Method 1
an elongated elastomer liner member that is generally structured for positioning along the inner wall of a grinding mill drum or shell
Implementation Method 2
A mill liner element composed of an elongated elastomer member with non-elastomeric inserts, providing a durable and lightweight solution
Data Source
AI summary
A mill liner element is structured with an elongated elastomer member having a non-elastomeric backing plate and a plurality of non-elastomeric inserts formed into the elastomer member to provide a liner element that provides a lifter bar element and a wear element that is less prone to cracking compared to conventional all-metal mill lining elements, and which provides ease of handling and replacement when worn. A multiplicity of mill liner elements are positionable in a grinding mill shell, and are suitable for use in a variety of types of grinding mill structures, including ball mills and AG and SAG mills.