Naipu Mining Machinery——Successful Application of Rubber Composite Liners in a European Mine

Client Information: A concentrator in Serbia, equipped with a φ5.03*5.0m SAG mill, is an important non-ferrous metal processing enterprise in the region with high requirements for equipment stability and cost control.

Original Problems:

1. Insufficient Service Life: The original CrMo alloy steel liners lasted only 4-5 months, with feed end liners lasting only 3.5 months, resulting in high replacement frequency
2. Poor Toughness: Traditional CrMo alloy steel had high hardness but insufficient toughness, prone to cracking from impact fatigue
3. Heavy Weight: The original liners weighed 79 tons, placing a high load on equipment and increasing energy consumption
4. Long Maintenance Cycles: Each liner replacement took considerable time, affecting effective production time

In May 2024, the client installed rubber composite liners developed by Jiangxi Naipu Mining Machinery Co., Ltd. These products feature a three-layer composite structure of NR natural rubber + Q235B steel + wear-resistant steel plate, combining the buffering and impact resistance of rubber with the high strength and wear resistance of steel plates. This innovative design突破了 the performance limitations of traditional single-alloy steel liners.

1. Short Life Problem: Shell liners extended from 4-5 months to 8 months; feed end liners from 3.5 months to 6 months, significantly reducing replacement frequency
2. Insufficient Toughness: The three-layer composite structure combines rubber's buffering properties with steel's wear resistance, solving the fatigue cracking problem of single-alloy steel
3. High Energy Consumption: 26-ton weight reduction (32.9%) significantly reduced motor load and power consumption
4. Maintenance Efficiency: Maintenance time shortened from 7 days to 3.5-4 days, a 50% efficiency improvement
5. Working Environment: Rubber layer effectively reduced workshop noise, improving working conditions

Customer Testimonial:

"Since installing Naipu composite liners in May 2024, the third and fourth rows of liners have been running stably for 242 days, far exceeding expectations! The first and second rows are still in service, with total life expected to exceed 9 months. Even more惊喜ingly, after the weight reduction, power consumption has significantly decreased, workshop noise has been reduced, and maintenance cycles have been cut in half – this is not just an equipment upgrade, but a revolution in production mode!"

Comprehensive Results:

• Operating Record: As of April 2025, third and fourth rows of liners had been running stably for 242 days, with first and second rows still in service
• Production Time: Annual effective production time increased by over 80 hours
• Cost Savings: 50% reduction in replacement frequency, directly reducing downtime losses and spare parts procurement costs
• Energy & Noise Reduction: Lower power consumption and reduced workshop noise, supporting green and low-carbon production