Nickel Mine in South America – Enhanced Wear Life & Reduced Maintenance

Customer: A large nickel mining company in South America

Challenge: The customer’s ball mill was facing severe abrasion issues, with the previous rubber liners requiring frequent replacement, leading to high maintenance costs and prolonged mill downtime. The aggressive grinding environment of nickel ore put great pressure on the liner’s tear and wear resistance, and the customer urgently needed a solution to extend service life and improve operational efficiency.

Solution: We provided custom-engineered rubber liners made of high-performance R67 elastomer compound, which is independently formulated and produced to ensure strict quality control. The liners were designed to fit the mill’s specific geometry and operating conditions, with enhanced tensile strength and abrasion resistance to withstand the aggressive grinding process.

Result: After a 10-month trial, the rubber liners achieved an incredible 45% increase in wear life at the feed end of the mill shell compared to the previous liners. The customer was highly satisfied with the performance and has since ordered additional liners for their other ball mills. The extended service life reduced maintenance frequency by 30%, significantly cutting downtime and maintenance costs, while ensuring stable mill operation and consistent ore processing output.