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Thread: Wear of liners: Prevention and PM's

  1. Wear of liners: Prevention and PM's

    We have a plant that discharges approximately 1 million tonnes of grain, soya and wheat (UK Based). We have an ongoing issue of chuting wearing through and becoming holed.

    We have tried replacing worn chutes and similarly installing liners over the chutes. Used plastic, mild steel, hardened 400 steel and now 500. They continue to wear.

    Has anyone a suggestion for:

    1. Better materials that can be used for this purpose? They are typically square chutes.
    2. A way of catching worn liners before they become holed i.e. a preventative maintenance suggestion that can help spot significant wear. (The plant has 33 conveyors - large site to visually check them all often).

    Thank you in advance.

  2. #2
    If you are getting high wear with wheat & soy beans then your whole plant should be examined.
    What are your belt speeds. Are your discharge trajectories OK? Thirty three belts required a competent specialist's input. Was this available. Its too late now & you will just have to live with it.
    Rectification cost for a grain import terminal would be high because of the need to maintain your inbye capability. It is cheaper to live with your situation & recommend that your management improve their contractor selection procedure.
    John Gateley
    johngateley@hotmail.com
    www.the-credible-bulk.com

  3. What are your belt speeds.

    Quote Originally Posted by johngateley View Post
    If you are getting high wear with wheat & soy beans then your whole plant should be examined.
    What are your belt speeds. Are your discharge trajectories OK? Thirty three belts required a competent specialist's input. Was this available. Its too late now & you will just have to live with it.
    Rectification cost for a grain import terminal would be high because of the need to maintain your inbye capability. It is cheaper to live with your situation & recommend that your management improve their contractor selection procedure.
    Thanks for your response John, I totally agree with you that the initial design could well be a large problem with the wear, it was designed and build several decades ago.

  4. #4
    Gary Blenkhorn
    Bulk Handling Technology Inc.

    Professional Experience 40 Years / 8 Month Gary Blenkhorn has 40 Years and 8 Month professional experience

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    You should have someone take a serious look at the chute designs themselves. Many wear problems can be corrected with proper chute design through material flow analysis. Much cheaper than trial and error.

    At a salt mine where I worked (9 million tons per year) we had what we thought was wear until we went with a 316 stainless steel liner or replaced the chute with 316 stainless and the problem went away. What we discovered was that we had more of a corrosion / erosion issue. Meaning the chute would start to rust and then the rust would be removed during the loading cycles. Repeating this process over and over again created loss of material over a short period of time. The higher the moisture area the greater the problem was.

    We started replacing chutes with stainless steel and the problem almost completely went away as the life of the chutes increased dramatically.
    Gary Blenkhorn
    President - Bulk Handling Technology Inc.
    gblenkhorn@bulkht.ca
    http://www.bulkht.ca

    Offering Conveyor Design Services, DEM Flow Simulation Services, Conveyor Transfer Design Services, SolidWorks Design Services for equipment layouts and Software for the Bulk Material Industry.

  5. Thank you both for your guidance. Flow analysis may be a step in preventing future wear. It may have to be something we look into and use it to help assist us, I would have to do some research on it however to see how it functions and what it finds. But thank you.

  6. #6

    You Can't Eliminate Wear.

    Nothing lasts forever: I certainly hope not.
    Why spend time & money to tart up an old girl who has done plenty of business. (do I sound like a real Scouser?)
    Your plant is surely on its last legs but still working. If you pull things apart in old age they might collapse unexpectedly.
    I am now even more convinced that it would be better to live with the wear issue. Suppose the newer, better, cleverer chutes & liners last longer but something else falls apart. Then you are left with good liners & a broken down plant.
    John Gateley
    johngateley@hotmail.com
    www.the-credible-bulk.com

  7. #7
    Join Date
    Feb 12
    Posts
    4

    High Alumina Ceramics lining (and rebuilding the chutes if necessary)

    Quote Originally Posted by keironarndell View Post
    We have a plant that discharges approximately 1 million tonnes of grain, soya and wheat (UK Based). We have an ongoing issue of chuting wearing through and becoming holed.

    We have tried replacing worn chutes and similarly installing liners over the chutes. Used plastic, mild steel, hardened 400 steel and now 500. They continue to wear.

    Has anyone a suggestion for:

    1. Better materials that can be used for this purpose? They are typically square chutes.
    2. A way of catching worn liners before they become holed i.e. a preventative maintenance suggestion that can help spot significant wear. (The plant has 33 conveyors - large site to visually check them all often).

    Thank you in advance.

    Hello Keiron,

    Kalenborn has numerous places working with our wear resistant linings. Big oversea ports for example, handling tons and tons of different types of grain (and materials a lot more abrasive than that). Companies like B?hler, Coperion, Neuero, they all rely on our materials and customized systems.

    You can write me an email on stefan.kurtenbach@kalenborn.com. To start talking about the specifics of your Problem. To see if we need to do something on the Engineering. But pretty sure most of it should be +/- ok. And pretty sure we find a common approach to longer the lifetime of your equipment considerably.

    Looking Forward to hear from you.

    Best regards

    Stefan Kurtenbach
    Kalenborn Kalprotect GmbH & Co. KG

    PS:
    No more falling liners, don't worry. One inspection per year to see everything still is working fine, somethingt like that...

  8. Quote Originally Posted by keironarndell View Post
    We have a plant that discharges approximately 1 million tonnes of grain, soya and wheat (UK Based). We have an ongoing issue of chuting wearing through and becoming holed.

    We have tried replacing worn chutes and similarly installing liners over the chutes. Used plastic, mild steel, hardened 400 steel and now 500. They continue to wear.

    Has anyone a suggestion for:

    1. Better materials that can be used for this purpose? They are typically square chutes.
    2. A way of catching worn liners before they become holed i.e. a preventative maintenance suggestion that can help spot significant wear. (The plant has 33 conveyors - large site to visually check them all often).

    Thank you in advance.

    Al2O3 ceramic liner will be a good choice.http://www.fuboon.com/alumina-cerami...omponents.html
    Abrasive-resistant valves:ceramic lined valves
    Corrosive-resisant valves:Telfon lined valves
    fuvalve.com
    ceramic-valves.com

  9. #9

    The Cat's Pajamas

    Get yourself a Kallenborn Handbook, study & compare. They don't mess about. If you have the dosh they are the bees knees. Chinese tiles might be comparable but you would have problems getting an installation staff on site.
    John Gateley
    johngateley@hotmail.com
    www.the-credible-bulk.com

  10. #10
    Leslie (Les) D. D. Dunn

    Leslie (Les) D. D. Dunn

    OwnerDirector

    Allenvee Holdings (Pty) Ltd.

    Allenvee Holdings (Pty) Ltd.

    Professional Experience 23 Years / 0 Month Leslie (Les) D. D. Dunn has 23 Years and 0 Month professional experience

    Discussions 22 Leslie (Les) D. D. Dunn acceded to 22 discussions, Publications 0 Leslie (Les) D. D. Dunn Dunn released 0 publications

    Know-How Maintenance (22) Leslie (Les) D. D. Dunn used this tag 22 times, Safety (8) Leslie (Les) D. D. Dunn used this tag 8 times, Conveying (6) Leslie (Les) D. D. Dunn used this tag 6 times

    Drop floor chute

    Quote Originally Posted by johngateley View Post
    Get yourself a Kallenborn Handbook, study & compare. They don't mess about. If you have the dosh they are the bees knees. Chinese tiles might be comparable but you would have problems getting an installation staff on site.
    Hi John, I have had a similar issue with wear in fertilizer chute where the chutes were wearing out quickly. ie:- rusting and then the rust was eroded each time the transports arrived. Back in those days, ceramics were not something that was common or available. Expensive Marine grade stainless steels were available but wear was still an issue to deal with. However, we used a system we employed in the quarrying where we made the chute base a 'Drop Down' 'Rock Box' that allowed the fertilizer to wear on it's self while in use and when the conveyor was stopped, or became blocked due to moisture packing, the feed was stopped and the 'Drop Box Floor' was flicked up using the cam lift mechanism to discharge the blockage or the end of run product retained in the 'Rock Box'. The conveyor & 'Rock Box' were still operational with just general maintenance lubrication and cleaning at close of the fertilizer plant some 30 years later. I will look at some of my drawings of similar 'Rock Box' in my hand drawings archives & scan then and post. Might take a while as I will be away due to medical conditions.
    Mechanical Doctor
    There is No such thing as a PROBLEM, just an ISSUE requiring a SOLUTION
    email:- tecmate@bigpond.com
    Patented conveyor Products
    DunnEasy Idler Assembly & Onefits conveyor Idler Roll
    [WINNER] Australian Broadcasters Corporation's TV
    'The New Inventors' Episode 25 - 27th July 2011
    http://www.abc.net.au/tv/newinventors/txt/s3275906.htm

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