Catastrophic lagging failure due to debonding occurred within two weeks of installation and operation of the pulley, resulting in a shutdown of production, and necessitated a replacement of the pulley. Within only two weeks of service, this ceramic lagging was already experiencing loss of the ceramic tiles.
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Early in 2019 Kledkaew Inter Products Co, Ltd. a rubber lining company based in Bangkok Thailand were approached by a representative from a major power station, with a request for a pulley lagging that would significantly extend the lagging service life beyond the 12 months that was typically being achieved with the rubber lagging currently in use.
Ceramic lagging is chosen for pulleys where a long trouble free service life is required to ensure that the conveyor is operational when required and to avoid unplanned conveyor shutdowns. This is a critical for mining companies where conveyor down time costs run into thousands of dollars per minute.
Correct pulley shell surface preparation is essential for good lagging adhesion. Grit blast to a 50-100 um surface roughness and check by measuring at multiple points across the pulley face and around the pulley circumference.
EL.IN. is an engineering company based in Grevena in northern Greece. For many years EL.IN. has been refurbishing pulleys for the Public Power Corporation (PPC) of Greece. PPC operates seven power stations that are fuelled by Lignite and a number of mines that supply the fuel for these mines. The PPC operations have conveyor systems with over 2,000 pulleys in service with a number of different lagging types in service, including rubber, cold vulcanised ceramic and direct bond ceramic.
The Curragh Coal Mine is an open cut coal mine located near Blackwater in Central Queensland, Australia. The mine supplies high quality, low ash coking coal and has reserves of approximately 90 million tonnes which is amongst the largest in the world. Coal from Curragh is shipped via the Blackwater rail system to the Port of Gladstone for export. Curragh Coal mine is owned by the Coronado Coal Group a US based company.
Oyu Tolgoi is a large copper mine that has both open-cut and underground operations and has been operating since 2013. The mine is jointly owned by the Mongolian government and Rio Tinto and is located in the South Gobi Desert. Once fully operational, the mine is expected to produce 450,000 tonnes of copper annually.
For the past five years, Elastotec has collected data from our network of Approved Applicators on the modes of lagging failure that are seen on pulleys sent for refurbishment.
Mining is an industry where reliability is crucial and unplanned down time can result in millions of dollars lost over a single day. Elastotec is focused in making the conveying process more reliable by eliminating unplanned maintenance due to lagging failure.
ELASTOTEC PTY LTD
1/61 Somersby Falls Rd,
Somersby 2250 NSW
T: + 61 2 8987 1922
Pulley Lagging And Wear Panel Products
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- Spare Pulleys – Hot Vulcanised vs Cold Bonded LaggingNovember 1, 2019 - 5:14 pm
- Elastotec expands lagging operationsSeptember 9, 2019 - 10:32 am
- Consequences of catastrophic failure with cold bonded lagging for new mining projectsMay 16, 2019 - 3:05 pm