Project Overview
A leading Copper Mine in Indonesia operates a large agglomerator drum as part of its heap leach copper extraction process. In copper processing, finely crushed ore is blended with binders, moisture, and acid solution inside an agglomerator to form uniform, durable pellets before they are stacked on the heap leach pad. This step is critical because well-formed agglomerates ensure even percolation of leach solution, improved copper dissolution, and overall higher recovery rates.
Due to the abrasive nature of copper ore fines, constant rotational forces, and continuous contact with acidic binders and moisture, the internal shell of an agglomerator drum requires reliable wear protection. The mine engaged one of Reglin’s distributors under a service contract to reline the drum and requested a premium, high-performance rubber lining system capable of handling the demanding copper processing environment.
The Challenge
Aggressive Processing Conditions Required a Fast, Reliable Lining Solution
The agglomerator at the Mine operates in harsh conditions where internal lining materials must endure:
- Continuous abrasion from tumbling ore
- Impact and sliding wear from agglomerated fines
- Acidic solution contact during pellet formation
- High humidity and tropical conditions which make rubber bonding challenging
- Complex installation over internal lifter ribs
The mine also required a custom thickness to match their existing design, and the project had to be completed during a tight shutdown window.
To maintain production continuity, the distributor needed a lining product that could be manufactured, exported, and installed quickly, while meeting all the performance expectations of the modern copper processing operation.
Solution: Reglin Delivered a Custom Regline 60 Rubber Lining System
Reglin supplied a custom-manufactured 30 mm thick Regline 60 lining rubber, produced specifically to the thickness requested by the client. Regline 60 is manufactured using our premium SAR 60 natural rubber compound, formulated for exceptional abrasion and impact resistance, making it ideally suited to the continuous wear present inside copper agglomerators.
The lining included a CN bonding layer, ensuring strong adhesion to the steel drum even under Indonesia’s tropical humidity, where rubber bonding is traditionally difficult. The material’s flexibility allowed it to be installed smoothly over the drum’s internal lifter ribs, forming a uniform protective surface without stressing the rubber or compromising bond integrity.
Reglin coordinated urgent production and shipment to meet the mine’s shutdown schedule, ensuring the lining arrived on time for the distributor’s installation team.
Results
The Regline 60 lining system performed exceptionally well inside the agglomerator, delivering:
- Strong, reliable bonding across all internal surfaces and lifter ribs
- Excellent resistance to abrasion, impact, and acidic process conditions
- Consistent protection of the steel drum structure
- A durable, low-maintenance wear lining capable of extended service life
The rapid manufacturing and delivery ensured the mine’s maintenance schedule stayed on track, preventing costly downtime and enabling a smooth recommissioning of the agglomerator.
Conclusion
This project demonstrates Reglin’s ability to deliver custom-engineered rubber lining solutions for demanding copper processing applications. By supplying a tailored Regline 60 lining system with excellent wear resistance, strong bonding capability, and fast turnaround, Reglin helped the Mine achieve a reliable and long-lasting protective lining for one of its critical pieces of equipment.
Our expertise in rubber lining for agglomerators, combined with our high-performance SAR 60 compounds, ensures dependable results across copper, fertiliser, iron ore, and mineral processing operations worldwide.