Project Overview
At a large iron ore mining operation processing magnetite, the site’s vibrating feeder floors were lined with hardened steel plates. Due to impact and the high flow rate of abrasive ore from the chute above, the steel liners were wearing out rapidly, requiring replacement during every scheduled maintenance shutdown. With four feeders in operation and a fifth used as a rotable spare, the site was seeking a more durable, low-maintenance wear lining solution to reduce downtime and improve overall feeder longevity.
Solution: Steel Backed Cera-Wear Extreme Ceramic Liners
To address the excessive wear and frequent changeouts, the site partnered with a local maintenance contractor to source and install a new solution. Reglin Rubber Cera-Wear Extreme Ceramic Wear Plates with steel backing were chosen.
These high-performance liners feature 92% alumina ceramic tiles fully vulcanised into a tough rubber matrix and are backed with mild steel for easy mechanical fastening. The rubber layer between and beneath the ceramic tiles provides shock absorption, allowing the tiles to move within the liner and absorb the impact energy from falling ore, while the ceramic surface offers superior abrasion resistance compared to hardened steel.
The liners were supplied pre-cut with welded studs and ready to install, designed to match the layout of the feeder floor, which streamlined the installation process. The on-site contractor installed the upgraded liners into the spare feeder, which was then rotated into service.
Results and Performance
Once operational, the ceramic-lined feeder delivered exceptional wear life, lasting 5 to 6 times longer than the previous steel liners under identical operating conditions. This significant improvement reduced maintenance frequency, eliminated repeated liner replacements during shutdowns, and delivered a noticeable reduction in long-term maintenance costs.
The Ceramic liner performance success set a new standard for the site’s feeder lining strategy, resulting in all feeders on site receiving the ceramic lining upgrade.
Conclusion
By switching from hardened steel to Reglin’s Cera-Wear Extreme Ceramic Liners, the mine was able to drastically improve the wear performance of its feeder floors. The combination of abrasion-resistant ceramic tiles and impact-absorbing rubber backing has proven ideal for managing the aggressive wear conditions caused by high flow rates of abrasive magnetite ore.