Wear Solutions

Wear Resistant Products

FLSmidth offer a range of wear

products that have been engineered
to meet the most arduous, abrasive
and high-impact duties experienced
in a wide range of industries.

Working intimately with customers,

FLSmidth achieves extended asset
life and operating cost reductions by
the careful selection and application
of wear resistant materials. In-house
engineering, combined with years
of on-site practical experience,
enables FLSmidth to specify and
design a comprehensive solution to
any site wear problem.

FLSmidth Wear Linings
Applied to
• Chutes and launders
• Hydrocyclones and Dense
Media Cyclones
• Hoppers and tanks
• Piping and pipe line
components, such as elbows,
tees, reducers and valving
• Crushing components
3
FLSmidth experts design,
manufacture and install wear
resistant linings according to
individual equipment, functions and
operating parameters.
With a wide range of wear resistant
materials available, FLSmidth
identifies and installs the correct
solution for customers wear lining
problems. Extending the life of high
wear components is a priority for all
operating sites and FLSmidth can
provide customised, cost-effective
solutions for a range of applications.
Material Features and Benefits
• Elastomers – Rubber and • Complete finished assemblies or
Polyurethane material-only supply
• Elastomer and Ceramic • Engineered alumina tiles to
– LudoLiner customer specifications or in kit
• Plastics – UHWPE, Matrox form for recurring applications
and Ezyslide • Ceramic linings can be pre-
• Epoxies, Epoxy and Ceramic engineered with correct side angles
– Wear Resist and High to achieve full face-to-face contact
Impact Crusher Backing and maximum interlock
• Basalt • Engineers recommend the best-
• Silicon Nitride suited wear lining material or
• Zirconia combination of materials to deliver
• Alumina (Tiles and Monolithic) maximum protection for equipment
• Silicon Carbide (Reaction • Numerous fixing methods to enable
Bonded and Sintered) installation in any situation
4
WEAR-RESISTTM Epoxy Ceramic
Ideal for
• Chutes and surfaces worn
by sliding abrasion
• Launders and pipes worn by
abrasive slurries
• Chutes where moderate
impact is present
• Elbows and tee junctions in
slurry lines
• Paste backfill applications.
• Pump casing repairs
• Any surface where sliding
abrasion with light impact
has caused wear
When the situation demands a
quick hard wearing solution you can
depend on FLSmidth WEAR-
RESISTTM Epoxy coating to not let
you down.
Fabricated from a proprietary
mixture of epoxy and wear resistant
beads, WEAR-RESISTTM, is a cost
effective and proven solution to
sliding wear problems commonly
occurring in bulk handling and
processing equipment.
WEAR-RESISTTM Quick Set is even
faster resulting in a quicker
turnaround time for repairs, reduced
down time and overall cost savings
Cured properties (typical)
• WEAR-RESISTTM (after 24hrs
23°C)
• Maximum operating
temperature 70°C
• Density - 2.1 Kg/litre
• Compression strength -
70 MPa
• Tensile bond strength - 10MPa
• Flexural strength -15MPa
when you want to get equipment
back into service quickly. Supplied in
convenient sized kits, complete with
all necessary mixing equipment,
WEAR-RESISTTM may be your sites'
handiest tool kit.
Also available in WEAR-RESISTTM
221 All Purpose (Non Dangerous)
option for urgent flight to site
requirements.
Features
• Combines the hard wearing
properties of a ceramic with
the flexible installation
properties of epoxy
• Propriety wear resistant bead
( 9 mohs hardness) blended
to a minimum 70%
concentration assures
superior wear resistance
characteristics
• Fast application and cure rate
- 30 minutes for standard set
and 15 minutes for quick set
- allows for quick equipment
turnaround with minimum
down time
• Cost effective wear
protection for broad areas:
coverage - 7kg covers
0.55m2 to 6mm thick
• 2 year minimum if unopened

Ludoliner Impact Wear Panels
Ideal for
• Mining and Quarrying
equipment that are subjected
to high abrasion due to high
feed rates, material impact
and sliding abrasion.
• Reducing environmental noise
• Transfer points in conveyor
systems
• Screen chutes
• Silos & Bins
• Deflectors
• Lining of Feeders
• Stackers & Reclaimers
Rapid Seal Clamps
5
Ludoliner is an easy-to-fit system of bolt-on wear panels combining the
properties of Alumina Ceramic and Rubber for exceptional wear and impact
resistance. Ludoliner impact wear panels feature the abrasion resistant
properties of high density alumina with the impact and noise absorbing
properties of rubber on a steel bolt on backing plate.
Material Features and Benefits
• 300 x 302mm • Easy maintenance
• 500 x 500mm • Increased equipment life
• 604 x 302mm • Less downtime
• Variety of custom • Improved profitability
sizes available • Variety of custom sizes available
• Thickness available • Customised mounting stud configuration
– 35mm and 64mm • Customised to individual shapes, including
curved shapes
• Ore characteristics and flow parameters
matched with liner attributes
• Reduces noise pollution
• FLSmidth’s extensive experience in the
supply and installation of Lining Systems
Rapid Seal Clamps ease the severity • Ceramic
and duration that a slurry pipeline • Steel
leakage can cause, providing plant
operators with immediate Standard Sizes:
assistance by effectively stopping • 90NB – 150NB
the discharge and providing a • 150NB – 300NB
reliable wear resistant patch. Once • 300NB – 500NB
equipment is shut down, the clamp • 500NB – 1000NB
can be removed and reused.
Features and Benefits:
Ideal for: • Simple and easy to use
• Slurry pipelines including coal, • Consists of ceramic embedded
iron ore, copper, gold, nickel, into resilient polyurethane with
cement and fertilizer a sturdy binding strap
• A range of piping materials • Installed in a matter of seconds
• Plastics – PE, ABS and PVC using a simple ratchet system
• GRP • Reusable
6
Wear Plates
High Impact Crusher Backing
Ideal for
• Backing crusher parts
• Grouting machinery
• Locking bearings
• Setting anchor bolts
• Chocking of machinery
FLSmidth Wear Plates are an
easy-to-fit alternative to bonding
tiles directly on to steel structures.
They provide superior wear
resistance of 92% alumina and
zirconia toughened alumina with
the convenience of modular
installation. The ability to replace
only the worn wear plates has
The FLSmidth High Impact Crusher
Backing (HICB) is a two-component
pourable epoxy grout for backing
crusher parts, grouting machinery,
locking bearings, setting anchor
bolts and chocking of machinery. It
has outstanding compressive
strength properties with very low
shrinkage. It is economical to use
compared with other epoxy resin
systems.
Cured properties (typical)
• Cures in 24 hours at 25°C
• Compressive strength 120 MPa
• Tensile strength 13 Mpa
• Available in 10kg packs -
all components are pre-metered
in correct proportions for
immediate use
many benefits including improved
operational efficiency, limited down
time and the reduction of overall
costs. Wear plates are
manufactured to a variety of
customised shapes, sizes
and thicknesses to accommodate a
range of requirements.
Features
• Excellent resilience, strength
and shock absorbance
• Easy mixing and application
• Economical solution reducing
ongoing maintenance costs
• Easily pourable and flows
readily resulting in complete
dispersal and coverage
• Very low shrinkage resulting
in consistent and superior
backing
 7

Advanced Engineered Ceramics

FLSmidth offer a complete range of

advanced ceramics in a multitude of
types, shapes and sizes designed to
extend the productive life of
material handling and processing
equipment. When there are
aggressive wear problems on site
you need to engage FLSmidth.

Utilising material characteristics,

years of experience and good
design, we provide appropriate and
cost-effective solutions.

The range of Ceramic

solutions includes:
• High density aluminas
• Silicon carbides
• Speciality ceramics including
silicon nitride and zirconia
• Engineered and custom
designed shapes
• Ceramics can be installed into
standard and non-standard
wear applications such as:
• Hydrocyclones
• Piping systems including
pipe, fittings, valves
and other pipe
work accessories
• Chutes and launders
• Deflector plates
• Distributors/ splitters
• Spray nozzles

.
8

WEAR-RESISTTM Lined Pipe and Fittings

FLSmidth engineer and manufacture Since modifications to finished pipe are

new pipe systems and individual
fittings lined with WEAR-RESISTTM
material for a range of applications.
Utilising the outstanding properties
of FLSmidth WEAR-RESISTTM
installed into the largest available
pipe and fittings allows for
economical wear resistant piping
systems to be available in a short
time frame. With manufacturing
facilities servicing all major
international mining markets,
able to be done on site, WEAR-RESISTTM
lined pipe is the most user friendly wear
resistant piping option in the market.
Additionally the capability to install wear
monitoring systems at time of
manufacture, provides stress free
operation of WEAR-RESISTTM Piping
Systems.

FLSmidth is readily able to service

your requirements for waste ore,
back fill, co-disposal, slurry and
tailings lines.

Usage
• Process piping
• Co-disposal pipelines
• Paste backfill pipelines
• Tailings lines
• Slurry transfer lines
Features
• One piece casting achieves a joint-less bore - reduced erosion propagation
• and improving pipeline life
• Elbows and fittings have a smooth bore - reducing turbulence experienced
• with segmented bores that follow the lobster back construction
• Linings are flush with the pipe end- reducing erosion propagation
• WEAR-RESISTTM Linings are 30% lighter & double the life of equivalent
basalt lining
• Optional wear indicator to monitor lining thickness in critical high wear
• areas without opening the pipe for inspection
• Pipes can be supplied in any length up to six metres - minimising joints and
• reducing costs for nuts and bolts or couplings
• Pipes can be supplied in a range of diameters and lining thicknesses to suit
• any requirement
• Pipes can be cut and welded on site allowing exact installation and remedial
work as required
• Wide variety of pipe joining methods and flange types

Advanced Ceramic Lined Piping
Systems
Materials
• Basalt
• High density alumina
• Siliconised silicon carbide
• Sintered silicon carbide
• Silicon nitride
• Zirconia
9
FLSmidth provides ceramic pipe
linings for a range of applications
with the capability to manufacture
cylindrical ceramic liners of different
sizes, shapes and materials.
Utilising the improved wear resistant
characteristics of ceramic materials
in pipe systems reduces plant down
time and associated maintenance
costs in high wear applications.
FLSmidth can provide a
comprehensive system installation
or individual components for high
wear points according to customer
requirements. Additionally,
customised solutions for valves,
orifice plates, chokes, nozzles and
numerous other pipe line
components can be designed,
manufactured and installed to suit a
variety of applications.
Shapes Features and Benefits
The following shapes can be lined: • High wear resistance
• Straight spools • Corrosion resistant
• Y spools • Reduced wall thicknesses
• T spools increase the piping bore size
• Elbows/bends resulting in improved processing
• Reducers capacity and reducing pumping
• Chokes and orifice plates energy costs
• Valves - ball and butterfly • Extended asset life results in less
down time, reduced frequency
of change out and lower
maintenance costs across the
lifetime of the asset
• Customised solutions using
monolithic pieces to eliminate
potential wear weak points often
found in inferior systems
10

Silicon Carbide Lined Piping Systems

As ceramic manufacturing
technologies continue to improve,
Silicon Carbide Ceramics have
become the material of choice for
highly-aggressive wear applications
on hard rock mineral processing
sites. More complex shapes and
increased diameters allow this
material to be a successful value
proposition in more and more
applications compared to traditional
materials.

FLSmidth have pioneered the use of

this material within the mineral
processing sector, our experience,
knowledge and manufacturing
capabilities allow us to develop
solutions to meet our customer
expectations.

Usage
• Complete piping systems
including pipe, fittings,
valves and chokes
• Hydrocyclones
• High temperature
applications
• Wear surfaces for
sliding abrasion
• Nozzles
• Mechanical seals
and pump parts
• Cylinders and plungers
Features
• Able to be formed with reduced wall thicknesses, compared to alumina and
basalt, providing greater efficiencies in slurry pumping and reducing
associated energy costs
• Manufactured in monolithic forms which reduce the number of joints
eliminating potential wear spots and premature failure
• Large range of sizes available to cover most applications involving
pumped slurries
• Working temperature of 1400°C allows it to be used in all but the most
extreme temperature applications
• Vickers Hardness of 2000kg/mm2 puts the hardness of the material well
beyond that of traditional mineral processing ceramics such as basalt and
alumina. This results in multiple times extended life providing outstanding
value for cost
• Exceptional processing abilities allow for complex shapes and designs to be
created, overcoming many wear issues

Ceramic Grinding Media
Range
• Low purity alumina
• High purity alumina
• Zirconia toughened alumina
• Zirconia
11
With the widest range of ceramic
grinding medias available to the
mineral processing market,
FLSmidth is able to supply your
complete needs for mineral
processing ultra fine grinding
applications.
As mining companies work on
mineral liberalisation from
increasing difficult orebodies,
ultrafine grinding equipment and
ceramic grinding media play a
major role in making these
recoveries cost effective.
Improvements in energy efficiencies,
cyanide usage reduction, product
recovery and reduced maintenance
costs are some of the benefits of
using FLSmidth Ceramic Grinding
Media.
Ideal for Features and Benefits
• Tower mills • Low wear rates, uniform microstructure and
• Ball mills chemical inertness are benefits unique to
• Stirred mills ceramic materials and result in improved
• ISAMillsTM processing efficiencies and lower overall
costs in grinding applications
• Flexible sizes ranging from 0.1mm to 80mm
• Different material grades to suit all
applications results in the right product for
the right application – no wasted media, no
wasted energy equals reduced processing
costs at the grinding mill
• Quality packaging material of 25kg, 500kg
or 1000kg bags or in steel drums of any
quantity to suit all needs
• Direct shipment from factory to site to
reduce lead times
• Logistics management offered
12
Ceramic Tiles and Tiling
FLSmidth offer a large selection of
standard alumina ceramic tile sizes.
Custom manufactured tiles can be
produced to suit a variety of
applications.
Supplying high alumina content
92% alumina tiles, with a fine
crystalline structure, enables
FLSmidth to confidently extend
plant and equipment life by
reducing wear of support structures
and components.
Ideal for providing a cost effective
wear resistant solution to large
areas, such as chutes and launders,
high density alumina tiles are a
proven performer.
Standard items Ideal For
• Square tiles Wear protection in equipment
• Rectangular tiles in the following industries:
• Pipe tiles - tapered sided tiles • Rock
• Hexagonal tiles • Coal
• Microtiles • Gravel
• Curved tiles • Minerals
• Sand
• Cement Clinker
• Lime
• Sinter
• Grains
FLSmidth specialise in the supply
and installation into a range of
applications involved in the coal,
iron ore, and hard and soft rock
mineral processing industries.
With the ability to provide a range
of services to customers, FLSmidth
can provide complete fabricated
units, onsite installation services or
provide products and information
to allow customers to complete
their own installation.
Features and Benefits
• Standard tile range is 92%
alumina with a fine grain
microstructure providing
exceptional wear resistance and
extended life
• Standard-sized tiles are available
off the shelf for immediate use
and quick delivery
• Customisation of tile shapes and
materials is available, for repeat
applications, customised tiles
reduce cutting requirements –
increasing installation efficiencies,
improving product delivery rates
and reducing cutting costs
• Consistency of dimensions allows
for increased speed in installation,
reduced cutting and wastage
• Complete product system of tiles,
adhesive and filler available

Chute Linings
Applied to
• Coal plant feed and
discharge chutes
• Iron ore beneficiation plants
• Grain and agricultural
products
• Hard rock mining
Material
• Range of standard sizes and
thicknesses available
• Variety of fixing methods
including; epoxy & urethane
adhesives being direct bonded
or welded to steel backing
plates
13
Plant chutes handle the bulk of the
work in a processing system. The
entire mineral product in the process
of cleaning and classifying flows
across them creating unique wear
and hang-up problems on entry and
discharge chutes. FLSmidth experts
assist with the selection and
installation of chute linings to ensure
maximum wear resistance and
operating life. Ceramic Tiles have a
0% porosity and uniform density,
which helps to minimise chute
plugging and wear. FLSmidth
experienced installers line chutes,
hoppers and bins.
Features and Benefits
• Robust mechanical strength
provides impact resistance
against fines
• Ideal for sliding abrasion
applications extending life
time usage of chutes and
other high wear areas
• Chemically inert so resists
salts, chemicals and
hazardous environments
• Liners can be direct bonded
or installed on Wear Plates
for reduced maintenance
down time
14
Ceramic Specialty Items
Materials Available
• Alumina of varying
compositions
• Silicon Carbides
• Stabilised Zirconia products
• Thermal ceramics including
Mullite and Cordierite
• Silicon Nitride/Syalon
• Hybrid ceramics such as
Zirconia toughened alumina
• Fused silica and porcelain
Often the ideal solutions to our
customer’s problems are not available
off the shelf. With over 20 years of
manufacturing, research and sales in
advanced engineering ceramics,
FLSmidth is consistently working
closely with customers to produce
cost-effective wear and thermal
ceramic solutions.
With no limitations to material
selection or manufacturing
techniques, FLSmidth is uniquely
positioned to evaluate the duty and
recommend the appropriate solution
or solutions.
Features and Benefits
• The variety of materials available results in the most appropriate ceramic
being used in service, not the one which is most expedient
• There are many differing manufacturing techniques available which allow
flexibility in design, producing the best engineered solution
• Constant research and development with materials and applications ensures
that our customers have access to latest technologies and successful
outcomes
 15

Gold Room Consumables

FLSmidth offers iso-statically pressed

foundry crucibles for melting non-
ferrous metals such as gold,
aluminium, copper and nickel at
temperatures between 400°C and
1500°C. FLSmidth supply the most
appropriate material choice,
dependant on local conditions, to
ensure that there is maximum crucible
life with minimum loss of product.

Material Features and Benefits

• Made from clay/graphite • Produced using iso-pressing system - ensuring blemish-free products
and carbon-bonded silicon • Low porosity - allows for excellent resistance to metal attack and
carbide improved heat transference
• High flux resistance - reduces wall corrosion and extends crucible
lifespan
• High thermal conductivity - reduces energy consumption and
lower costs
• Oxidation resistant - less cost per melt
• Various sizes of pouring spouts and crucible bases
 Rev.31/07/2013 pjoh-au

Copyright © 2013 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or
warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com

Technology Centre for Wear Solutions FLSmidth Regional Office

55 Alacrity Place Henderson, WA 6166 67 Randle Road Pinkenba, QLD 4008
Australia Australia
Tel: +61 8 9437 1155 Tel: +61 7 3121 2900
Fax: +61 8 9437 1156 Fax: +61 7 3121 2988
Email: wearsolutions@flsmidth.com Email: info.brisbane@flsmidth.com