Product Range Mill Linings SKEGA

Product range

Skega® Mill Linings, Mill Trommels and Trunnion Linings

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Optimized linings for all types of millsMetso offers the market’s most complete range of mill lining products. This makes it possible for us to offer you the type of lining that best suits your operating conditions and design it to optimize your process.

Service to our customers• Product and application know-how backed by over 50 years of experience• Worldwide service network• Tailor-made linings developed in close cooperation with our customers to meet their needs and requirements• Detailed proposals with drawings• Lining life estimations and cost analyses• Installation manual with drawings and spare parts list• Installation and training• After sales service, i.e. - performance follow-up - wear readings - replacements schedules - estimate of spare parts requirement - lining development

Responsibility for our commitments•

Metso is alone at the forefront of mill lining development. Our wide range of products, combined with the world’s largest resource of know-how and experience enables you to secure your mill lining requirements from Metso with unparalleled confidence.

Skega® Mill Linings are manufactured in nine countries around the world. The strategic locations of our sales, service, engineering and production facilities and the combined efforts of our hundreds of service representatives enables us to stay in close contact with our valued clients.

Our goal is that all our customers should be afforded the same high level of technical support and service, no matter where they might be located.

We offer rubber linings, metallic linings, magnetic linings and polymer/metallic hybrid linings.

Skega® Rubber Mill Linings • Page 4-5Skega Poly-Met® Mill Linings • Page 6-7Skega® Metallic Mill Linings • Page 8-9Skega Orebed® Mill Linings • Page 10-11Skega® Mill Trommels • Page 12-13Skega® Discharge Systems • Page 14Skega® Trunnion Linings • Page 15

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Long experience of developing rubber mill linings has led to an unparallel bank of know-how. We offer superior designs that ensure optimal grinding and lining perfor-mance.

Special grades of rubber compounds for liningsMetso has developed grades of wear resis-tant rubber for specific operating conditions in all types of mills. Each grade is based on the experience of thousands of real-world applications. Most of our development work is carried out in close cooperation with our customers throughout the world.

The invaluable knowledge gained during new product testing and evaluation enables us to provide reliable solutions to the often complex problems handed to us by our clients.

Skega® Rubber Mill Linings

High quality productsMetso wear resistant rubber is the long-lifefoundation of a total linings system. From start to finish, production involves continuous quality control. Advanced polymer expertise is applied for total batch testing of rubber to ensure precisely the right compound.

Optimized for high performance From feed head through the discharge system, Skega® Mill Linings deliver benefits that add up to lower costs and more profita-ble grinding operations. Metso’s application expertise ensures that the lining is tailored to your specific requirements.

In 1959, Metso, through Skega, was the first company in the world to develop and manufacture rubber mill linings.

Main advantagesTailor-made design• Safe and easy handling of • lightweight componentsNo leakage or peening• Easy installation and replacement• Reduced noise level - rubber • components act as a vibration damper and noise filterWe can simulate grinding and lining • performance to evaluate selected applications and configurations Our approach to lining design is • based on experience, grinding performance and improved mill availability

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Modular design facilitates configuration of the lining for maximum performance in terms of grinding media and mill throughput.• Predictable service intervals meanless scheduled downtime.• Consumption of grinding media can be reduced.• User-specific profile design.

Attachment systemsBased on standard bolts or T-bolts, clampblocks and metal profiles chemically bonded to rubber, this system has been developed and perfected by Metso. Minimal profile/bolt height enables the lining to be worn down to a minimum without damaging the attachment system. Lightweight elements and simplified attach-ment systems save time and manpower at installation and replacement.

Application areasFully autogenous mills • Semi-autogenous mills• Pebble mills • Secondary ball mills • Regrind mills • FGD mills • Raw mills • Scrubbers and washing drums• Batch mills• Continuous mills•

Standard attachment system

T-bolt attachment system

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Skega Poly-Met® Mill Linings

The Poly-Met concept combines the most desirable properties of rubber and steel to maximum advantage. This combination opens the possibility to use harder and more wear resistant alloys of iron/steel than can be used in a conventional metallic lining, as the rubber substantially dampens impact forces.

To date, the Poly-Met concept has demonstrated its success most clearly in primary grinding applications, such as primary ball mills, rod mills, autogenous (AG) and semi-autogenous (SAG) mills.

AG and SAG millsLinings for AG and SAG mills are typically highly profiled and can be supplied as high/low or equal height configurations. The advantages of a high/low arrangement are lining cost savings and performance benefits as a profiled configuration is always maintained.

The main advantage of an equal height design is reduced downtime as a result of fewer stops for maintenance and for monitoring of wear rates.

Wide spaced linings can be supplied for most AG and SAG mill applications. Some of the potential benefits are reduced change out time as a result of fewer liner parts, more freedom to increase liner height to gain wear life in combination with increased lifter face angles to maintain or improve performance. Ball millsPoly-Met ball mill linings are typically less profiled than AG/SAG linings to cope with finer feed size material. The compact design of Skega Poly-Met® Mill Linings promotes optimal grinding performance while maximizing wear life.

The development of the Poly-Met concept started in the 1980’s and led to a patent in 1987.

Main advantagesAlloys and profiles are tailor-made • based on application and operating conditionsSafe and easy handling of light-• weight componentsNo leakage or peening• Easy installation and replacement• Reduced noise level - rubber • components act as a vibration damper and noise filterImproved mill availability• The design is based on performance • optimization using high fidelity (HF)simulationAdvanced Total Cost Comparison • (TCC) software calculates total mill operating costs, including the value of lost revenue due to mill down-time

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Unique application expertiseIn Poly-Met solutions where two materials are combined, extended knowledge of materials and process is especially essential to reach optimal grinding and lining performance. Metso was first in the world with rubber/metal hybrid linings. Efficient installationAt Metso, we recognize that ease of installation and adherence to maintenance schedules are vital. Skega® Mill Linings are high quality products with long wear life. We have developed optimized installation systems and methods that generate considerable savings for our customers.

Equal height

High/low

Wide spacing

Less profiled

Application areasFully autogenous mills• Semi-autogenous mills• Primary ball mills• Secondary ball mills• Rod mills• FGD mills• Raw mills• Scrubbers and washing drums•

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Skega® Metallic Mill Linings

The components for Skega® Metallic Mill Linings are produced at our own foundries, which specialize in production of carbon steels, manganese steels, alloy steels and high-chromium white cast irons.

The Metso foundries have established an international reputation as producers of high-quality castings for various types of industrial applications, including linings and structural parts for mills.

With modern facilities and comprehensive R&D programs, production at the Metso foundries is focused on meeting the deman-ding needs of the international market.

More than three decades of experienceFor more than three decades, the Metso foundries have developed expertise in the founding of ferrous alloys, as well as in meeting user demands for quality and performance.

Application of state-of-the-art technology has kept our foundries in the forefront of the market, as they develop new alloys and profiles for specific user applications.

Analysis and controlThe Metso foundries maintain a strong R&D program that serves as a foundation for advanced analysis and control in all phases of production.

Facilities for analysis and control include chemical, physical and metallographic laboratories. Non-destructive testing to inter-national standards includes tests involving ultrasonics, magnetic particle analysis and gammagraphy.

Alloys of iron and steel are traditional mill lining materials that Metso has produced for more than 30 years.

Main advantagesLong experience of alloy and design • selection for any mill application More than 30 years experience of • manufacturing metallic mill linings Fast installation, scheduled mainte-• nance stoppages and long service intervals due to long life, high quality and optimized installation systems/methods Worldwide service network•

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for R&D in alloys of iron and steel. Tailoring alloys and profiles for specific types of appli-cations pays off for users in the form of higher wear resistance, longer service life and improved overall grinding economy.

Wide range of mill componentsThe product range at the Metso foundries includes a wide variety of wear parts and replacement parts for mills, made of high chromium white iron, manganese steel and chrome-moly steel. These products include everything from table and roller mill segments to shell liners, head liners and discharge grates.

Application areasFully autogenous mills• Semi-autogenous mills • Primary ball mills • Secondary ball mills • Rod mills•

Comprehensive quality assuranceThe Metso foundries apply quality assurance programs that conform to ISO 9001 in every phase of research, development and produc-tion. This ensures high, uniform quality for the alloys in Skega® Mill Linings, and it means that the entire lining wears evenly. High quality standards also involve close toleran- ces and precise dimensions, so that every Skega® Mill Lining is a perfect fit.

Compliance with a comprehensive quality assurance program doesn’t stop at our foundry gates. The same rigorous standards assure our valued clients of reliable deliveries throughout the world.

Development pays off for users Continuous monitoring of lining installations by Metso engineers generates valuable input

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Skega Orebed® Mill Linings

The Skega Orebed® magnetic lining system was developed to increase throughput, particularly in secondary and tertiary mills grinding ferromagnetic material.

Greater working diameter means more efficient grindingThe lining consists of a series of powerful permanent magnets embedded within a matrix of highly abrasion-resistant rubber. Magnetic force ensures that the lining attracts the ferromagnetic material in the mill load, forming a continuous wear layer with a wave profile. Magnetic force also keeps the lining in place, so that no bolts are needed for installation.

The total thickness of the Skega Orebed® Mill Lining and the wear layer is substantially less than that of a conventional lining. Once fitted with Orebed®, your mill operates with a larger effective diameter, resulting not only in higher capacity but also in improved grinding efficiency.

Simple structure - one size fits allIn a Skega Orebed® Mill Lining, the wave form generated by alternating magnetic forces provides an optimal, autogenously generated tractional lining surface that lifts the material being ground, so that a profiled configuration is unnecessary. The friction of the corrugated lining surface does the job. The configuration of the entire lining is as simple as it could be. There is only one type of element in only one size, and it fits any mill regardless of dimensions.

Lasting strength with no maintenanceThe elements grip the shell with the lasting force of a permanent magnet. A Skega Orebed® Mill Lining is so strong that it stays in place with undiminished performance for many years, with absolutely no maintenance.

During the 1970’s Metso developed and patented a magnetic lining system with unique properties, Skega Orebed®.

Main advantagesAlmost 40 years experience of • designing magnetic linings makes it possible for us to offer optimized solutions Rapid installation and no mainte-• nance, since no bolts are needed and the attractive forces are so strong that it stays in place with constant performance for years The thin lining makes the grinding • process more efficient and can increase throughput as a result of a greater mill working diameter

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Fast, easy installationInstalling a Skega Orebed® Mill Lining takes less time and requires less effort than the installation of a conventional lining, since the individual elements don’t have to be bolted to the shell. All installation work is performed inside the mill. There’s no need to drill holes through the shell or adjust fastenings on the outside.

Existing bolt holes in the shell are simply sealed with rubber plugs.

A better bottom lineWith your Skega Orebed® Mill Lining, you have two options for improving your bottom line.

Application areasPebble mills • Regrind mills• Light secondary ball mills • Vertimills•

The lining promotes energy-efficient attrition The charge in a mill with a Skega Orebed® Mill Lining is much more compact than that in a mill with a conventional lining. A com-pact charge exerts a higher internal pressure and generates greater shearing forces, a con-dition which favors energy-efficient attrition grinding over less efficient impact and abra-sion grinding mechanisms. This is not simply a theoretical analysis; practical experience has demonstrated that Skega Orebed® Mill Linings operate in this manner, ensuring that more energy is effectively transmitted to the charge.

Greater efficiency, lower ball consumptionThe design results in an overall reduction of damaging ball-on-ball impacts. With less energy expended on these impacts more power is utilized in grinding your product and media consumption is reduced.

Option 1 - Maintain your throughputSkega Orebed® Mill Lining can generate savings of up to 10% in grinding media, and up to 8% in electrical power.

Option 2 - Increase your throughput If you maintain your current power draft, the Orebed® lining can generate up to a 5% increase in throughput.

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Skega® Mill Trommels

Mill trommels, whether used for sizing or scalping, play a vital role in the efficiency and stability of your grinding circuit.

Our high-capacity, robust, and easily maintained trommels are constructed in modular form, using highly wear-resistant and time-proven materials for the manufac-ture of every major component.

The screen panels themselves are pro-duced in an easily handled standard size of 305 x 610 mm, and are available with either square, rectangular, or rounded apertures in a wide variety of sizes. Depending on the operating conditions, the panels are manu-factured using either abrasion resistant rubber or polyurethane materials, selected on a purpose-specific basis.

FEA analyzed framesAll trommel frames within the product range are designed to resist the effects of fatigue using established Finite Element Analysis (FEA) techniques, and all structures are protected against mechanical erosion using

either polyurethane or vulcanized rubber, again chosen purpose-specifically. Adapting flanges, if required are available to suit the design of virtually any trunnion or trunnion liner interface.

Skega® Mill Trommels of modular design are available in sizes from 1500 mm inside diameter and larger. For installation flexibility each spiral is bolted to a single panel. We also offer a variety of proven designs for smaller mill trommels, and in these cases there is virtually no lower-size limitation.

Unique know-howMetso and its group of ancestor companies have supplied trommels since the earliest days of tumbling mills, and over the years we have gathered an unparalleled resource in the know-how to engineer trommels from both the endurance and capacity points of view.

Metso has more than 40 years of experience in the design and manufacture of mill trommels. With this broad knowledge base behind us, a new product range of high-performance trommels was launched in 2002.

Main advantages - TrommelFrames designed to resist the effects • of fatigue (FEA)Lightweight panels are easily • handled Quick and easy replacement• Wide selection of apertures• Tapered openings minimize or • eliminate blindingThe snap-on system offers flexibility; • blind panels and panels with different aperture sizes or materials of construction can be combined within the same unit Available in rubber or polyurethane • materialsPanels in areas of elevated wear can • be individually replaced

Application areasFully autogenous mills• Semi-autogenous mills• Ball mills• Pebble mills •

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The rubber spiral is available in the following heights:• 125 mm• 150 mm• 200 mm• 250 mm

Quick installation and serviceInstallation and replacement of the snap-on screen panels is easily accomplished with a minimum number of basic tools, and since the panels are replaced from the inside of the trommel, there is generally no need to remove the trommel housing covers. Change-outs can therefore normally be performed in conjunction with regular mill maintenance, resulting in minimal if any impact on mill availability.

Skega® Trommel SpiralIn 2007 Metso patented a versatile trommel spiral system that has the potential to im-prove your process efficiency even further.

The feet of the spiral are adjustable to suit our range of modular screen panels. The pitch angle is also adjustable and the feet and vane can be replaced separately.

Main advantages - SpiralIncreased performance due to • adjustability of spiral pitch angleBy adjusting the angle, you can • fine-tune the flow and screening characteristics of your trommelThe feet of the spiral are adjustable • so it is possible to install on any rubber or polyurethane panel from our modular screen rangeEconomically beneficial, since you • can replace the feet or vane if one is worn out before the otherLonger wear life, as it is possible to • turn the individual spiral elements end-for-end mid way through their life to uniformly distribute wearAll components are constructed of • moulded rubber, providing superior wear performance and uniform quality

Patented design

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Skega® Discharge Systems

Material selection based on application The design of your mill’s discharge system has a substantial influence on the efficiency of your grinding circuit.

Metso offers close-tolerance pulp lifters, discharge cones and diaphragm assemblies consisting of steel fabrications expertly lined with highly abrasion resistant rubber. Where appropriate, we also supply engineered discharge systems manufactured of cast steel.

Our rubber grates are available in a wide range of aperture sizes and their flexibility prevents blinding, ensuring that the entire open area is fully utilized. We also offer steel grates in a variety of alloys to resist high charge pressures and direct media strikes.

These products can be combined into tailor-made systems, meaning that we can provide optimal designs for virtually any wet grinding application.

Custom-made designOur discharge systems are designed specifically for your operating conditions.

Metso has manufactured Skega® Discharge Systems since the 1960’s.

Main advantagesFits tightly to the mill’s shape• Long and predictable service life• Easy and quick installation • Flexible rubber grates prevents • blindingCustom-made design based • onapplication and operating conditionsPossibilities to make lightweight • rubber parts or heavy duty steel parts or combinations of both according to customer objectives

Application areasFully autogenous mills • Semi-autogenous mills• Pebble mills • Primary ball mills (light applications)• Secondary ball mills • Regrind mills • Raw mills • Scrubbers and washing drums • Continuous mills•

We supply pulp lifters in radial, curved or ‘dog-leg’ configurations depending on the variables of mill size, speed and drilling patterns. All of our discharge systems are designed to maximize flow rate while minimizing back flow.

Tight fit and easy installationThe experience of our engineers and the skill of our craftsmen ensures that our discharge systems conform perfectly to the contours of your mill, preventing harmful racing of slurry. This attention to detail also greatly simpli-fies installation, resulting in a minimum of downtime.

Our wide range of products, custom designs, high quality and application expertise enables long and predictable service life, helping you to increase your total grinding efficiency.

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manually lined with durable, abrasion-resis-tant rubber. When worn out, trunnion liners of this type are replaced as an entire unit.

Replaceable Sleeve Trunnion Liners This innovative design incorporates a lightweight, replaceable inner sleeve, that is tack-welded into a heavier outer steel fabri-cation. With this arrangement it is possible to replace only the sleeve without having to remove the structural part of the trunnion liner. This design combines the benefits of simple installation with excellent lining economy, and is available for applications with internal diameters up to approximately 2.5 meters.

Trunnion Liners with Bolted Wear ElementsThis system has been designed to accommo-date the most extreme applications, for which the cost of downtime is of absolute importance. The general concept is that all parts exposed to wear are individually replaceable from the inside using a

Skega® Trunnion Liners are custom-made rubber covered steel structures, designed to protect your mill trunnions from internal wear. Fit is critical, so even though trun-nion liners can be made to almost any size or shape, all Skega® Trunnion Liners are manufactured to close tolerances to ensure precise, watertight installation.

Typical design features include internal spirals or dams to control material flow, flanges for the mounting of trommel screens, inclusion of threaded holes for jacking screws, inspection ports, etc. Whether for OEM or after-market applications, Skega® Trunnion Liners are industry standard in the heaviest applications, for which we offer designs with individually replaceable components. The designs of Skega® Trun-nion Liners are grouped into three principle categories.

One-Piece Trunnion LinersThis traditional alternative, time-tested since the earliest days of tumble milling consists of a precisely machined external steel shell,

Skega® Trunnion LiningsFor more than 40 years, Metso has supplied a wide range of trunnion lining alternatives.

Main advantagesLightweight components• Easy to replace • Designed to suit your specific mill • Wide product range • Long wear life•

Application areasAll types of grinding mills, wet • process

minimum compliment of tools, and mainte-nance can be carried out without the requirement of removing the structural part of the trunnion liner. There is no upper size limit to Skega® Trunnion Liners manufac-tured according to this design.

Metso Minerals (Wear Protection) AB, SE-934 81 Ersmark, Sweden, tel +46 910 58 41 00, fax +46 910 58 42 00, www.metso.com Subj

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Your mill linings are a vital part of your grinding operation, and can have a major impact on the performance of your circuit.

Metso is the market‘s most comprehensive supplier of mill linings and trommels. Please allow us to review your grinding process and identify areas of potential improvement. Together, we can produce a solution to make your production processes more efficient.

Our mill linings and trommels clearly save time and money, and improve productivity for companies in the mineral processing industry.

This is supported by the fact that our linings are used in more than 4,000 mills worldwide. Contact us if you would like to find out more about how we can help you increase your profitability.www.metso.com/miningandconstruction