AU2015100120A4 - Improved material transport wear liners - Google Patents

Abstract

The present invention relates to wear resistant materials and components useful in material transport applications. In one form the present invention provides a ceramic polymer composite liner having a curved wear face and one or more mounting faces which mount into a corner of a transfer chute, hopper, bin or deflector. Fig 4a

Description

1 IMPROVED MATERIAL TRANSPORT WEAR LINERS FIELD OF INVENTION [0001] This invention relates to the field of wear resistant materials and components useful in material transport applications. In one form the invention relates to ceramic polymer composites and it will be convenient to hereinafter describe the invention in relation to ceramic-polymer composite components in the area of materials handling and transport, particularly as lining for transfer chutes, hoppers, bins and/or deflectors. However it should be appreciated that the invention is not necessarily limited to that use only. BACKGROUND ART [0002] The discussion throughout this specification comes about due to the realisation of the inventor and/or the identification of certain related art problems and, moreover, any discussion of documents, devices, acts or knowledge in this specification is included to explain the context of the invention. It should not be taken as an admission that any of the material forms a part of the prior art base or the common general knowledge in the relevant art in Australia or elsewhere on or before the priority date of the disclosure and claims herein. [0003] Transfer chutes, hoppers, bins and deflectors are typically steel structures used to transport material, such as iron ore and the like, between conveyors and/or other process equipment such as screens, crushers, mills and feeders. Conveyors in the iron ore industry may typically transport in excess of 12,500 tonnes per hour. The abrasive nature and flow of material through the transfer chutes, hoppers, bins and deflectors leads to wear of the structure. To prevent structural damage sacrificial wear liners may be used for protection. Conventionally wear liners have been manufactured as flat plates and hence transfer chute design has been based on flat plate structures. [0004] Transfers chutes, hoppers, bins and deflectors not only change the direction of the incoming material, they usually control the profile in order to direct the material efficiently onto the receiving belt or next process equipment. In order to control the material profile the equipment encloses the material typically from 180 to 270 degrees 2 and up to full 360 degree coverage. To create such enclosure with flat plates, corners are inevitable. [0005] Two issues are generated by the presence of corners in this environment. When transporting dry free flowing material, increased wear has been found to occur in the corners. On the other hand, when transporting wet sticky cohesive/adhesive material, build-up of material occurs in the corners leading to modified flow characteristics and potential blockage. Modified flow characteristics can result in off centre loading on the receiving conveyer which can result in unbalanced belt tracking leading to spillage and increased pulley and idler wear. [0006] Ceramics are becoming a popular alternative to metallic liners in abrasive applications. Ceramics typically outperform metallic wear liners in abrasion resistance, but are more brittle. Historically, ceramics were 'direct-bonded' (e.g. using epoxy resin) onto the transfer directly or onto a steel plate, wherein the epoxy set hard and resulted in low impact toughness. Accordingly, ceramic liners may be manufactured as a composite material with polymers (rubber or polyurethane) used to bond the ceramic tiles to a mild steel plate, typically with studs used to mechanically fasten the liner to the transfer structure. The composite material adds impact resistance to the overall product and supports the ceramic tiles reducing the potential of cracking due to point loading from uneven surfaces. Maintenance of ceramic tiles directly bonded to the structure also requires the old lining be removed manually by physically breaking the old tiles off before new lining material can be installed. The modular mechanically fastened composite liners allow for faster removal and hence decreased maintenance time. [0007] For ease of manufacture and convenience, ceramic wear liners for chutes and the like are typically constructed from flat tiles pieced together over planar surfaces. Where the chute, for example, has adjoining surfaces that meet at an angle to form an internal corner, the tiles are made with angled edges that abut along the corner. It has been found, however, that such corner edges of wear liners can, in use, lead to higher wear, promote build-up of detritus that affects the material flow characteristics, and can lead to blockages causing equipment down-time.

3 SUMMARY OF INVENTION [0008] It is an object of the present invention to overcome or alleviate at least one disadvantage associated with the prior art, or to at least provide a useful alternative to related art systems. [0009] In accordance with the present invention there is provided a ceramic polymer composite liner tile having a curved wear face and one or more mounting faces which mount into a corner of a transfer chute, hopper, bin or deflector. [0010] The polymer preferably comprises a polyurethane material or a vulcanised rubber material. [0011] The ceramic polymer composite liner tile may further include a metal mounting plate bonded to one or more of the mounting faces by way of the polymer material. [0012] In a particular form of the ceramic polymer composite liner, one of the mounting faces is of substantially greater extent than the other. This permits the liners to be alternated in orientation in the corner of the deflector, hopper, bin or chute in order to avoid longitudinal liner joint seams. [0013] In accordance with the present invention there is further provided a material handling chute for directing flow of material in a longitudinal direction, the chute having first and second longitudinally extending walls that meet at an obtuse internal angle, wherein interior surfaces of the first and second walls are covered by wear liners formed of composite ceramic and polymer materials, and wherein the wear liners include curved ceramic sections arranged such that the wear liners form a substantially smoothly curved surface along the juncture of the first and second walls. [0014] In preferred embodiments at least one mechanical fastener is used to attach the liner to the materials handling and transport system such as, for example, attachment to the transfer chute, hopper, bin or deflector. [0015] Other aspects and preferred forms are disclosed in the specification and/or defined in the appended claims, forming a part of the description of the invention. [0016] Further scope of applicability of embodiments of the present invention will become apparent from the detailed description given hereinafter. However, it should be 4 understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure herein will become apparent to those skilled in the art from this detailed description. BRIEF DESCRIPTION OF THE DRAWINGS [0017] Further disclosure, objects, advantages and aspects of preferred and other embodiments of the present application may be better understood by those skilled in the relevant art by reference to the following description of embodiments taken in conjunction with the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the disclosure herein, and in which: Figure 1 illustrates in perspective cross-section a deflector with wear lining constructed according to the prior art; Figure 2 is a perspective cross-sectional view of a deflector incorporating wear liners according to an embodiment of the present invention; Figure 3 is a perspective view of a deflector constructed according to an embodiment of the present invention; Figures 4A and 4B are perspective views of a composite wear liner according to an embodiment of the present invention; Figures 5A and 5B are perspective views of assembled wear liners according to an embodiment of the present invention; Figures 6A & 6B are plan and side view specification drawings, respectively, of a curved ceramic component for use in wear liners according to an embodiment of the present invention; Figures 7 & 8 are specification drawings illustrating the form and dimensions of two prototype composite wear liners in accordance with an embodiment of the present invention; Figure 9 illustrates mould inserts for forming the prototype composite wear liners; Figures 10A, 10B & 10C are perspective, side and plan photographs of a particular prototype composite wear liner constructed in accordance with an embodiment of the present invention; and Figure 11 is a flow chart diagram outlining a composite liner manufacturing procedure.

5 DETAILED DESCRIPTION [0018] An embodiment of the present invention is described hereinbelow in the context of equipment used for transporting and processing ore in a mining environment. Equipment such as transfer chutes, hoppers, bins and deflectors are designed to contain and control ore flow between conveyors and other equipment. The shape required to control the ore flow results in internal corners within the design. Conventionally, using ceramic wear liners that meet edgewise at the corners, over time this design can lead to build-up and potential blockage. The build-up also changes the flow characteristics of the equipment, reducing control. Accordingly, embodiments of the present invention aim to provide a wear lining resulting in a reduced likelihood of such occurrence and thereby improve ore transfer control. [0019] Figure 1 illustrates a deflector 10 of conventional design shown in cross sectional perspective view. Transfer chutes and deflectors are designed to contain and control ore flow between conveyors and other equipment. In order to contain the ore flow the cross section of a deflector, for example, contains internal corners 12 where the planar surfaces of the deflector structure meet. The interior planar surfaces are covered with wear liners 14 which are also planar. Each planar surface is covered with a separate set of wear liners, for example as indicated at 14A and 14B. Where the liners from separate surfaces meet (e.g. as shown at 15), a lengthwise 'seam' is formed along the corner, which region is subject to the aforementioned increased wear and build-up of detritus. [0020] In order to improve ore control and wear, curved ceramic liners have been investigated. Figure 2 illustrates a deflector 100 fitted with curved liners. As can be seen, each curved liner 102 extends across two planar surfaces of the deflector with a smooth surface. This enables avoidance of an angular corner, and alternating asymmetric liners can be used to avoid a lengthwise seam as well. [0021] Figure 3 is a perspective view of a complete deflector incorporating the wear liner structure. The angles between the back wall and the wing transition plates in the deflector are 45-degrees. [0022] An individual wear liner 120 is shown in front and rear perspective views in Figures 4A and 4B. The liner 120 is of composite construction involving ceramic, 6 polymer and metal materials. The ceramic portions 122 of the liner have an inner surface that curves smoothly through a 45-degree angle to suit the deflector of Figure 3. The liner ceramic may be formed in several sections that are integrated into a composite unit by the polymer materials 124 and metal backing plate 126. The wear liner as shown is asymmetrically shaped with respect to the curved section 122A, having a larger flat section 122B at one end than the other (122C). This enables the liners to be placed in an alternating arrangement, as illustrated in Figures 5A and 5B, such that there is no extended longitudinal seam (where adjacent tiles abut) parallel to the axis of the curved section. [0023] Figures 6 to 10 are diagrams illustrating the design and construction of prototype wear liners. In Figures 6A and 6B the specification diagrams for the curved ceramic tile section is shown in plan and side views, respectively. The internal corner radius of the curved tile section has been selected at 125mm, extending through a 45 degree arc. The angle and radius of the curved tile can be varied, however, as long as the liner and mould fit within the press working envelope. [0024] Two wear liner designs were selected for trial manufacture having liner dimensions as outlined in Figures 7 and 8. The two different liner designs are adapted to fit different portions of the deflector shown in Figure 3. Both trial liners are able to be formed in the same rubber press. The ceramic tiles are formed by compressing ceramic powder in a press mould and then sintering. The ceramic tiles and rubber are then assembled in the rubber press and their final shape is determined by mould inserts, illustrated in Figure 9. [0025] The mould inserts shown in Figure 9 fit together in the press to form two cavities that contain the ceramic tiles, un-vulcanised rubber and backing plate. The flat portions of the liners are formed beneath the inserts 150, 151, and the curved portions are formed within the cavity created by the inserts labelled A & B. The completed trial liner, including bonded polymer and steel backing plate, is shown in Figures 10A, 10B and 10C. The polymer may comprise an impact resistant rubber or polyurethane material. Although the trial composite liner tile shown has ceramic formed in several parts bonded together with polymer, in practice the ceramic may be formed as a unitary structure with polymer bonded around the sides and back. The backing plate is made to cover the full length of the liner, including the bend in the liner. However it is also 7 possible to construct the liner with only a flat backing plate to cover one mating face of the liner. The metal backing plate includes a removable fastening mechanism such as bolts, studs or hooks (not shown) to enable the liner to be secured in place on the deflector, in use. [0026] The flow chart diagram in Figure 11 outlines the manufacturing procedure 200. Once the curved ceramic tiles are formed to the desired dimensional specifications through moulding and sintering (202), the side and rear faces of the ceramic are treated with a primer (204) to ensure high bond strength in the composite construction. Sheet rubber material is then applied to the primed ceramic surfaces (206) as the tiles are arranged onto a mild steel backing plate of the final shape (208). The assembly is then inserted into a rubber press (210) and the rubber is vulcanised (212) in order to securely bond the composite materials together. Finally studs are welded onto the backing plate (214) for mounting. [0027] The process for composite wear tiles utilising polyurethane polymers may differ slightly from that described above in connection with a rubber polymer. In particular, the uncured polyurethane material is in a liquid state and can thus be poured around the sides of the ceramic tile and between the ceramic and steel backing plate whilst in the final forming mould. The polyurethane also sets without requiring a vulcanisation stage. [0028] Although a particular example of a composite wear liner tile has been described, having certain dimensions and materials, other dimensions and materials are also possible within the scope of the present invention. For example, ceramic materials beside alumina may be used, in addition or in substitution, such as: zirconia, zirconia toughened-alumina, partially stabilised zirconia, aluminium oxides, tungsten/titanium/silicon carbides, and others as would be understood by those with knowledge in the art. Furthermore, whilst a curved tile adapted for a 45-degree structural corner has been shown and described, chutes and deflectors of the relevant type may have corners of other angles, up to around 90-degrees in some cases. The actual radius of the tile curvature may thus vary depending upon the particular structure, tile thickness and application. [0029] While this invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification(s).

8 This application is intended to cover any variations uses or adaptations of the invention following in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth. [0030] As the present invention may be embodied in several forms without departing from the spirit of the essential characteristics of the invention, it should be understood that the above described embodiments are not to limit the present invention unless otherwise specified, but rather should be construed broadly within the spirit and scope of the invention as defined in the appended claims. The described embodiments are to be considered in all respects as illustrative only and not restrictive. The following sections I - Ill provide a guide to interpreting the present specification. 1. Terms [0031] The term "product" means any machine, manufacture and/or composition of matter, unless expressly specified otherwise. [0032] The term "process" means any process, algorithm, method or the like, unless expressly specified otherwise. [0033] Each process (whether called a method, algorithm or otherwise) inherently includes one or more steps, and therefore all references to a "step" or "steps" of a process have an inherent antecedent basis in the mere recitation of the term 'process' or a like term. Accordingly, any reference in a claim to a 'step' or 'steps' of a process has sufficient antecedent basis. [0034] The term "invention" and the like mean "the one or more inventions disclosed in this specification", unless expressly specified otherwise. [0035] The terms "an embodiment", "embodiment", "embodiments", "the embodiment", "the embodiments", "one or more embodiments", "some embodiments", "certain embodiments", "one embodiment", "another embodiment" and the like mean "one or more (but not all) embodiments of the disclosed invention(s)", unless expressly specified otherwise.

9 [0036] The term "variation" of an invention means an embodiment of the invention, unless expressly specified otherwise. [0037] A reference to "another embodiment" in describing an embodiment does not imply that the referenced embodiment is mutually exclusive with another embodiment (e.g., an embodiment described before the referenced embodiment), unless expressly specified otherwise. [0038] The terms "including", "comprising" and variations thereof mean "including but not limited to", unless expressly specified otherwise. [0039] The terms "a", "an" and "the" mean "one or more", unless expressly specified otherwise. [0040] The term "plurality" means "two or more", unless expressly specified otherwise. [0041] The term "herein" means "in the present specification, including anything which may be incorporated by reference", unless expressly specified otherwise. [0042] The phrase "at least one of", when such phrase modifies a plurality of things (such as an enumerated list of things), means any combination of one or more of those things, unless expressly specified otherwise. For example, the phrase "at least one of a widget, a car and a wheel" means either (i) a widget, (ii) a car, (iii) a wheel, (iv) a widget and a car, (v) a widget and a wheel, (vi) a car and a wheel, or (vii) a widget, a car and a wheel. The phrase "at least one of", when such phrase modifies a plurality of things, does not mean "one of each of" the plurality of things. [0043] Numerical terms such as "one", "two", etc. when used as cardinal numbers to indicate quantity of something (e.g., one widget, two widgets), mean the quantity indicated by that numerical term, but do not mean at least the quantity indicated by that numerical term. For example, the phrase "one widget" does not mean "at least one widget", and therefore the phrase "one widget" does not cover, e.g., two widgets. [0044] The phrase "based on" does not mean "based only on", unless expressly specified otherwise. In other words, the phrase "based on" describes both "based only on" and "based at least on". The phrase "based at least on" is equivalent to the phrase "based at least in part on".

10 [0045] The term "represent" and like terms are not exclusive, unless expressly specified otherwise. For example, the term "represents" do not mean "represents only", unless expressly specified otherwise. In other words, the phrase "the data represents a credit card number" describes both "the data represents only a credit card number" and "the data represents a credit card number and the data also represents something else". [0046] The term "whereby" is used herein only to precede a clause or other set of words that express only the intended result, objective or consequence of something that is previously and explicitly recited. Thus, when the term "whereby" is used in a claim, the clause or other words that the term "whereby" modifies do not establish specific further limitations of the claim or otherwise restricts the meaning or scope of the claim. [0047] The term "e.g." and like terms mean "for example", and thus does not limit the term or phrase it explains. For example, in the sentence "the computer sends data (e.g., instructions, a data structure) over the Internet", the term "e.g." explains that "instructions" are an example of "data" that the computer may send over the Internet, and also explains that "a data structure" is an example of "data" that the computer may send over the Internet. However, both "instructions" and "a data structure" are merely examples of "data", and other things besides "instructions" and "a data structure" can be "data". [0048] The term "i.e." and like terms mean "that is", and thus limits the term or phrase it explains. For example, in the sentence "the computer sends data (i.e., instructions) over the Internet", the term "i.e." explains that "instructions" are the "data" that the computer sends over the Internet. [0049] Any given numerical range shall include whole and fractions of numbers within the range. For example, the range "1 to 10" shall be interpreted to specifically include whole numbers between 1 and 10 (e.g., 2, 3, 4, . . . 9) and non-whole numbers (e.g., 1.1, 1.2 .... 1.9). II. Forms of Sentences [0050] Where a limitation of a first claim would cover one of a feature as well as more than one of a feature (e.g., a limitation such as "at least one widget" covers one widget as well as more than one widget), and where in a second claim that depends on the first claim, the second claim uses a definite article "the" to refer to the limitation (e.g., "the 11 widget"), this does not imply that the first claim covers only one of the feature, and this does not imply that the second claim covers only one of the feature (e.g., "the widget" can cover both one widget and more than one widget). [0051] When an ordinal number (such as "first", "second", "third" and so on) is used as an adjective before a term, that ordinal number is used (unless expressly specified otherwise) merely to indicate a particular feature, such as to distinguish that particular feature from another feature that is described by the same term or by a similar term. For example, a "first widget" may be so named merely to distinguish it from, e.g., a "second widget". Thus, the mere usage of the ordinal numbers "first" and "second" before the term "widget" does not indicate any other relationship between the two widgets, and likewise does not indicate any other characteristics of either or both widgets. For example, the mere usage of the ordinal numbers "first" and "second" before the term "widget" (1) does not indicate that either widget comes before or after any other in order or location; (2) does not indicate that either widget occurs or acts before or after any other in time; and (3) does not indicate that either widget ranks above or below any other, as in importance or quality. In addition, the mere usage of ordinal numbers does not define a numerical limit to the features identified with the ordinal numbers. For example, the mere usage of the ordinal numbers "first" and "second" before the term "widget" does not indicate that there must be no more than two widgets. [0052] When a single device or article is described herein, more than one device/article (whether or not they cooperate) may alternatively be used in place of the single device/article that is described. Accordingly, the functionality that is described as being possessed by a device may alternatively be possessed by more than one device/article (whether or not they cooperate). [0053] Similarly, where more than one device or article is described herein (whether or not they cooperate), a single device/article may alternatively be used in place of the more than one device or article that is described. For example, a plurality of computer based devices may be substituted with a single computer-based device. Accordingly, the various functionality that is described as being possessed by more than one device or article may alternatively be possessed by a single device/article. [0054] The functionality and/or the features of a single device that is described may be alternatively embodied by one or more other devices which are described but are not 12 explicitly described as having such functionality/features. Thus, other embodiments need not include the described device itself, but rather can include the one or more other devices which would, in those other embodiments, have such functionality/features. Ill. Disclosed Examples and Terminology Are Not Limiting [0055] Neither the Title nor the Abstract in this specification is intended to be taken as limiting in any way as the scope of the disclosed invention(s). The title and headings of sections provided in the specification are for convenience only, and are not to be taken as limiting the disclosure in any way. [0056] Numerous embodiments are described in the present application, and are presented for illustrative purposes only. The described embodiments are not, and are not intended to be, limiting in any sense. The presently disclosed invention(s) are widely applicable to numerous embodiments, as is readily apparent from the disclosure. One of ordinary skill in the art will recognize that the disclosed invention(s) may be practiced with various modifications and alterations. Although particular features of the disclosed invention(s) may be described with reference to one or more particular embodiments and/or drawings, it should be understood that such features are not limited to usage in the one or more particular embodiments or drawings with reference to which they are described, unless expressly specified otherwise. [0057] The present disclosure is not a literal description of all embodiments of the invention(s). Also, the present disclosure is not a listing of features of the invention(s) which must be present in all embodiments. [0058] A description of an embodiment with several components or features does not imply that all or even any of such components/features are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present invention(s). Unless otherwise specified explicitly, no component/feature is essential or required. [0059] Although process steps, algorithms or the like may be described in a particular sequential order, such processes may be configured to work in different orders. In other words, any sequence or order of steps that may be explicitly described does not necessarily indicate a requirement that the steps be performed in that order. The steps of processes described herein may be performed in any order practical. Further, some 13 steps may be performed simultaneously despite being described or implied as occurring non-simultaneously (e.g., because one step is described after the other step). Moreover, the illustration of a process by its depiction in a drawing does not imply that the illustrated process is exclusive of other variations and modifications thereto, does not imply that the illustrated process or any of its steps are necessary to the invention(s), and does not imply that the illustrated process is preferred. [0060] Although a process may be described as including a plurality of steps, that does not imply that all or any of the steps are preferred, essential or required. Various other embodiments within the scope of the described invention(s) include other processes that omit some or all of the described steps. Unless otherwise specified explicitly, no step is essential or required. [0061] Although a product may be described as including a plurality of components, aspects, qualities, characteristics and/or features, that does not indicate that any or all of the plurality are preferred, essential or required. Various other embodiments within the scope of the described invention(s) include other products that omit some or all of the described plurality. [0062] All embodiments are illustrative, and do not imply that the invention or any embodiments were made or performed, as the case may be.

Claims (5)

1. A ceramic polymer composite liner having a curved wear face and one or more mounting faces which mount into a corner of a transfer chute, hopper, bin or deflector.

2. A ceramic polymer composite liner as claimed in claim 1, wherein the polymer comprises a polyurethane material or a vulcanised rubber material.

3. A ceramic polymer composite liner as claimed in claim 1 or 2, including a metal mounting plate bonded to one or more of the mounting faces by way of the polymer material.

4. A ceramic polymer composite liner as claimed in any one of claims 1 to 3, which is mounted into a material handling equipment for directing material flow, the equipment having intersecting/adjoining walls that meet at an obtuse internal angle, wherein interior walls are covered by wear liners, and wherein the wear liners include curved ceramic sections arranged such that the wear liners form a substantially smoothly curved surface along the junction.

5. A ceramic polymer composite liner as claimed in claim 4, wherein at least one mechanical fastener is used to attach the liner to the transfer chute, hopper, bin or deflector.