What was failing
BHI Coatings performs Ball Mill and Crusher Liner Rebuild for industrial plants in Alvin and across the Texas Gulf Coast.
The liner backing and feed-end housing of a mill had worn through behind the plates, so the wear plates no longer sat on solid metal. With the backing gone, every impact worked the bolts loose instead of being carried by the shell, and the play kept getting worse between repairs.
At the crusher transfer points the metal had ground down thin enough that impact was starting to reach the shell directly. Left alone, the loose plates and the thinning shell put the mill at risk of a failure that would pull it out of service on no notice.
How BHI Coatings approaches Ball Mill and Crusher Liner Rebuild
We start by cleaning the backing and feed-end housing areas back to sound metal so the rebuild has something to key to. Then we rebuild the worn shell metal and the housing back to profile so the wear plates bed on a solid seat instead of bridging a void, which lets the impact be carried by the shell rather than working the bolts loose. At the transfer points we blast the thinned metal and apply an abrasion-resistant lining keyed to the duty, protecting the shell and giving the liners a sound surface to ride against through the grinding cycle. Where a face flexes or takes repeated impact, we use a cold-applied elastomer instead.
Assess backing and transfer points
We inspect the liner backing, feed-end housing, and crusher transfer points to find where the metal has worn through and where the plates have lost their seat.
Clean and prep
We clean and blast the backing, housing, and transfer-point metal back to a sound, profiled surface so the rebuild and lining bond properly.
Rebuild the shell and seat
We rebuild the worn shell metal and housing back to profile so the wear plates bed on a solid seat instead of bridging a void.
Bed plates and line wear faces
We bed the wear plates back down on the rebuilt seat and line the transfer points with an abrasion-resistant system keyed to the duty, using a cold-applied elastomer where a face flexes or takes repeated impact.
Return to service
We cure and check the rebuilt areas, then hand the mill back ready to run through the grinding cycle.
The result
What Ball Mill and Crusher Liner Rebuild looks like
Repair and protection work of this kind, performed by BHI Coatings crews across the Texas Gulf Coast.
