CASE STUDY: Cast liners
The aranzu Casted Liners are suited to all high impact, high abrasion environments, where the existing liner is not achieving the required service life.
These liners came about as a result of the previous product which was in use, not meeting the requirement. Aranzu worked with the client to solve the issue and developed a solution. Below we unpack how this came about.
THE PROBLEM WITH THE PREVIOUS PRODUCT:
The mine was previously using liners cast entirely from polyurethane (PU). While PU is known for its flexibility and resistance to certain types of wear, it struggled under the harsh conditions in the process plant, particularly withstanding the impact and abrasion from large stones. As a result, the liners wore out quickly, necessitating frequent maintenance and replacement, leading to costly downtime and increased operational expenses.
THE IMPACT THE PREVIOUS PRODUCT HAD ON THE PROCESS PLANT:
The rapid degradation of the original PU liners significantly affected the process plant's efficiency. With frequent liner failures, the plant experienced more unplanned maintenance stoppages, reducing throughput and productivity. Moreover, the increased need for replacements led to higher material and labour costs, putting a strain on the mine’s overall operational budget.
HOW ARANZU'S CASTED LINERS HAVE MADE A DIFFERENCE:
Aranzu designed new Casted Liners that would offer a major improvement over the original product. Our innovative approach combined the flexibility and cushioning properties of PU with the toughness of our specially formulated steel. By embedding steel strips into the PU liner, we were able to enhance its ability to absorb the impact from larger stones while significantly improving its resistance to abrasion. The steel components take on the brunt of the mechanical wear, while the PU continues to provide cushioning, creating a durable and high-performance liner solution.
IMPROVEMENTS OUR CLIENTS HAVE SEEN:
Clients have reported a dramatic improvement in liner longevity since implementing aranzu’s Casted Liner solution. On average, the lifespan of the liner has increased by at least four times compared to the original PU-only liners. This has translated into less frequent maintenance, reduced downtime, and substantial cost savings over the operational life of the process plant. The improved wear resistance also means that the plant can operate more consistently at higher efficiency levels, further optimising overall performance.
