Modern Mining December 2019

Longer wear life at Africa’s largest copper operation pipeline. Known for its outstanding wet abrasion properties, Linatex® rubber also requires a considerably shorter time for lin- ing installation when compared to alumina ceramic tiles.

Kansanshi mine has significantly reduced costs and improved productivity by apply- ing Weir Minerals’ Linatex® premium rubber lining solutions. Kansanshi, Africa’s largest copper mine, is located near Solwezi in Zambia. The mine is very remote, so getting parts and replacement material to site is time con- suming and costly. Of particular concern for the operation was excessive wear in the tailings lines, as well as the overflow tank in the continuous counter-current decantation (CCD) circuit. There are approximately 8 km of tail- ings pipes running from the plant to the tailings dam. The mine had previously lined its pipes with a combination of HDPE liners and alumina ceramic tiles. These, however, only achieved a wear life of approximately nine months. Kansanshi approached Weir Minerals Africa for an alternative solution and the company, which has a long-standing rela- tionship with the mine, specified Linatex® premium rubber to line the tailings

The lining was completed well within the allotted time, saving Kansanshi unneces- sary and costly plant downtime. After 36 months in operation, the Linatex® lining showed minimal signs of wear, and the installation has reduced the mine’s total ownership cost by over R1,6 million per annum. Kansanshi also needed a more cost effective wear solution for the overflow tank in the CCD circuit. This had previ- ously been lined with alumina ceramic tiles, which only lasted between 60 and 90 days. The tiles were wearing away quickly due to the high impact and abrasion of the stones and sand flowing through the tank. Wash‑out between the tiles was preventing the tiles from adhering to the metal sub- strate and the subsequent damage to the tank required repair work.

A tailings pipe lined with Linatex premium rubber.

In response, the Weir Minerals team specified Linagard® nitrile-based rubber (NBR). The expected cost savings from the increased production and reduced mainte- nance offset the installation costs. The Weir Minerals technical lining man- ager was on site for the duration of the tank re-lining to provide technical assistance to Kansanshi’s maintenance team. Since installation, the Linagard® NBR 30 has lasted 36 months without any visible signs of wear. Weir Minerals Africa: website: www.minerals.weir