矿山艾萨砂磨机橡胶包覆升级聚氨酯包覆完整技术方案

              一、改造背景

      矿山艾萨砂磨机主轴、分散盘、隔离套、出料套、静环护套和研磨内筒体原厂橡胶包覆

      矿山工况：高磨蚀矿浆、重介质、石英砂高硬度颗粒、酸碱矿水、长期连续重载

      原有橡胶痛点：

 1. 耐磨差、易磨损掉块，3～6个月失效更换；

2. 耐水解、耐矿浆腐蚀差，发胀、脱胶、开裂；

3. 高温工况发软变形，动平衡失衡抖动；

4. 易掉屑污染矿料，频繁停机检修；

5. 承压、抗冲击弱，易遭撞击破损；

        升级高耐磨浇注聚氨酯CPU包覆，完全替代橡胶，寿命提升3～5倍

              二、选型材质（矿山专用重载耐冲击聚氨酯配方）

1. 胶种：矿山耐磨聚醚浇注聚氨酯CPU

2. 硬度：邵氏90A～95A（抗冲击+超高耐磨兼顾）

3. 核心优势

- 耐磨是天然橡胶4～6倍

- 抗冲击不崩块、不脆裂；

- 耐矿浆酸碱、耐泥水长期浸泡不溶胀；

- 粘接强度极高，不脱层、不鼓包、不脱落；

- 低摩擦、不粘矿、自润滑，降低磨机负载；

- 耐高温0～60℃长期稳定，不软化变形；

                  三、新旧包覆性能对比（矿山艾萨砂磨机专用）

          四、施工改造工艺流程（现场可施工/返厂加工）

1、旧橡胶彻底剥离

- 去除老化破损橡胶层，清理干净残留残胶

- 主轴、护套、分散盘基材无损伤、无锈蚀

2、基材表面强化处理

 - 喷砂粗化处理，增大结合附着力

- 丙酮+无水乙醇双重除油除污除水分

- 烘干除湿，严控基材含水率，杜绝发泡脱层

3、专用高强度聚氨酯底涂粘接

- 涂刷矿山专用金属-PU粘接底胶

- 常温活化固化，保证PU与金属一体结合

4、模具浇注成型包覆

- 精密专用工装模具，保证同心度、圆度、尺寸公差

- 高压真空脱泡浇注，无气孔、无砂眼

- 精准配比矿山耐磨AB料，恒温浇注

5、恒温固化+后熟化

- 常温初固 + 高温二次硫化

- 保证交联密度，耐磨、韧性、强度一步到位

6、精车精加工

- 外圆精磨、尺寸匹配原厂装配公差

- 端面倒角、去毛刺，不刮伤组件、密封件

- 校正动平衡，避免磨机高速震动

7、出厂质检

外观无气泡裂纹、厚度均匀、硬度达标、拉扯不脱层、尺寸合格

五、矿用艾萨砂磨机重点升级部件

1. 主轴护套聚氨酯包覆

2. 上下隔离套聚氨酯包覆

3. 出料导流套耐磨包覆

4. 分散盘外圈耐磨防护层

5. 动静密封配合环包覆

 6.研磨内筒体聚氨酯包覆

六、矿山工况注意要点

1. 禁用普通聚酯PU，只用耐水解PU，矿山泥水必不老化；

2. 流量严禁猛烈冲击，避免瞬间冲击过大；

3. 聚氨酯导热略低于橡胶，磨机油温正常无需改动冷却；

4. 安装间隙与原厂橡胶一致，不用改设备、不用调配件，直接互换安装；

七、改造效益

1. 大幅减少停机维修次数，提升矿山连续选矿产能；

2. 单备件寿命翻倍，年度采购更换成本下降；

3. 不污染矿浆品质，选矿回收率更稳定；

4. 降低磨机震动、噪音，延长整机轴承、减速机寿命；

5. 一次包覆，长期省心，矿山湿法磨矿标配升级方案；

          Mining ISA Sand Mill Rubber Cladding Upgraded to Polyurethane Cladding

Complete Technical Solution

1. Renovation Background

The main shaft, dispersing disc, isolation sleeve, discharge sleeve, stationary ring protective sleeve and grinding inner cylinder of mining ISA sand mill are originally clad with rubber.

Mining Working Conditions:

Highly abrasive slurry, dense medium, high-hardness quartz particles, acid-base mine water, long-term continuous heavy load operation.

Defects of Original Rubber Cladding:

1. Poor wear resistance, prone to abrasion and block falling, fails and needs replacement within 3～6 months;

2. Poor hydrolysis resistance and slurry corrosion resistance, easy swelling, debonding and cracking;

3. Softening and deformation under high temperature, resulting in dynamic balance deviation and equipment jitter;

4. Easy particle shedding to contaminate mineral materials, causing frequent shutdown and maintenance;

5. Low pressure bearing and impact resistance, vulnerable to damage by impact.

Upgraded with high-wear resistant cast CPU (Cast Polyurethane) cladding to completely replace rubber, with service life increased by 3～5 times.

2. Material Selection (Mine-Dedicated Heavy-Duty Impact-Resistant Polyurethane Formula)

1. Material Type: Mine wear-resistant polyether cast CPU

2. Hardness: Shore 90A～95A (balanced impact resistance and ultra-high wear resistance)

3. Core Advantages

- Wear resistance is 4～6 times that of natural rubber;

- Impact resistant, no chipping or brittle cracking;

- Resistant to acid and alkali slurry, no swelling after long-term immersion in muddy water;

- Extremely high bonding strength, no delamination, bulging or falling off;

- Low friction, non-mineral adhesion and self-lubricating, reducing mill load;

- Long-term stable at 0～60℃, no softening or deformation.

3. Performance Comparison Between Old and New Cladding (Special for Mining ISA Sand Mill)

Item Original Rubber Cladding Upgraded Polyurethane Cladding Improvement Multiple 

Service Life 3~6 months 18~30 months 3~5 times 

Impact Resistance Easy damage and block falling Impact and tear resistant Greatly improved 

Corrosion & Hydrolysis Resistance Prone to swelling and aging Long-term stable without swelling Excellent 

Dynamic Balance Accuracy Easy deformation and jitter Dimensional stability without deformation High precision 

High-Frequency Friction Wear Resistance Rapid wear Ultra-high wear resistance More than 5 times 

Adhesion Performance Easy debonding and falling off Super strong bonding between metal and PU Never delaminate 

Working Condition Adaptability Weak acid and alkali only Adapt to strong acid & high-abrasion mine slurry Full range adaptation 

4. Construction & Renovation Process (On-site Construction / Factory Rework Available)

1. Complete Stripping of Old Rubber

- Remove aged and damaged rubber layer, thoroughly clean residual glue;

- Ensure the base materials of main shaft, protective sleeve and dispersing disc are intact and rust-free.

2. Enhanced Substrate Surface Treatment

- Sandblasting roughening to improve bonding adhesion;

- Double degreasing and decontamination with acetone and absolute ethanol;

- Drying and dehumidification to strictly control substrate moisture content, avoid foaming and delamination.

3. High-Strength Special PU Primer Bonding

- Apply mine-dedicated metal-PU bonding primer;

- Activate and cure at room temperature to realize integrated combination of PU and metal.

4. Mold Casting & Integral Cladding

- Adopt precision custom tooling mold to guarantee concentricity, roundness and dimensional tolerance;

- High-pressure vacuum defoaming casting, no air holes or sand holes;

- Accurate proportioning of mine wear-resistant AB material, constant temperature casting.

5. Constant Temperature Curing & Post-Curing

- Initial curing at room temperature + high-temperature secondary vulcanization;

- Ensure crosslinking density, with wear resistance, toughness and strength formed in one process.

6. Finish Machining

- Cylindrical precision grinding to match original assembly tolerance;

- End face chamfering and deburring to avoid scratching components and seals;

- Dynamic balance correction to prevent high-speed vibration of the mill.

7. Factory Quality Inspection

No bubbles or cracks on surface, uniform thickness, qualified hardness, no delamination by pulling, qualified dimension.

5. Key Upgraded Components of Mining ISA Sand Mill

1. Polyurethane cladding for main shaft protective sleeve

2. Polyurethane cladding for upper and lower isolation sleeves

3. Wear-resistant cladding for discharge flow guide sleeve

4. Wear-resistant protective layer on outer ring of dispersing disc

5. Cladding for dynamic and static sealing matching ring

6. Polyurethane cladding for grinding inner cylinder

6. Key Notes for Mining Working Conditions

1. Ordinary polyester PU is prohibited; only hydrolysis-resistant PU is adopted to avoid aging in mine muddy water;

2. Forbid severe instantaneous impact of material flow to prevent excessive instant impact force;

3. The thermal conductivity of polyurethane is slightly lower than rubber; no modification to cooling system is required with normal oil temperature of the mill;

4. The installation clearance is consistent with original rubber parts; no equipment modification or parts adjustment needed, direct interchangeable installation.

7. Renovation Benefits

1. Greatly reduce shutdown and maintenance times, improve continuous mineral processing capacity of the mine;

2. Double the service life of single spare part, reduce annual procurement and replacement cost;

3. No pollution to slurry quality, more stable mineral processing recovery rate;

4. Reduce mill vibration and noise, extend service life of bearings and reducer of the whole machine;

5. One-time cladding with long-term stability, a standard upgrading solution for mine wet grinding.