Wear-lining Solution on Chutes

A leading Brazilian lithium producer has turned to Multotec Brazil for a durable, sustainable wear-lining solution, after being faced with relentless abrasion on its rubber-lined chutes, leading to frequent, unplanned shutdowns. To address this critical uptime risk, Multotec developed a custom solution to restore operational reliability.

Located in the state of Minas Gerais, Brazil, the client is a prominent hard-rock lithium producer supplying high-purity lithium concentrate essential for supporting the global shift toward a low-carbon future.

Excessive wear

The lithium producer experienced frequent production stoppages due to excessive wear on the rubber-lined chutes within its mineral processing plant. The operation uses Dense Media Separation (DMS) to separate the lithium minerals from the hard rock ores to produce a lithium concentrate. However, the highly abrasive nature of the coarse material being transported from one process step to another proved too harsh for the conventional rubber-lined chutes to withstand.

As a result, the rubber-lined chutes had a wear life of between 2-3 months before requiring refurbishment or replacement. This led to costly maintenance and regular production stoppages to refurbish or replace the chute linings.

 Making the switch

Multotec Brazil recommended switching to ceramic-lined chutes. These wear-resistant ceramic tiles offer exceptional abrasion and impact resistance, while their smooth surface reduces friction, improving material flow at transfer points throughout the plant.

The team collaborated with wear-lining experts from Multotec South Africa, custom-designing and installing wear-resistant ceramic-lined chutes thus significantly extending wear life and restoring operational reliability for the client. The project involved lining 23 chutes with high-grade ceramic alumina tiles manufactured at Multotec’s wear linings factory in Pretoria, South Africa.

Substantial operational gains

A team of four experienced South African tilers spent three months in Brazil completing the project, working alongside their Brazilian counterparts. Together, they exchanged best practices, conducted training, and transferred valuable operational insights to ensure local skills development and project sustainability.

The impact of the ceramic-lined chutes was substantial. The plant experienced increased uptime, improved operational efficiency, and reduced maintenance costs due to the improved wear rate of the ceramic linings. Whereas the previous rubber-lined chutes lasted just 2–3 months, the new ceramic-lined chutes now deliver a wear life of 12–18 months which is a four- to sixfold improvement.

Proactive maintenance

To maintain these performance gains, Multotec continues to provide after-sales support, which includes monthly inspections, operator training on field-cutting ceramic tiles, and comprehensive wear audits. This approach ensures the ongoing efficiency of the ceramic linings and proactive maintenance when necessary.

Building on the success of this project, Multotec Brazil is also in discussions with the lithium producer to establish a maintenance contract. This agreement would streamline the ongoing maintenance of the ceramic linings and cover several other Multotec technologies in operation at the plant, including DMS cyclones, magnetic separators, demagnetising coils and screening media.

Client specifications

In addition, the partnership could pave the way for a dedicated local workshop, further enhancing service support in the Minas Gerais region.

“Multotec’s Wear Linings factory in Pretoria, South Africa, produces between 60–200 tonnes per month of standard and bespoke engineered ceramics,  80% of which are engineered to specific client specifications,” says Jaco Erasmus, Manager: Linings at Multotec.

Looking ahead, Multotec Brazil will also provide support for the redesign and modification of all new steel chutes, using insights from current wear patterns to improve wear resistance before lining installation. Beyond its commitment to delivering tailored wear solutions, the company recognises that proper chute design is critical, no matter the lining quality, as poorly-designed chutes will still suffer from premature wear.