RIO Liquid-Phase Natural Rubber: Application Feedback on Flotation Impellers and Stators at a Jiangxi Tungsten Mine
Customer Profile
In April 2022, a large tungsten mining enterprise in Jiangxi purchased a batch of flotation cells for its processing plant. The impellers and stators paired with 12 CLF-4 and 18 CGF-2 flotation machines were manufactured using traditional wear-resistant rubber materials. However, once put into operation, these conventional parts exhibited a service life of only 50 to 60 days. Such poor wear performance was inadequate for the severe operating conditions of the mine. Frequent component replacements severely disrupted the plant's continuous production schedule and drove up maintenance labor and material costs, becoming a critical bottleneck to production efficiency.
Product Selection Background
To address the short service life of traditional rubber impellers and stators, the company collaborated with the flotation equipment supplier and RIO Mining. Utilizing RIO's core patented technology—liquid-phase natural rubber (known for superior wet wear resistance)—they co-developed a new type of wear-resistant flotation impeller and stator.
In October 2023, these liquid-phase rubber impellers and stators were installed on the 7# CLF-4 flotation machine in the concentration plant. The pilot run focused on evaluating their wear resistance and operational stability under real-world mining conditions.
On-Site Application Performance Feedback
(1) Key Operating Data
Since commissioning, the liquid-phase rubber impellers and stators have demonstrated outstanding wear and corrosion resistance. Below is the operational performance data for the first batch installed on the 7# flotation cell:
(2) Specific Operating Parameters
The processing plant flotation circuit operates under highly abrasive conditions, with the specific test parameters detailed below:
(3) Wear Inspection and Comparison Results
On December 2, 2024, a stator fixing bolt broke during operation, causing the stator to shift. This resulted in mechanical damage to the impeller due to strong impact, forcing a plant shutdown for replacement.
Upon disassembly, technical specialists measured the wear depth and evaluated the parts. The results showed: even after operating for over 330 days, the residual thickness of the liquid-phase rubber wear parts remained in a safe range, and the theoretical remaining service life was still 2 to 4 months.
During the trial period, the processing plant also tested flotation rotors and stators from other traditional suppliers in Hebei and Yunnan. However, on-site data indicated that these dry-compounded rubber products only offered minor improvements in lifespan and failed to deliver a substantial breakthrough, leaving the plant vulnerable to frequent maintenance shutdowns.
"After six consecutive operating cycles (50 to 60 days per cycle) of rigorous comparison and wear tracking, RIO's new liquid-phase natural rubber impellers and stators, installed under identical operating conditions and locations, achieved over 6 to 8 times the service life of conventional rubber parts!"
This remarkable lifespan extension delivered multi-dimensional benefits:
- Significantly Reduced Maintenance Labor Intensity: Wear parts that previously required replacement 6 times a year now only need to be replaced once a year, eliminating over 90% of the maintenance workload.
- Enhanced Equipment Operation Rate: Decreased unplanned downtime for parts replacement, ensuring long-term stable and highly efficient flotation operations.
- Expanded Application Potential: Driven by these outstanding results, the technical evaluation team recommended accelerating the rollout of RIO parts in other flotation cells and agitators, and exploring applications in other high-wear areas like rubber screen decks and slurry pipe linings.
Product Scope & Application
RIO liquid-phase natural rubber is a high-performance material manufactured using a proprietary liquid compounding process. By fully preserving the natural long macromolecular chains of natural rubber, it offers exceptional tear, impact, and wet wear resistance. This material has been successfully deployed in severe mineral processing environments across key systems:
Rubber Hoses & Bends: Utilizes a specialized liquid-phase natural rubber inner layer to accommodate vibration and reduce leakage risks.
Conclusion
As a pioneer in liquid-phase natural rubber technology and wear-protection products, Wuxi RIO Mining Technology Co., Ltd. has established a leading position in the heavy-erosion and high-abrasion industrial rubber market. RIO's patented liquid-phase rubber is extensively utilized in mining extraction and mineral processing plants, and is deployed at scale in environmental wastewater treatment, chemical anti-corrosion linings, mechanical impact cushioning, and lithium-ion battery material grinding. Looking forward, RIO Mining will continue to uphold its vision of "reducing consumption through extended lifespan, and protecting green mines with low-carbon manufacturing," delivering state-of-the-art wear protection technology to heavy industries globally.