Rio-Carb: Mastery of Wear

11 Nov 2022

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Rio-Carb is an internationally recognized manufacturer of abrasion-resistant liner materials for the mining, chemical, and power generating industries. With their R-C 700 Chromium Carbide Overlay (CCO) liner plate and Impact plate range, they strive to deliver top quality products and services to their clientele. In doing so, they have acknowledged gaps in the abrasion-wear resistant liner materials field and sought knowledge and understanding on how to fill these gaps to give them a competitive edge and be involved in ground-breaking projects. An example of such a gap is the study of transition depth range on impact and sliding wear and its effect on hardening of abrasion-resistant liner materials.

Their collaboration with the University of Johannesburg’s Department of Engineering Metallurgy yielded a Masters in Engineering Metallurgy dissertation entitled the Study of transition depth range between on impact and sliding wear: effect on hardening of abrasion-resistant liner materials. The dissertation authored by Mr. Kgotso Bhabha, a Metallurgy student boasting 22 distinctions throughout his academic career at UJ. Under the supervision of Prof. Elizabeth Makhatha and Rio-Carb’s founder, Mr. Martin Maine, the project produced fruitful results despite challenges faced from the pandemic.

Empirical evidence through a High Velocity Projectile Impact Test revealed that the work hardenability of the Impact plate range can reach 55 HRc from an average base hardness of 33 HRc. That equates to a 66% increase in hardness, while R-C 700 liner plates produce a 22% increase in hardness. The R-C 700 liner plate range’s shortfall in work hardenability is heavily compensated for with its high abrasion resistance. A mass loss of 0.13% was recorded before the next sample abraded the rubber wheel from the ASTM G65 test, procedure A. The takeaway from these results is that when it comes to efficient wear-resistance one size does not fit all.

Smart Chute: Engineered Smarter

Given the multitude of adverse service conditions in the mining, chemical and power generating industries, it is no surprise that one size does not fit all. Rio-Carb’s Smart Chute is Engineered Smarter and is the response to one size does not fit all. Gone are the days of a miracle cure for all your wear aches and pains with just one wear-resistant material. Now is the time for efficiency before expansion. Where you have to be 100% fit for purpose before going big, otherwise you will find yourself always going home.

The need for an efficiency before expansion approach comes from the industries affected by wear-damage having diverse types of wear. These can include but are not limited to impact, abrasion, erosion, corrosion, oxidation, cavitation, compression and metal-to-metal wear. No one material is resistant to all these types of wear, but a combination of the right materials that are fit for purpose is the ultimate solution.

Our engineers will survey the site and analyse the factors for the most prevalent types of wear on a site. The most suitable and cost-effective materials will be selected. The smartest chute design will be engineered and presented to the end user. Once implemented, the design will be monitored, and the efficiency measured against its predecessor.  The success of Rio-Carb’s Smart Chutes can be seen in places such as Glencore Wonderkop, with 2 successful chutes. Samancor TC Smelters and Ferroglobe with one Smart Chute each.

Edited by Creamer Media Reporter