Answers to questions

In the mining and processing industry, crushing equipment is one of the most important mechanisms for processing rocks and other materials. Under constant impact and vibration loads, crusher parts are subject to significant wear, which can lead to downtime and significant financial costs for repairs. In this context, epoxy compound plays an important role, providing protection for crusher mechanisms, extending the service life of the equipment and increasing its productivity.

Epoxy compound used in gyratory and cone crushers is able to withstand high loads that occur during the crushing process. Its main function is to fill the space between the working parts of the crusher, where it acts as a shock-absorbing layer. Such a layer helps to evenly distribute the loads and vibrations that occur during crushing of hard materials.

Epoxy compound is a two-component system: component A (resin-based) and component B (hardener). When these components are mixed, the polymerization process begins - a chemical reaction during which the resin, which acts as a binder, hardens and forms a strong cross-linked structure. An important element of the composition are the solid particles of mineral filler present in component A. It is thanks to this filler that the cross-linked structure becomes dense and resistant to loads, capable of withstanding the extreme mechanical impacts that the equipment encounters during operation.

FINSAD Group has been producing epoxy casting compounds since 2017. We have accumulated an extensive database of various types of crushers and their typical failures. We used the data obtained to analyze the types of failures, identify the most vulnerable areas and design features of crushers that require additional attention during operation and maintenance. As a result, we came to the conclusion that the quality of protective compounds in gyratory crushers is crucial for the following reasons:

- Extends the service life of crushing elements.
This reduces the need for frequent replacement of parts and increases the overall productivity of the equipment.

- Reduces downtime.
The use of high-quality protective compounds reduces the likelihood of breakdowns and damage to equipment. This helps reduce downtime, which is especially important.

- Cost savings.
Although high-quality protective compounds may have a higher cost, their use can lead to significant savings due to reduced maintenance and replacement costs.

Therefore, the quality of protective compounds directly affects the performance, reliability and cost-effectiveness of crushers.

The use of low-quality epoxy compounds in crushers can lead to a number of serious problems and negative consequences: rapid wear of crushing elements, frequent shutdowns and repairs of equipment, increased risk of accidents.

Understanding what serious consequences can arise from the use of low-quality compounds in crushers, we decided to create our own direction for the production of high-quality protective compounds. In the process of creating a high-quality product, we pay attention to every detail, from the choice of materials to engineering solutions.

Our approach to quality is closely linked to understanding the needs of customers and the desire to offer a product that not only meets but exceeds their expectations. 

Let's consider the characteristics of our BELABOND compound, which make it unique and effective:
1.    Sufficiently high compressive strength. Typically, the strength should be from 110 to 140 MPa. Low strength of epoxy compounds can lead to their deformation or destruction under intense impact and loads, which increases the risk of breakage and failures in the crusher.
2.    Good adhesion to metal surfaces. Low-quality compounds may not provide reliable adhesion, which can lead to peeling of the protective layers and damage to the equipment.
3.    Low viscosity for ease of pouring. Typically, it is necessary to pour about 300 kg of compound through fairly small holes, and if the compound has a high viscosity, then the pouring time increases and there is a possibility that voids may form. This problem is especially aggravated if pouring is carried out at low temperatures.
4.    Adequate curing time of the compound. It is very important to maintain a balance in time: if the compound hardens very slowly, we get lower internal stresses in the material, but this leads to unjustified equipment downtime. If you select a "fast" curing system, then such high stresses in the material may arise during the cross-linking process that cracks form in the filler even before the start of operation, and, as a result, the protective compound simply does not perform its function.
5.    Sedimentation stability. When using unsuitable fillers and additives during transportation and storage, stratification of the system and the formation of a very dense sediment may occur. This can lead to serious problems when preparing the compound (especially when working in the cold) for pouring. In addition, the likelihood of filler agglomerates forming increases, which will be stress concentrates, which will lead to a decrease in the mechanical strength of the material. 

Ensuring all of the above characteristics in a single product is a complex and multifaceted scientific and technical task that requires a deep understanding of the principles of chemistry and physics of polymers. Our approach to this task is based on the integration of advanced knowledge in these areas and innovative approaches to the development of materials. To solve these problems, we organized our own laboratory and consulted with scientists, and as a result, in 2017, a workshop for the production of a two-component compound based on epoxy resin was opened in the Republic of Belarus. Over the years, we have been constantly improving our product, conducting customer surveys and eliminating deficiencies. By the end of 2023, we completely eliminated the human error factor and automated the compounding process. In addition, our laboratory was equipped with new equipment that allows us to thoroughly study the properties of our products and their behavior under various conditions. The experimental approach allows us to adjust formulas and processes to achieve optimal results. We pay special attention to quality control at every stage of production. This includes not only the final product, but also quality control of the raw materials used and intermediate production stages.

We value partnership with our customers and actively include their feedback in the development process. This allows us to better understand the specific needs of consumers and improve our compounds to best meet their requirements.