The new formulation of Matrox has specifically been developed for the bulk material handling and mining industry to reduce typical flow problems of bulk solids in bins, hoppers, chutes, truck beds and other applications. However, every application makes its own special demands on the lining material.

The Matrox range combines the best surface friction qualities with abrasion resistance not only to promote bulk material flow but also to withstand the abrasion of flowing bulk materials in rugged applications under different environmental conditions.

The Matrox grades are based on a specific formulation of Ultra-High-Molecular Weight Polyethylene (PE-UHMW/PE 1000) that has been developed for use as a lining-material either in new construction or as a retrofit.

MATROX CLASSIC

The classic lining material with general characteristics of a very high standard. Matrox has a very low co-efficient of sliding friction which is particularly important for the bulk transport.

The new formulation of Matrox has specifically been developed for the bulk material handling and mining industry to reduce typical flow problems of bulk solids in bins, hoppers, chutes, truck beds and other applications. However, every application makes its own special demands on the lining material. 

The Matrox range combines the best surface friction qualities with abrasion resistance not only to promote bulk material flow but also to withstand the abrasion of flowing bulk materials in rugged applications under different environmental conditions.

The Matrox grades are based on a specific formulation of Ultra-High-Molecular Weight Polyethylene (PE-UHMW/PE 1000) that has been developed for use as a lining-material either in new construction or as a retrofit.

Matrox is a family of polymer alloys that solve the problems of friction, wear and the flow of material across many industry sectors. An exceptional low friction surface, outstanding wear resistance, high impact strength, excellent chemical resistance and superior performance in demanding applications characterise the key properties of the product.

Compared to steel, Matrox has considerable economic benefits:

• Lower cost
• The cost for lining an existing bin with Matrox is only about one third of the cost for construction steel.
• Lower weight
• For example, the refurbishment of a 200m Matrox would achieve a reduction in weight of almost three tons compared to the standard method of welding steel sheets. Matrox reduces the load on the structure and makes installation work much simpler.
• Longer life span
• Conventional construction steel. In the sand-slurry wear test, at 150 (S235JR).

UNDERSTANDING FLOW PROBLEMS

Cohesive bulk materials do not flow easily e.g. in chutes and hoppers. They stick to the walls and will affect productivity. Moisture, storage time at rest and other factors affect the flow properties of the bulk material. Arching and rat holes are two common problems that usually develop when either the outlet is too small or when the hopper lining material does not promote flow due to shallow wall angles or rough wall conditions caused by corrosion.

Segregation will occur if material discharges from the bin in a funnel flow pattern. The centre portion of the bin empties first, followed by the material along the walls. This creates segregation because as the bin was loaded the finer particles collect in the centre of the bin under the charging point while the coarse particles roll to the periphery of the bin along the walls. In order to remix the material during discharge a mass flow pattern is required to minimize or eliminate segregation.

Matrox reduces the friction between the bulk material and the walls of the hopper and thus allows the material to flow out and to empty the hopper completely.

RESULTS OF FLOW PROBLEMS

• Delayed start-up - increased cost
• Limited live storage
• Spontaneous combustion (stagnant coal)
• Quality compromised
• Segregation
• Silo vibrating or shaking
• Silo structural failure
• Wear of equipment
• Process out-of control
• Operator intervention

Funnel flow is referred to as first-in last-out and is ideal for free flowing bulk materials. The bulk material discharges from the bin through a small channel in the centre of the bin above the outlet and the material along the wall remains stationary until the end. Mass flow is referred to as first-in first-out and is required for cohesive bulk materials. It is defined as all the material is in motion whenever any is withdrawn.

In order to create mass flow, the hopper walls must be smooth and steep enough and the outlet must be large enough to prevent arching.

FIXING SYSTEMS

Matrox is installed by mechanically fastening it to the substrate using bolted or welded fasteners. Both types are acceptable and are usually chosen based on the requirements of the application and the structure being lined.

In order to fix linings in position, the sheet is always pre-drilled at the fixing points using a special drill or CNC Router. The distance between the individual fixing points depends on the geometry, material

thickness and the material of the container being lined, the operating conditions and the type of fixing process selected.

When the sheets are bolted into position with bolts and hex nuts, we recommend a distance of 50 mm. The distance between the holes and the edge of the sheet should not exceed 50 mm. When the pre-drilled lining sheet is positioned in the container it is used as a template for welding. For stud welding, stud is welded to match a hole in the sheet to the metal surface below.

POLYSTONE CAPPED DEADBOLT INSTALLATION SYSTEM

A hexagon nut is then screwed onto the bolt. For lining purposes, nuts and threaded bolts, size M10 have proved to be most suitable. For simpler installation on uneven surfaces, we have special threaded bolts with predetermined breaking points.

INSTALLATION ADVANTAGES

Easy removal of the sheets
Ideal applications - For thicker sheets >12mm

Equipment required:

• Suitable graduated drill
• Stud-welding unit
• Threaded studs (if necessary with pre-determined breaking point)
• Hex nuts
• Fixing tool for tightening the disk nuts.

EDGE PROTECTION

When installing all types of lining, the top row of sheets must be protected by a sealing strip to prevent material from working its way under the sheets. The strips may be of aluminium (truck bed) or stainless steel plates. When fixing the strips, ensure that the material can expand and contract freely due to thermal effects.

LINER JOINTS - FUSION WELDING

Fusion welding of the joints between the sheets is recommended. If the joints are not welded they will open and close due to thermal expansion and contraction of the liner material. Fusion welding provides a totally sealed liner and eliminates ingress of material behind the sheet. Material build up between the joints or behind the liner will result in lifting of the liner, thus exposing the liner to premature wear. Material caught between the joints can also cause hang up and interrupted flow, hence defeating the purpose of lining. Joints to be welded are prepared prior to the panels being fastened to the substrate. Welds can be ground, planed or polished flush with liner for fine powder applications.

Matrox materials are used in a wide variety of industries that handle bulk materials from the mining level up to and including the final processing or use of the product. Changes in moisture and particle size affect the product's flowability. Traditional steel surfaces become rough or corroded, causing the bulk material to stick to the steel. Ultimately productivity and quality control are compromised.