Why Is Wear-resistant Steel The Optimal Choice For Mining Steel Hoppers And Chutes?

Abstract

Steel structure in mining

 

With the global rise in environmental awareness and the growing demand for sustainable mining practices, the metallurgical and mining industries are undergoing a structural transformation.

 

Steel structures, renowned for their superior mechanical properties high strength, impact resistance, and seismic resilience along with modular construction advantages, are increasingly replacing traditional concrete as the cornerstone of mining infrastructure. From headframes and conveyor systems to hoppers and chutes, from heavy equipment foundations to tunnel support systems, steel structures play an irreplaceable role in enhancing operational efficiency and safety in mining.

Wear-resistant steel in mining

 

According to SSAB, the use of wear-resistant steel plates like Hardox 450 in mining hoppers can extend equipment life to 2-3 times that of standard steel plates, with maintenance costs reduced by approximately 40%.

 

In the manufacturing of critical mining equipment such as hoppers and chutes, the use of wear-resistant steel plates has emerged as a pivotal technological solution-beyond high-strength low-alloy (HSLA) steels-to extend equipment lifespan and reduce maintenance costs. So, what specific role do wear-resistant steel plates play in mining equipment? This article aims to provide a detailed explanation.

1. Superior wear resistance

Abrasion resistance against bulk materials

 

The main function of the mine hopper and chute is to load and transport hard materials, such as iron ore (Mohs hardness 5-6.5), coal (1.5-3), and granite (6-7). These materials will produce friction and cutting effects during transportation, resulting in serious wear on the inner wall of the mining equipment. Wear-resistant steel plates effectively deal with this problem with their high hardness characteristics. For example, Hardox 450 has a hardness of 450 HBW (Brinell Hardness), which significantly improves its wear resistance compared to high-strength steel plates (Hardness of about 150-200 HBW). Hardox 450 steel can reduce the inner wall rate to 1/3 of that of steel plates in harsh wear environments.

Impact and erosion resistance

 

Free-fall loading of 50-ton ore batches generates impact velocities exceeding 15 m/s, causing erosive wear rates of 3-5 mm/year in carbon steel. Thus, high hardness and large size materials such as ore and coal will have impact due to height difference during falling, resulting in erosion wear. An Australian mine adopted wear resistant steel plate, which reduced the frequency of erosion damage on the inner wall of the chute by 60%.

2. High-impact load tolerance

Abrasion-resistant steel liners combine hardness with outstanding toughness, enabling them to absorb and dissipate shock loads from oversized rocks or coal chunks.

This feature is particularly important in practice. For example, in open-pit coal mines, the loading of giant ore blocks can produce impact forces of up to 500 kN and carbon steel plates can be deformed or cracked, while abrasion-resistant steel plates can effectively disperse energy and maintain equipment integrity.

3. Extend service life for mining equipment.​​​​​​​​​​​​​​​​​​​​​​​​​​​​ 

(1)Reduced downtime

By significantly lowering the risk of chute and hopper damage, wear-resistant steel plates ensure continuous operation, minimizing costly production interruptions for maintenance.

(2)Lower maintenance costs

While periodic inspections remain necessary, wear-resistant liners outperform standard high-strength steel by extending maintenance intervals. This reduces labor, material replacement, and operational costs over the equipment lifecycle.

Comparison of properties of wear-resistant steel and high-strength steel plate

4.Enhanced material quality and flow consistency

When the inner walls of hoppers and chutes experience wear, metal impurities are generated, contaminating the materials and compromising their purity and quality. Wear-resistant steel plates address this issue by maintaining the structural integrity of the inner walls, significantly reducing the formation of metal particles and ensuring high material purity. For instance, in the metallurgical industry, the purity of iron ore is critical to the quality of downstream steel production. The use of wear-resistant steel plates can effectively control impurity levels to below 0.1%, meeting stringent industry standards.

Additionally, wear-resistant steel helps preserve the dimensional stability of equipment, which is essential for maintaining consistent material flow. In applications such as coal transportation, uniform flow directly impacts combustion efficiency and emission control, highlighting the broader operational benefits of this material.