High frequency rubber hose: resistant to 150 ℃ high temperature+14MPa high pressure, 40mm diameter
In the transportation of media such as ore and tailings slurry in mines, rubber hoses serve as the core transportation components, and their performance directly affects transportation efficiency, equipment loss, and operational safety. Among them, large-diameter wear-resistant rubber hoses and ordinary rubber hoses have significant differences in performance in mining scenarios due to their different design positioning. These differences are mainly reflected in four key dimensions: wear resistance, compressive strength, environmental tolerance, and service life, which directly affect the operating costs and operational stability of mining enterprises.
1、 Wear resistance: the core difference in dealing with high wear media in mines
The media transported by mines (such as iron ore slurry and quartz sand mixture) often contain high hardness particles, which will continuously erode the inner wall of the hose during high-pressure transportation. This places extremely high demands on the wear resistance of the hose, and the difference in wear resistance design between the two directly determines the ability to resist erosion.
The inner rubber layer of ordinary rubber hoses is mostly made of conventional natural rubber or styrene butadiene rubber, with a hardness usually between Shore A50-A60 and no special wear-resistant reinforcement design. In mining scenarios, the inner walls of such rubber hoses are prone to scratches caused by particle erosion. After 1-3 months of use, the inner walls may become thinner, locally damaged, and even leak due to wear and tear, requiring frequent shutdowns for replacement. This not only increases consumable costs but also delays the progress of mining transportation.
Large caliber wear-resistant rubber hoses are optimized for wear issues: the inner rubber layer is mostly made of a composite formula of nitrile rubber and wear-resistant carbon black, and some high-end products also add ceramic particles or polyurethane coatings, increasing the hardness to Shore A70-A85. At the same time, the inner wall adopts a smooth mirror process to reduce the friction resistance between particles and the inner wall. Actual test data shows that when transporting ore slurry containing 5% quartz sand, the inner wall wear rate of large-diameter wear-resistant rubber hoses is only 1/5 of that of ordinary hoses, and the service life can be extended to 12-18 months, significantly reducing replacement frequency and downtime losses.
2、 Pressure resistance: the key difference in adapting to high-pressure conveying systems in mines
In order to achieve high flow medium transmission in mining conveying systems, the conveying pressure is often increased by a high-pressure pump body (usually working pressure 8-16MPa). The pressure resistant design of ordinary rubber hoses is difficult to meet this requirement, while the reinforced structure of large-diameter wear-resistant rubber hoses gives them stronger pressure resistance.
The reinforcement layer of ordinary rubber hoses is mostly single-layer fiber weaving or sparse steel wire winding, with limited pressure bearing capacity, and the rated working pressure usually does not exceed 6MPa. In the high-pressure transportation scenario of mines, ordinary rubber hoses are prone to bulging, steel wire layer breakage, and even pipe burst accidents due to high pressure, which not only causes medium waste but may also lead to equipment damage or personnel safety hazards. In addition, large diameter models of ordinary rubber hoses (such as those with a diameter of 150mm or more) are prone to pipe diameter deformation under high pressure, resulting in unstable conveying flow and affecting operational efficiency.
The large-diameter wear-resistant rubber hose adopts a composite structure of "multi-layer steel wire weaving+spiral steel wire reinforcement". The density of the reinforcement layer is 2-3 times that of ordinary rubber hoses, and the rated working pressure can reach 10-20MPa, fully covering the high-pressure transportation needs of mines. At the same time, the pipe body adopts the "integrated vulcanization of inner and outer rubber layers and reinforcement layers" process, and the pressure can be evenly dispersed throughout the pipe body, avoiding structural damage caused by local pressure concentration. In practical applications, even if the conveying pressure fluctuates (such as pressure impact during pump start stop), large-diameter wear-resistant rubber hoses can maintain stable pipe diameter and ensure uniform conveying flow.
3、 Environmental tolerance: Differences in the ability to adapt to complex mining conditions
The mining operation environment is harsh, with outdoor scenes facing high temperatures, low temperatures, and ultraviolet radiation, while underground scenes are exposed to humid and corrosive gases. Ordinary rubber hoses have weak environmental adaptability, while large-diameter wear-resistant rubber hoses have improved environmental tolerance through special material formulations.
The weather resistance of the outer rubber layer of ordinary rubber hoses is poor, and they are prone to softening and cracking in the high temperature environment of open-pit mines in summer (surface temperature above 60 ℃); When the temperature is low in winter (below -10 ℃), it will become hard and brittle, and is prone to fracture when bent. If tailings water containing weak acidity is transported, the inner rubber layer of ordinary rubber hoses will also be corroded, causing the inner wall to fall off and block the pipeline.
The outer rubber layer of the large diameter wear-resistant hose is added with anti ultraviolet and anti-aging agents, and the temperature resistance range is expanded to -40 ℃ -120 ℃, which can maintain elasticity under the extreme temperature difference environment of the open pit mine; The inner adhesive layer adopts an acid and alkali resistant formula, with a corrosion resistance rate of over 95% to weak acidic and weak alkaline media commonly found in mines, avoiding performance degradation caused by chemical corrosion. At the same time, its pipe body also has a certain resistance to rolling, and in areas where mining vehicles frequently pass, even if occasionally crushed, structural damage is not likely to occur.
4、 Comprehensive cost: cost-effectiveness difference in long-term use
From the perspective of short-term procurement costs, the price of large-diameter wear-resistant rubber hoses is usually 2-3 times that of ordinary rubber hoses. However, considering the service life and maintenance costs, the long-term cost-effectiveness of large-diameter wear-resistant rubber hoses is significantly higher.
Taking a medium-sized mine as an example, if ordinary rubber hoses are used to transport ore slurry, 2-3 of them need to be replaced every month, with a single procurement cost of 800 yuan and an annual consumables cost of about 24000 to 36000 yuan. Each replacement requires a shutdown of 4-6 hours, resulting in an annual shutdown loss of about 50000 yuan; If a large-diameter wear-resistant rubber hose is used instead, it will be replaced every 18 months, with a single purchase cost of 2000 yuan and an annual consumables cost of about 13000 yuan. The number of shutdowns will be reduced to 1-2 times per year, and the annual shutdown loss will be reduced to less than 10000 yuan. Based on comprehensive calculations, using large-diameter wear-resistant rubber hoses can save costs of 50000 to 60000 yuan per year and avoid medium leakage and pollution caused by hose damage.
Overall, in the mining transportation scenario, large-diameter wear-resistant rubber hoses have become a more suitable choice than ordinary hoses due to their superior wear resistance, pressure resistance, weather resistance, and lower long-term comprehensive costs. When selecting, mining enterprises should consider the characteristics of their conveying medium, working pressure, and environmental conditions, and prioritize the use of large-diameter wear-resistant rubber hoses to improve the stability of the conveying system and reduce operating costs.