Case Study: Extending Milling Disc Lifetime with LUCANYL‑HB in TiO₂ Slurry Processing
In TiO₂ pigment production, milling efficiency is key to maintaining consistent quality and cost‑effective operation. A leading TiO₂ producer in the UK operating a pressurised wet slurry mill was experiencing rapid wear on their milling discs, causing unstable particle size distribution and increased energy use. LUC Group collaborated with the customer to engineer a durable, high‑performance solution using advanced polyurethane technology.
Why Is Wear Resistance Critical in TiO₂ Slurry Processing?
The combination of zirconium beads, titanium dioxide slurry and free chlorine creates one of the most demanding environments for milling equipment. Components must withstand continuous abrasion, chemical attack and high operating loads. Choosing the right polyurethane material can significantly reduce wear, improve process stability and lower maintenance costs.
The Challenge: High Wear in an Extremely Harsh Environment
The milling system relies on Zirconium beads and processes a TiO₂ slurry containing free chlorine — a combination that is both highly abrasive and chemically aggressive. This caused:
- Premature disc wear
- Reduced milling efficiency
- Out‑of‑spec particle size
- Increased power consumption
Traditional polyurethane grades struggled to withstand these conditions, leading to frequent maintenance intervals
The Solution: LUCANYL‑HB 90°A for Superior Wear and Chemical Resistance
LUC Group recommended upgrading the milling discs and spacers to LUCANYL‑HB 90°A, a polyurethane specifically engineered for:
Exceptional wear resistance
Strong chemical resistance, including free chlorine
High durability under high torque levels
Reliable performance in abrasive and pressurised slurry mills
This custom PU grade was developed to outperform generic polyurethane traditionally used in the industry.
The Results: Lifetime Extension Beyond Expectations
The improvement was significant:
- The generic PU discs normally lasted up to 3000 hours
- With LUCANYL‑HB, the system reached 14000 hours, almost 5 times the lifetime
- The aluminium insert became the new weakest link, showing how far the PU component performance had advanced
This upgrade resulted in:
- Longer maintenance intervals
- More stable particle size distribution
- Better milling efficiency
- Lower energy consumption
- Increased system reliability in harsh chemical environments
LUC continues to support the industry by exploring opportunities to upgrade the aluminium hub for even greater system durability.
Trusted in the Industry
This solution is already applied successfully at multiple TiO₂ pigment plants across the world, demonstrating its effectiveness in some of the harshest processing conditions.
Frequently Asked Questions
LUCANYL‑HB increased milling disc lifetime from approximately 3,000 hours to 14,000 hours, delivering nearly five times longer service life in TiO₂ slurry processing.
TiO₂ slurry processing combines abrasive particles, zirconium beads and chemically aggressive conditions. High wear resistance helps maintain milling efficiency, stable particle size distribution and lower maintenance costs.
LUCANYL‑HB was selected because it combines exceptional wear resistance, strong chemical resistance and high durability under demanding slurry mill operating conditions.
Yes. High-performance polyurethane components can reduce wear, improve process stability, maintain particle size consistency and help reduce energy consumption.
LUCANYL‑HB was chosen specifically for this application because of its ability to perform in environments containing free chlorine while maintaining excellent wear resistance.
LUC Group develops customised polyurethane components for abrasive and chemically aggressive processing environments. Contact our team to discuss how LUCANYL materials can increase component lifetime, improve efficiency and reduce maintenance costs.
