R100 CRUSHER LINER(S)
Project Location: Australia
Project Phase: Phase 1
Round about 100% product life improvement
Product Series: R100 – Solid Bits
In Comparison With: 22%Mn Casting(s)
Areas to Improve:
Even wear curve across liner body (not even), to accomplish at Phase 2 by re-design R100 layout.
Success Ratio of Next Phase (2): +90%
During the period of crushing, the R100 Compound seemed to be well casted into parent manganese steel castings; it did not have issues of falling out.
It should be noted that product feed size to the HP500 ranges from 120mm to 12mm; therefore the crusher is being operated above its design capacity as it crushes at a 10/1 reduction ratio on feed that has a Bond Working Index number ranging from 18 to 24, (design capacity 5/1 reduction ratio). The Resources Unity liners created no adverse effects on the crusher compared to existing liners.
New Liner New Liner
Stage 2: View of the mantle (just consumed the surface parent manganese steel. 30,000 crushed tonnes with BWI of 24)
Stage 3: View of the bowl liner from below. (The compound materials started to abrade away. 45,000 tonnes crushed with BWI of 24)
Stage 3: View of the mantle. (The compound materials started to abrade away. 45,000 tonnes crushed with BWI of 24)
Stage 3: View of the mantle. The material has continued to abrade away in the crushing zone. Evidence that the liner profile or distribution of compound material needs changing. (54,000 tonnes crushed, last 10,000 tonnes at BWI of 20).
View of the mantle. Liners removed due to crushing efficiency starting to diminish and therefore changed-out. Total of 64,000 tonnes crushed, 42,000 at bwi of 24 and 20,000 at bwi of 20.
These photos of bowl and mantle clearly show the need to change compound configuration and thus achieve further increase in liner life and throughput.
Final Stage: View of the bowl liner. Liners removed due to crushing efficiency starting to diminish and therefore changed-out.
Phase 1. objective was successfully accomplished.
Entering Phase 2 will be a smooth and simple process, because Phase 2 is only to modify design of R100 material to have even wear curve(s) of the liners.
Phase 3 will be looking at further life improvement by maintaining achievement of Phase objective.
It is likely that the client goes over 100% product life improvement; final improvement ratio yet to further explore.