SOLUTIONS

Pain Points:

• The replacement cycle of liners in different crushers within the production process varies, and replacing the liners in any crusher requires a complete shutdown of the production line.
• The inconsistent replacement times for liners across crushers in different stages lead to frequent system shutdowns, preventing maximum capacity.

Solution:

• Analyze the ore characteristics and the material properties of the liners in each crusher, and assess production data to match or customize the best wear parts for each crusher in the process. This optimizes the lifespan of the liners in each crusher.
• Once the liner optimization plan is established, trial the liners and collect data on their lifespan.
• Based on the lifespan data, establish a synchronized shutdown schedule for replacing all liners, minimizing system downtime and maximizing system capacity.

Case Study:

A tungsten mine in southern China: The crushing process involved three crushers: one for coarse, medium, and fine crushing, respectively. The liner in the fine crusher had the shortest lifespan, lasting only around 10 days. The other crusher liners lasted between 10 and 20 days.

SISUPER designed a customized liner solution for the customer, extending the fine crusher liner's lifespan by 46%, up to 14 days. Simultaneously, the lifespan of the other crusher liners was also improved.

The replacement cycle for the liners was adjusted to a multiple of 14 days, allowing all crusher liners to be replaced during a single shutdown, reducing planned downtime and boosting system capacity.

Pain Points:

• High Ore Hardness and Abrasiveness: The liners wear out quickly due to the hardness and abrasiveness of the ore, resulting in a short service life.
• Frequent Liner Replacements: This leads to frequent liner changes at the production site, placing operators under prolonged high labor intensity.

Solution:

• Ore and Liner Material Analysis: Analyze the properties of the ore and liner material, as well as production data, and match the optimal wear part supplier from the SISUPER database.
• Production Simulation: Simulate production conditions to verify the lifespan increase of the final product selection. After confirming the plan, provide the product to the customer.

Case Study:

A gold mine in northern China: The site had 4 crushers, and the original liners lasted 5-7 days. Liner replacements were needed almost every working day, placing a heavy burden on the operators.

With SISUPER liners: The liner lifespan extended to 10-12 days, significantly reducing the frequency of liner replacements and the labor intensity for operators.

Equipment Challenge:

The equipment was using OEM standard chamber liners, which had low efficiency in operation. The crushers could not reach full load operation until after a certain break-in period, affecting production efficiency.

Solution:

• Collect various technical parameters during the crusher's operation and analyze the liner chamber profile when the crusher reaches its optimal working state.
• Analyze chamber profile changes and design a custom liner chamber shape.
• Simulate production conditions to verify the chamber profile curve. Once confirmed, apply the solution on-site.

Case Study:

A molybdenum mine in northern China: The OEM liners only allowed for 60%-70% efficiency in the initial phase, requiring about 20 hours of break-in time before reaching full load production.

With SISUPER custom-designed liners: Based on customer's operating conditions, SISUPER designed an optimized chamber profile. After using SISUPER's customized liners, the crusher reached optimal working conditions and full load production within just one hour of operation.