Crusher Liner Optimisation - Improves Wear Life and Reduces Downtime - Case Study

Case story
M 02-23 0000-30-ENG V2
Liner optimization
improves life and
reduces downtime
Background and objective crusher lining solution was therefore required.
Changes in the geology and mining practices The solution we proposed would more than FLSmidth A/S
2500 Valby
at a West African gold producer had resulted in double the lifetime of the liners, and
Denmark
a more challenging run-of-mine (ROM) ultimately help to raise annual production at Tel. +45 36 18 10 00
feedstock (greater hardness) for its gyratory the mine. This not only strengthened the [email protected]
crusher. This was causing higher rates of wear mine’s financial performance, but also
on the crusher lining system. In addition, the brought important sustainability and health
mine experienced uneven wear of the crusher and safety benefits.
FLSmidth Inc
liners due to: Salt Lake City Operations
Changes to ore geology were causing
Midvale, UT 84047-5559
■ A single-side dump hopper, which fed operational challenges with the USA
material asymmetrically into the crusher, liners of a West African gold mine. Tel. +1 801 871 7000
In response, FLSmidth provided [email protected]
and led to uneven wear of the concaves.
■ A tendency for fines to stick together and a customised wear solution that www.flsmidth.com
not be free flowing, particularly when wet, boosted liner life, optimized crusher
leading to packing of the crusher. performance, and resulted in an
overall increase in mine throughput.
Copyright © 2023 FLSmidth A/S.
All Rights Reserved. FLSmidth is a
When FLSmidth visited the site to assess the Defining the project (registered trademark) of FLSmidth
situation, the concave liners were only lasting FLSmidth worked with the customer to define A/S. This brochure makes no offers,
representations or warranties (express
an average of 2.75 million tonnes, while the their goals and understand the crusher or implied), and information and data
mantle liners had an average lifespan of just operating conditions. This included an contained in this brochure are for
0.75 million tonnes. As a result, liners needed analysis of the feed material, crusher general reference only and may
change at any time.
replacing more frequently than they had in performance and operating parameters.
the past. This extended the time the crusher As a result, the following aims for the new
was out of service for maintenance and wear solution were identified:
impacted the mine’s productivity. ■ Improve wear life of the concave and
mantle liners.
On top of this, the mine wanted to increase ■ Minimise downtime and improve reliability.
throughput of its SAG mill. This placed
■ Reduce the size of crusher output material,
additional demands on the crusher to deliver
while maintaining current power draw, to
an optimal feedstock to the mill. A new
support the targeted increase in SAG mill
throughput.
The solution
Results were achieved over two design phases.
In the first phase, we recommended a new concave and mantle
liner profile to operate at a smaller open side setting (OSS).
This reduced the size of the feed going through to the SAG mill,
and meant that mill throughput could be increased, even with
the more challenging ore. To compensate for the smaller OSS,
crusher capacity was lowered to ensure sufficient available
power in the motor to achieve a smaller product size. This
ensured the process stayed within safe operating parameters
and did not shut down due to high power draw or high
pressure.
In the second phase, we recommended a different concave

liner metallurgy to increase liner lifespan. This required an
adjustment to the mantle liner replacement schedule, with two
additional mantle rotations added per concave. As a result of
these changes, the downtime needed for liner maintenance
was significantly reduced.
The results
The new liner design exceeded the objectives for the project:
■ Concave liner life more than doubled to 5.99 million tonnes.
■ Mantles life increased by 60% to 1.2 million tonnes

■ Downtime was reduced by 30%.
■ Sizing of the SAG mill feed was optimised.
“Despite the difficult operating conditions faced by the

mine, we were able to create a custom solution, more
than doubling the lifespan of the lining, and optimising
crusher operating conditions to support higher SAG mill
throughput,” concluded Trevor Kupstas. “This was a
huge success for FLSmidth and for the mine, which was
able to increase production as a result of this work. ”
New concave and mantle liner

design doubles life
7.0
6.0
5.0
Metric tonnes
4.0
3.0
2.0
1.0
0.0
Original Phase Phase
Concaves I Design II Design
New concave and mantle liner design

reduces shutdown hours by 30%
350
300
Shutdown hours
250
200
150
100
50
0
Original Phase Phase
Concaves I Design II Design

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Case story

In the second phase, we recommended a different concave

■ Mantles life increased by 60% to 1.2 million tonnes

“Despite the difficult operating conditions faced by the

New concave and mantle liner

New concave and mantle liner design

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