Wear in rock crushers causes great costs in the mining and aggregates industry. Change of the geometry of the crusher liners is a major reason for these costs. Being able to predict the geometry of a worn crusher will help designing the crusher liners for improved performance.
A model for prediction of sliding wear was suggested by Archard in 1953. Tests have been conducted to determine the wear coefficient in Archards model. Using a small jaw crusher, the wear of the crusher liners has been studied for different settings of the crusher. The experiments have been carried out using quartzite, known for being very abrasive. Crushing forces have been measured, and the motion of the crusher has been tracked along with the wear on the crusher liners. The test results show that the wear mechanisms are different for the fixed and moving liner. If there were no relative sliding distance between rock and liner, Archards model would yield no wear. This is not true for rock crushing applications where wear is observed even though there is no macroscopic sliding between the rock material and the liners. For this reason, Archards model has been modified to account for the wear induced by the local sliding of particles being crushed. The predicted worn geometry is similar to the real crusher.
A cone crusher is a machine commonly used in the mining and aggregates industry. In a cone crusher, the geometry of the crushing chamber is crucial for performance. The objective of this work, where wear was studied in a jaw crusher, is to implement a model to predict the geometry of a worn cone crusher.
Crusher Wear Parts is an industry leader in supplying the best jaw liner parts for a specific application. We offer OEM as well as specialty configurations. We have decades of experience in supplying wear parts to the aggregate and mining industries. We conduct wear studies to evaluate which jaw liner configuration will perform best for your application. If the best configuration is not currently available, we will design one. Modifications available for jaw crusher dies include:Tooth Pitch/Height This can be modified to reduce chamber opening, increase breaking action, and surface area. Tooth Type Many tooth profiles such as round, high round, flat, or sharp can be selected depending on the application. Curve Curve may be added to allow crushing to start higher in the chamber and also to improve the nip angle lower in the chamber. Filled in Ends Ends can be filled in to combat the high wear area at the bottom of the stationary liner allowing liners to wear at the same rate.
Robust, reliable and ready to handle all your requirements. Whether its aggregates, mining, construction & demolition, recycling or road building our McCloskey jaw, cone & impact crushers are ready for any job.
Is there any standards or guidelines to determine the expected or typical "life span" of all wearlife of parts of jaw crusher, cone crushers or VSI crushing plant. Any help on what wear & tear can do to liners and other crusher parts is highly appreciate.
Hi, this is highly dependant on density of materials being crushed, maintenance schedules, and of course quality of wear parts being used to name but a few of the contributory factors so in my opinion it is VERY difficult to standardise life span on any crushing plant.
The standard can only be determined through the material being crushed, as the abrasive nature will be the main variable in determining wear. For example basalt is generally very low wear, granite is very high.
Historical data is very much available for various materials and there various "A typical" wear rate hours in specific regions of countries which can be used as a guideline. Ask people doing that job what wear rate they are in fact experiencing on the product you want knowledge on.
Silica content in aggregates is a huge factor. The higher the content - the more abrasive the material. Crushing wet material (for example when keeping the dust levels lower) also contributes to higher wear situations. Without mentioning the obvious factors such as tonnage or throughput as mentioned in previous comments from others, different wear alloys - manganese versus chrome/moly/manganese, different grades of hard-facing or other hardened steels all contribute. One of the factors people often forget is actual operator habits. The same crusher can wear at different rates depending on % feed into the crusher as well as rotation or operating speed set by the operator.
Many great comments offered to which I completely agree. Feed characteristics I believe is your number one factor. Abrasiveness and hardness are important factors but so are the amount of fines allowed to enter the crusher. This will also effect wear part life. The other factor is of course water. If you are using dust suppression it can have a big effect on wear life. Other factors mentioned like crusher speed and your reduction ratios all have an impact on wear life. The key to wear life is to get the best bang for your buck. If you can optimize your crusher to its best production efficiency you can then justify wear cost as your cost per ton goes down the more efficient you get. You cant change your materials natural characteristics but you can buy wear parts with the correct composition best suited for your specific application.
I agree to all of the comments that the main factor that effects the life span of the crusher liners is the abrasiveness and hardness of stone and addition to this choke feeding to the crusher can helps a lots to prolonged the life of the liners especially to the cone crusher and the VSI.
It is highly KEY that when folks are suggesting wear life it is a bit of a mugs game. You must compare the wear rates of "that specific material" in that specific quarry or very close to that operation to get HIstorical actual wear rates vs "theoretical wear rates".
That is an excellent point that youmake concerning feed consistency as this applies to all types of crushers. We tend to forget sometimes that with all the variables mentioned they simply dont mean much unless we start with the beginning which is the feed consistency. Anytime you have less then consistent feed rate to your crusher your wear parts life will be dramatically reduced regardless of your choices of wear parts. Its like I had mentioned earlier your crushers efficiency will determined wear part life. In order to achieve feed consistency you need to begin with sized material so that you can reach maximum consistency and by doing so achieve true attrition crushing. In other words let your rock become a wear part.
In order to choose the correct wear parts you should educate yourself on what your material is made up of. Knowing what your material characteristics are will help you to make the best decisions as to what type of wear parts to purchase. The best way to learn what your material is made of is to have your material tested. Some tests would include;
We have had good success in gathering data relating to the CSS over the last year at one minesite. This has provided data for trending mantle life. http://www.crushervision.comworking in a manganese casting foundry,which supply the Metso and Sandvik parts.
At the same time in Russia they have alsoconsideredaggregate shape. Quarry may have a lot of aggregate for very good price but clients (mainly - road contractors, interested in volcanic rock material) refuse to buy it due to poor shape. Some cone crushers (for example, from your brother company - Telsmith) can produce very good product, most crushers - not. The plant owner had to pay extra to get better shape - either additional passing through VSI, or bigger recirculation to get optimal feed in crushing chamber. First variant gives additional cost, second - less lifetime of wear parts per ton of product.
Long time ago I was involved in EBRD (European Bank of Reconstruction and Development) investment project in Belarus. It was about refurbishing road from Poland border to Russian border. Project was sophisticated with comprehensive feasibility study. It should be three crushing plants as well.
I don't remember expert names (or company names) involved in the study. But I remember a few figures they operated with. For limestone aggregate cost of wear/spare parts was 3-7% of new plant cost per 2000 hours, for medium abrasive granite - 5-10%, for high abrasive material - 7-15%. If material is harder than standard - plus one percent for low abrasive rock, two - for medium and three for high. For equipment older than 6000 hours spare/wear parts cost got 1-3% higher for every 2000 hours. Experts made choice of this figures mainly depends on equipment specs and their knowledge.
I remember it was stressed that these figures are more or less valid for crushing plants made by first class European manufactures according to European specifications. It was 1995-1996 and I don't now if these figures are still valid because nowdays it looks like everything made outside of China should be considered as infringing goods :)). I mean that prices and specs which are much more important may differ.
You can keep all the log books in the world but if you use low quality manganese and chrome alloys from cut rate foundries, you are only wasting your time and throwing your companies money in the GARBAGE! Look for suppliers that aren't necessarily the cheapest but that aren't slamming you over the head either. AND, LAST BUT NOT LEAST, be cautious of the OEM! All too often they source materials out from whomever has the best price or parts in stock. You may think because you are buying direct from the OEM that you are getting the BEST product, NOT ALWAYS TRUE!
Here's my personal thought, if your rock is hard Do not use impact crushers or VSI use cone and jaws I realize what foundries have good days and bad. The problem I have with most sales guys, in the industry is they sell the wrong machine into the wrong application. Make sure the mag is right for the app, if your buying direct keep the foundry responsible for the mag.
Best would to record what is happening in your crushers have it all documented and drawn out. From there you can start redesigning your mantels, bowl liners, jaws, blow bars and start playing with you material specs to improve your lifetime on them.
There is no standard but big companies have software to estimate life time. Shortly higher manganese increase life time but to increase manganese you need to increase carbon which make liner brittle.And I must disagree about VSI thing.
The rate of consumption of wear parts is as stated by several others driven by material being crushed, wear part quality and by site crushing practices. As a manufacture of crushing equipment we have some typical guidelines and we can test for part consumption in VSI crushers. But experience tells me that in most cases the utilization of wear parts is heavily dependent on proper feeding of the equipment. Under feeding or gap feeding causes issues that are portrayed by utilizing a small portion of the available wear material in a part such as a jaw plate or a cone liner.
The main wearing mechanism in crushercavity is abrasive wearing. Fatigue wear isalso present as wear part are subjected tomultiple compression or impact loads.Abrasive wear (or abrasion)Crushers typically compress the feed material between the fixed and movable wearparts. Besides the breakage of the feedmaterial, this is also wearing material awayfrom the wear part. Wearing micromechanisms are:
During the crushing cycle, gouging orhigh stress abrasion is present depending onthe particle size of feed material. Betweenthe crushing cycles when particles of feedmaterial are sliding against wear parts, lowstress abrasion is present.
DISCLAIMER: Material presented on the 911METALLURGIST.COM FORUMS is intended for information purposes only and does not constitute advice. The 911METALLURGIST.COM and 911METALLURGY CORP tries to provide content that is true and accurate as of the date of writing; however, we give no assurance or warranty regarding the accuracy, timeliness, or applicability of any of the contents. Visitors to the 911METALLURGIST.COM website should not act upon the websites content or information without first seeking appropriate professional advice. 911METALLURGY CORP accepts no responsibility for and excludes all liability in connection with browsing this website, use of information or downloading any materials from it, including but not limited to any liability for errors, inaccuracies, omissions, or misleading statements. The information at this website might include opinions or views which, unless expressly stated otherwise, are not necessarily those of the 911METALLURGIST.COM or 911METALLURGY CORP or any associated company or any person in relation to whom they would have any liability or responsibility.