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Crusher Liners

TTM-5004-B

Crusher Liners Presentation

MP SERIES CRUSHER

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The Mantle and Bowl Liner

BOWL LINER

MANTLE

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Bacin! Material

Standard Bacin!Standard backing is a general purpose backing material used in Cone Crushers under normaloperating conditions. This backing material has a compressive strength of !"000 #S$ and a

cure time of ! hours at %0&'.

HP Bacin!(# backing is an intermediate strength backing material used in Cone Crushers such as the

(#)00 to (#500 and all *mnicones operating in tougher applications. This backing

material has a compressive strength of !"500 #S$ and a cure time of 5 hours at %0&'.

W" Bacin!+' backing is an ultra performance backing material used in such Crushers as the M#,00

M#000 in highl demanding applications. This backing has a compressive strength of

,"000 #S$ and a cure time of % hours at %0&'.

Note: Zinc should not be used as a liner backing material as the high temperature may

dimensionally damage the head bore!

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What Causes Liner Wear

The abrasiveness of the rock being

crushed is measured as an /brasion $nde

number. The hardness of the rock being

crushed is measured as a +ork $ndenumber.

The abrasiveness of the rock is 1hat

1ears the liner material a1a.

The hardness of the rock dictates ho1

much rock ou can crush 1ith a givenamount of horsepo1er.

The characteristics of the material being crushed" abrasiveness andhardness" determines ho1 long liners 1ill last.

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A#rasi$eness and Hardness

Canadian 2imberlite 3+T

*hio 6imestone

+isconsin 6imestone

Non%A#rasi$e Material A#rasion Inde& Wor Inde&Non%A#rasi$e Material A#rasion Inde& Wor Inde&

A#rasi$e MaterialA#rasi$e Material

'er( A#rasi$e Material'er( A#rasi$e Material

0.0

0.0)

0.05

5.,

7.5

4.

/labama Basalt

South 8akota 9holite

Canadian :ranite 3*T

;tah Copper *re

0.),

0.)

0.5!

0.)!

0.%

!.!

%.)

.

*klahoma :ranite

evada :old *re

/ri

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Crushin! is )one in Sta!es

/s no one single Crusher can reduce shot rock or large gravel tofinished product si

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Standard * Shorthead Crushers

/pplied in the second 3secondar

stage

ormall produces products over >

3)5mm

! to ,? maimum ratio of reduction

;suall operated in open circuit

ormall is not choke fed

ormall prepares the material for

the net stage of crushing

/pplied in the third 3tertiar stage

ormall produces products under >

3)5mm

4 to !? maimum ratio of reduction

;suall operated in closed circuit

*perated choke fed for best results

ormall produces the desired

products

Standard Shorthead

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Standard Liner E&a+,le

The liner sho1n to the left

illustrates the difference

bet1een the open side feed

opening dimension and the

closed side feed opening

dimension of an M#000

Standard coarse liner.

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Shorthead Liner E&a+,le

The liner sho1n to the left

illustrates the difference bet1eenthe open side feed opening

dimension and the closed side

feed opening dimension of an

M#000 Short (ead coarse liner.

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Con$ertin! Liner Con-i!uration

Bo1l 6iner

Bo1l

+edge Bolts

Bo1l 9ing

3M#000 onl

/ll M# Crushers can be converted

from a standard crusher

configuration to a short head

crusher configuration or vice versa

at antime.

The onl item that changes is theliners.

The @uantit of backing material

re@uired 1ill also change.

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O,en * Closed Crushin! Circuits

OPEN CLOSE)

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Crusher Settin! Su!!estion

To optimi

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Product Si.e $s/ Settin!

/pproimatel ,0 3D of the material coming out of an M# coneCrusher 1ill be passing itEs closed side setting dimension.

CRUSHER SETTIN0 'S/ PRO)UCT SI1E

MP Crushers

Note: ( True as long as the "# crusher is choke fed.

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Settin! Co+,ared to Power )raw

C)osed Side Settin*

Horse+ower/!on

0" ,1" ,2" ," ,4" ," ,"

0

,2

,4

,

,8

1,0

1,2

1,4

1,

1,8

2,0

2,2

2,4

1,. HP / !on ," c,s,s,

,0 HP / !on ,-" c,s,s,

/ small change in setting

results in a large change in

po1er dra1.

There 1ill al1as be a

direct relationship of@uantit of material

produced in comparison to

po1er being used.

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Ma&i+u+ "eed Si.e

00 of the Crusher feed material should be e@ual to or smaller than

the liners closed side feed opening dimension

MP Crushers

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Ma&i+u+ "eed Si.e

Closed side feed opening is 5.0=>"maimum feed si

*pen Side 'eed *pening - !.=

Closed Side 'eed *pening - 5.0=

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Concerned A#out Throu!h,ut

$f at some point in time" our concerned about the @uantit of materialpassing through our cone Crusher" ou can make a capacit check to

determine actual Crusher throughput and compare it to the capacit chart

in the instruction manual.

S F belt Speed 3'#M

+ F +eight of foot of material

!0 F !0 minutes in one hour

)000 F )000 pounds per short ton

S & W & 23

43335 TPH

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Co++it to A Liner Stud(

The follo1ing three eercises can be completed in the field

b anone 1ho is concerned about the liners that are being

used. This Gliner stud is used to determine if the liners

being used are correct for the application.

67 Create a Liner Wear Pro-ile

47 Calculate the A+ount o- Liner Utili.ation

87 )eter+ine the Crusher9s Ratio o- Reduction

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Create a Liner Wear Pro-ile

Cut through a mantle A bo1l liner from top to

bottom verticall

Trace the 1ear profile on paper or cardboard

Send 1ear profile to Metso Minerals

+e scan the 1orn profile

+e 1ill compare the 1orn profile to a ne1

profile via computer image overlapping

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)eter+ine Liner Utili.ation

+eigh the 1orn mantle and

bo1l liner

+eigh the ne1 mantle and

ne1 bo1l liner

Calculate the amount of liner

utili

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)eter+ine the Ratio o- Reduction

Take samples of the feed and product

9un sieve analsis on samples

8etermine si

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Calculate the Ratio o- Reduction

Material samples are taken of the feed entering the Crusher and discharging out ofthe Crusher. Sieve analsis is completed on both samples.

SizeCumulative

% Passing

" (12.mm) 100

" (.mm)

1-/4" (44mm) 28

1-1/2" (8mm) 22

./8" (22mm) 4

SizeCumulative

% Passing

1-1/2" (8mm) 100

./8" (22mm) .

/4" (1mm) .

1/2" (1mm) 4

/8" (10mm) 2

4 (4,.mm) 1

8 (2,mm) .

"EE) PRO)UCT

*&ample abo+e: ,- (./ 0 #- (.12/ 3 4atio of 4eduction ('.5:6

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Use The Pro,er Liners

'eed si

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;ee, in Mind

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Product =ualit( ;e(s

To +a&i+i.e ,roduct >ualit( and uni-or+it(? the

-ollowin! ,oints +ust re+ain consistent:

2eep the Crusher feed gradation consistent b maintaining consistent Crusher

settings 3all Crusher settings Maintain consistent feed distribution 3center feeding a must

Iliminate feed segregation

9un at a consistent cavit level 3) above the feed plate

*perate at a consistent po1er dra1

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Incorrect Liner E&a+,le

'eed material percolates around

the feed opening #roduction decreases as the feed

opening is bridged over

Jolume limit is eceeded at

minimal po1er dra1

I- "eed Si.e is too Lar!e

TOO BI0@

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Incorrect Liner E&a+,le

MaKorit of crushing takes place in the

lo1est portion of the cavit

#roduction decreases due to a poorratio of reduction

#o1er andAor force limit of the

Crusher is eceeded at a minimal

volume level

9isk of improper bearing alignment

I- "eed Si.e is too S+all

TOO SMALL

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Ca,acit( )ro,,in! O--

T(,ical reasons that ca,acit( #e!ins to dro, o--:

'eed opening has closed off

Itremel slabb feed

$ncorrect feed distribution

'eed contains a high amount of debris

Tilted adKustment ring

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Lon! and Short Liners

;suall" long liners 1ill allo1 the Crusher to do more 1ork than short liners 3dra1

more po1er.

The etra 1ork 1ill usuall sho1 up in the generation of a finer product" rather thanhigher production.

6ong liners ma help generate a more cubical shaped product.

The di--erence #etween lon! and short liners:

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Use Matched Liners@

Make certain ou are using matched liners

;se the correct mantle 1ith the correct bo1l liner

;se a long mantle 1ith a long bo1l liner

;se a short mantle 1ith a short bo1l liner

;se a ne1 mantle 1ith a ne1 bo1l liner

Mi&in! and +atchin! liners #( accident or on ,ur,ose usuall( does

not wor/ Liners are desi!ned to #e used as a +atched set/ Usin! a

+atched set o- liners assures that the ni, an!le #etween the +antle

and #owl liner is correct thus !i$in! o,ti+u+ ,er-or+ance/

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Ti,s to E&tend Liner Li-e

*perate 50 rated po1er 3!5 amps 1ith a full cavit for ! hours.

*perate %5 rated po1er 3,0 amps 1ith a full cavit for ) hours.

*perate at or near 00 rated po1er 300 amps from this point on.

The Crusher normall operates near full po1er dra1

$ncreasing the Crusher setting in order to operate at the lighter po1er levels does not

effect the crushing circuit.

Note: "etso "inerals has found that when customers ha+e followed this procedure% they

ha+e seen as high as 7) increases in liner life.

"ollow these ste,s a-ter new liners are installed:

The -ollowin! ite+s +ust in ,lace:

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The M# head rotates @uickl clock1ise 1hile operating no load.

+hen feed enters the crushing cavit" it rubs against the fast moving mantle and if done

fre@uentl throughout the da 3s1itching from load to no load" it ma prevent the liners

from 1ork hardening properl.

6iners 1ill 1ork harden and get tougher if ou can maintain a stead feed rate to thecrusher all da long.

Ti,s to E&tend Liner Li-e

Man times 1ater is used above the Crusher to control dust.

Too much 1ater can cause fines to be 1ashed do1n the face of the mantle 1hich can cause

premature liner 1ear.

Li+it the >uantit( o- water used to control dust@

;ee, a +aterial load on the Crusher all da(@

Note: The "#- is a+ailable with an $nti89pin system that pre+ents the head from

turning during no8load operation.

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Storin! Liners

Store liners right side up to prevent distortion of the liner 3egg shaping and keep them inmatched sets to prevent confusion at liner change time.

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Considerin! Thic Liners

There must be a minimum of L bo1l threads

engaged into the adKustment ring threads in

order to keep the bo1l tight 1hile crushing.

The potential problem 1hen using thick liners is

a lack of thread engagement. This can lead to

thread damage and ver costl repairs.

Thick liners increase the feed opening nip angle.

This can lead to percolating of the feed

material" not allo1ing the material to flo1

properl through the crushing cavit.

The additional 1eight of thick liners can also

lead to a Crusher balance problem.

Must be

proper

TTM 5004 B

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When To Chan!e Liners

/ thinning mantle and thinning bo1l liner 1ill fle.

'leing liners 1ill crack out the backing material.

Continued fleing 1ill Gpo1der out the backing material.

The fleing deteriorates the head and bo1l seating surfaces.

The seating surfaces eventuall 1ill need reconditioning as liners 1ill no

longer sta tight.

Liners ,ushed too lon! can and will lead to+echanical ,ro#le+s with the Crusher

Note: iners need to be changed well before they are cracked% broken% loose% or ha+e

holes in them!

TTM 5004 B

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When to Chan!e Liners

Some customers measure the

distance bet1een the

underside of the adKustment

cap and the top of the

adKustment ring. This creates

a reference point for the net

liner change.

Change the liners at the same

time each time b 1atching

the adKustment cap height

Possi#ilit( 6

/dKustment

Cap

/dKustment9ing

TTM 5004 B

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When To Chan!e Liners

Some customers 1atch and

record the total number of

crushing hours on a set of

liners. *nce established" this

creates a bench mark for thenet set of liners.

Change the liners at the same

time each time b 1atching

the total number of crushing

hours on the liners

00%55

Crusher Hour

Meter

Possi#ilit( 4

TTM 5004 B

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When To Chan!e Liners

Some customers 1atch and

record the total tons of feed

material that passed through

the liners. *nce established"

this creates a bench mark forthe net set of liners.

Change the liners at the same

time each time b 1atching the

total tons of material that passed

through the set of liners

Possi#ilit( 8

TTM 5004 B

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When to Chan!e Liners

The volumetric area of the liner

decreases late in liner life as the feed

opening closes off. This results in

lo1er throughput and a substantial

loss in salable product. /n ecellenttime to change liners is 1hen a 0

loss of product is noticed.

Change the liners at the sametime b 1atching for a reduction

in throughput caused b the

closing off of the liners feed

opening.

'eed *pening Closes *ff

Possi#ilit( D

TTM 5004 B

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E&cessi$e Liner Utili.ation

6iners pushed too long can cause serious damage to the cone Crusher. / cracked" loose"

or fleing liner 1ill deteriorate the head seating surface and the bo1l seating surface.

These surfaces 1ill eventuall need to be re-conditioned a costl maintenance repair that

drives up the cost of producing the finished product.

TTM 5004 B

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Tra+, Iron Passa!e

Tramp metal passage should be kept to a minimum as it can be damaging to the cone

Crusher. / metal detector and magnet can be added to the circuit in front of the Crusher

to minimi

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