Considerations When Selecting a New Crusher Liner

If you're considering replacing your crusher's liners, there are several factors to consider. These include the feed gradation, Manganese content, Machined liners, and downstream screening capacity. To save money and time, consider changing both liners at once. In addition, a new liner can reduce your overall shutdown time by up to four hours.

Similar to the output, a certain amount is anticipated at the conclusion of each crushing step for the next phase of the process. Aggregate producers who match the proper crusher liners stage with the proper stage will be most efficient and profitable.

Feed gradation

The feed gradation of your crusher is a key factor in determining the type of liner you need to replace. Improperly graded feed will increase wear on the lower part of the liner, resulting in reduced capacity. The difference between a new and worn liner can be as much as 50% in capacity.

Feed gradation is just as important as feed size for maximizing chamber efficiency. Specifically, feed size determines the size of the cavity opening. A smaller feed will cause material to sink to the bottom of the cavity, causing more wear on the bottom part of the liner.

Manganese content

The hardness of a crusher liner depends on the amount of manganese present in it. Manganese is an important element of steel and is often used as a liner material. The content of manganese in a liner is about 11 percent by weight. The composition of the steel can also play a role in the hardness of the crusher liner.

Manganese steels are soft and work hardenable and have outperformed most other materials used for crusher wear liners for over 100 years. Manganese binds with carbon and forms barriers against dislocation movement. It is also a low-thermal conductor. A crusher liner made from a 14 percent Mn steel typically has a hardness of 200 to 220 BHN in its as-quenched heat-treated condition. Higher Mn content will increase the hardness.

Machined liners

Whether you're replacing an old crusher liner or upgrading to a new one, you need to make sure you're choosing the right one for your specific application. In order to choose the right crusher liner, you must first determine the type of feed that your machine will be processing. Some crusher liners are made for coarse materials, while others are designed for fine materials. The grade of feed is the most important consideration in liner selection.

Depending on the type of feed material, gradation, and discharge setting, different crusher liners wear at different rates. You should perform a wear study with your replacement wear part provider to determine the best type of liner for your machine. If necessary, the replacement wear part provider should be able to thicken liners in critical areas for longer service life. However, the amount of material that can be added should be carefully calculated, because too much material can negatively impact product throughput.

Screening capacity downstream of the crushing circuit

Screening capacity is an important consideration for the performance of a crushing plant. Screens separate material into a variety of sizes and types before they enter the crushing circuit. The optimal combination of screening and crushing capacity will produce a high output while minimizing maintenance and operating costs.

Screening efficiency depends on the size of the openings and the size of the screen decks. The opening size of the screen should be selected so that it allows for minimum oversize material. Too small an opening will lead to carryover and reduce screening efficiency. Increasing screen speed can increase screening efficiency, but there are tradeoffs. Higher speed increases G-force, which reduces bearing life. Screening efficiency is calculated as the percentage of undersize material passing through the openings divided by the amount of material that is fed into the screen. For example, 75 percent screening efficiency would mean that only 25 percent of the desired product size range is rejected.

Cost of replacement liners

Replacement crusher liners are not cheap. They can be a significant cost for a mining operation. The materials used in a crusher can vary widely, from limestone to sand and gravel. The materials also affect wear and tear. In some cases, the liners can be so damaged that they need to be replaced.

For example, if you need to replace the jaw dies every five years, a ten percent reduction in production can cost you about $2,000 a day. You have fixed costs as well as variable costs, so this adds up quickly. A single week of serious losses can easily cost you $10,000 to $12,000, which is often enough to buy two new sets of liners.