Dayhuangshan tuff quarry of Zhejiang communication resources investment Co., LTD. (hereinafter referred to as "Dayhuangshan quarry") is located at the north of Cezi island in Zhoushan. In October 2019, the phase 1 project of 15 million tons/year sand and aggregate production line was fully put into operation. It has also been awarded the "National Green Mine" in 2020, with the comprehensive utilization efficiency of resources up to 100%. As a perfectionist, Dahuangshan quarry made a more ambitious plan to further reduce cost and increase efficiency, improve quality and productivity.
On-site expert service for equipment failure rate reduction
According to Dahuangshan’s shutdow plan made by Metso Outotec, monthly service is executed by service experts lasting for one week to inspect and evaluate equipment and repair if necessary, in order to reduce equipment failure rates with less maintenance and operational costs. At the same time, the training about equipment operation and maintenance is carried out for onsite worker, as well as safety and special occupation training. For emergency service needs, Metso Outotec experts provide timely remote guidance and can be on site within 24 hours if required. "Our quarry is located in coastal areas, where supply and demand are seasonally dependent and production is volatile, and these services from Metso Outotec provide efficient production of 65,000 tons per day at peak times", said Dahuangshan quarry machinery and material department manager, Ma Yanquan.
On-site consignment warehouse setup for ensuring parts availbility
The on-site consignment warehouse is used to store common crusher spare and wear parts. This is to ensure that the parts for planned maintenance can be at their fingertips, and the parts for unexpected shutdown can also be "prepared." To this purpose, Metso Outotec provide professional inventory suggestions according to the actual use of parts combined with maintenance solution after routing inspection, and then arrange delivery in advance to replenish inventory in time.
Optimization of crushing chamber and liner for improving equipment availability
Tuff from Dahuangshan quarry is a kind of high abrasive ore, which cases huge consumtions for cruser wears, resulting in high costs for wear parts and labor. It is also a big barrier encountered by Dahuangshan quarry when promoting the work of " reduce cost and increase efficiency ". The large workload of maintenance also increases the security risk virtually. The core of LCS is processes and equipment optimization based on the specific ore properties.
The earliest problem encountered was the abnormal consumption of Barmac wear parts. Through investigation and research, Metso Outotec engineers guided customers to make appropriate changes to crusher and associated equipment, reducing wears consumption by more than 50%
In the subsequent liner optimization project of the gyratory crusher, Metso Outotec engineers collected partical size of feeding materials, liner wear profile curve and process parameters on site, and gradually promoted the liner optimization by adopting a holistic thinking. After several rounds of optimization, tracking and re-optimization, at present, the gyratory crusher uses the fourth edition of optimized concaves. This includes WX52 and WX65 alloy concaves, which can match with 3 sets of bowl in different specifications. In addition, in the whole optimization process, manganese steel optimization solution and alloy optimization solution are simultaneously carried forward to ensure a smooth transition and stable production operation.