Anglo American adopts Metso technology that doubles liner lifetime in crushers

MX wear parts contribute to fewer shutdowns, higher availability 

MX liners incorporate a hybrid design with metallic inserts, engineered to withstand both high impact and abrasive conditions typical of crushing applications. This combination enables up to 100% longer lifetime compared to conventional liners. 

At Anglo American, the extended wear life translated directly into fewer maintenance shutdowns for mantle and bowl liner replacements. As a result, the operation achieved: 

• Increased crusher availability 
• Higher throughput per operating cycle 
• Reduced maintenance frequency 
• Lower exposure of personnel to operational risks 

In addition, the reduced number of interventions led to a 58% reduction in CO₂ emissions associated with backing consumption, contributing to the operation’s sustainability targets. 

Implementing the optimization strategy

The successful implementation followed a structured optimization process conducted in close collaboration between Metso and Anglo American’s operation, maintenance, and engineering teams. 

Before installation, Metso specialists carried out a detailed assessment of the existing liners, including: 

• 3D scanning of wear profiles 
• Drone-based inspections 
• Analysis of wear patterns and utilization rates 

The evaluation confirmed that, while the original liners performed within expected parameters, there was clear potential for lifetime extension through optimized design. 

Field trials with MX liners were conducted between late 2024 and early 2025, with both on-site and remote monitoring by Metso experts. The results were validated in 2025, confirming the technology’s performance under real operating conditions. 

“The combination of impact resistance and wear protection is what ultimately drives the extended lifetime,” explains João Marquesin, Product Support Engineer at Metso. 

Following the successful campaign, Anglo American adopted MX liners as the standard solution for its cone crushers at the Minas-Rio operation. 

Achieving award-winning performance

The results achieved through the project led Metso to be recognized at the Anglo American Supplier Awards, receiving the “Optimization Highlight” award, as well as the Overall Winner distinction. The ceremony took place on March 4 in Conceição do Mato Dentro in an in-person event. 

About Anglo American 

Anglo American is a global mining company focused on the responsible production of copper, premium iron ore, and crop nutrients — essential resources to enable a low-carbon future and enhance food security. Its Minas-Rio operation in Brazil is a fully integrated iron ore system, including mine, processing plant, pipeline, and export terminal at the Port of Açu. 

Metso and sustainability in Brazil 

Sustainability is at the core of Metso’s strategy, with a commitment to achieving net-zero emissions by 2030. In Brazil, this is reflected through initiatives such as carbon-neutral certifications for its foundry and rubber plant, circular economy programs, and the development of technologies that enable the reuse of tailings and support fully renewable energy operations.