Metso Chamber Optimization boosts crusher efficiency at TISCO Yuanjiacun iron mine

From commissioning in 2012 to the beginning of the mine construction, Lanxian Mining Company has worked closely with Metso. The large mine operation is supported by core minerals processing equipment and services from Metso, including crushers, vibrating screens and SAG mills, as well as automation control systems.

Challenges with primary gyratory crusher downtime

The iron mine runs two large primary gyratory crushers in the coarse crushing stage, a Metso Superior™ MKII 60-110e and a third-party brand gyratory crusher. In the early stages of the mining operation, the third-party primary gyratory experienced frequent maintenance and replacement stops. The standard manganese steel liners were not living up to the wear life needs of the operation.

Not only did the short lifetime led to downtime and reduced production time, but it also had downstream effects on the process. The customer felt it was imperative to improve the performance of this primary gyratory crusher and the lifetime of the wear parts.

Metso solution: Chamber optimization for longer wear parts lifetime

Metso and the customer launched a chamber optimization project on the third-party crusher to address concerns about performance. Data was gathered by sampling and analyzing ore properties, scanning of wear parts and examining the operating data of the crusher.

Metso’s own unique digital simulation software was used in the design of the solution. This software allows Metso to simulate how changes can impact the performance before finalizing the design. The resulting new chamber was tailored to meet the needs of the ore characteristics, performance targets and alloys living up the process requirements.

By August 2020, the first set of optimized liners were put into use resulting in 2.3 times the original wear life of the manganese liners. By optimizing the liner design, in addition to increased wear life, there was a notable improvement in output and downstream processes, such as through finer mill feed contributing to better mill throughput.

Continuous wear parts optimization and partnership

Over the following years, Metso continued to provide three optimized liner sets for the customer to reach targets. This was achieved through tracking, analysis and new target setting for continuous improvement. The third set further achieved targets of improving wear life, maximizing production of desired product and minimizing power spikes.

Data shows that the third set of optimized lining solutions has processed more than 10.21 million tons of ore, and its lifespan has reached 3.17 times that of the original manganese steel linings; the annual maintenance time had also been reduced from the original 491 hours to 155 hours. This reduces the backing consumption of the mantle and concaves by 21% and 76.5% respectively, and the steel consumption was reduced by 40%.

Metso Senior Technical Sales Support Manager, Zheng Shaoping, reflects on the partnership: “Optimizing the crusher cavity is a long-term development plan. We have worked closely with Lanxian Mining Company for years to offer Metso’s extensive expertise.”

The benefits speak for themselves, and the customer is satisfied with the improvements: “the performance of the gyratory crusher has improved, as well as reduced production costs and minimized safety risks through fewer maintenance stops”, adds Zheng. What’s more, the finer feed material ensures the production stability of the downstream grinding process.

The partnership between Metso and Lanxian Mining Company showcases how continuous optimization can transform operations. By combining Metso’s expertise with Lanxian’s operational insights, the partnership met targets to improve crusher efficiency and extend wear part life, also contributing to safety and sustainability.