ME Elecmetal strengthens its presence with its first installation of large primary crusher liners at a major copper mine in southern Peru
As a supplier and strategic partner to the mining industry, ME Elecmetal aims to be a competitive option for the Peruvian market by delivering new and improved integral solutions.
Aligned with the Customer's Needs
After seven months of operation with concaves supplied by another provider—projected to last 18 months—the client experienced a fracture. This incident triggered an alert that required a timely, high-quality response, which the ME Elecmetal team delivered within 48 hours, as requested by the client.
A maintenance and liner replacement plan was developed for the complete Fuller 60"x113" crusher (mantles and concaves). During this operation, ME Elecmetal liners with an 18-month service life were installed. Although a few issues arose during maintenance (resolved remotely), the operation was completed in 48 hours, as scheduled.
ME Elecmetal Solution
The ME Elecmetal crushing team developed a technical proposal for the 60”x113” NT primary gyratory crushers at a major copper mine plant in southern Peru, aiming to process 36 Mton per concave campaign, with two mantle sequences. It is proposed to use four mantles for a normal concave campaign: used mantle (112.5”), used mantle (113.5”), new mantle (114.5”), and new mantle (115”). Two of these mantles were used in the previous campaign.
ME Elecmetal proposes the use of chrome-molybdenum for the lower, intermediate, and upper concaves. For the lower, intermediate, and upper mantles, a manganese steel alloy is considered. These alloys have proven and validated results of improved performance in various equipment and sites.
The proposed configuration includes the following:
- Set of concaves grouped in 3 rows with 16 units each.
- Use of a mantle configuration Ø112.5”, Ø113.5”, Ø114.5”, and 115”.
- Operating C.S.S. of 5”.
Solution considerations:
- Evaluation of implementing a two-mantle campaign with a conical profile to optimize the available stroke according to operating parameters.
- Use of Elecmetal alloy for the concaves, increasing the projected campaign duration by 25% compared to the last campaign.
- With the new designs, we expect to better utilize the operational stroke and thus achieve the target constant 5” C.S.S. Considering the new mantle designs and the use of new alloys for the concaves, we can estimate crusher processing of 36 Mton.
The developed proposal suggests a steel utilization rate of 24% in the mantles because they are reused in the subsequent campaign, achieving better steel utilization in the market. According to ME Elecmetal’s experience, the steel utilization rate is around 16%, which is already a good percentage, as ME Elecmetal designs aim to maximize steel use and improve the effective cost of operation.
Additionally, an integrated project was developed for this mining company, which includes after-sales service, on-site support, simulations, technological developments, improvement projects, and training integrated into a customized work plan (ME FIT Work Program) for the client to achieve the best TCO (Total Cost of Ownership) using the full range of ME FIT Crushing tools offered by ME Elecmetal.
Benefits
Competitiveness and Efficiency
Introducing ME Elecmetal crusher liners enables a more competitive operation by providing an alternative supplier option in the event of unforeseen situations.
Differentiation and Service Life
ME Elecmetal's alloys and designs carry a distinctive signature, offering a supply engineered to achieve a longer service life than other suppliers.
Reliability
Thanks to its material composition and oil-tempered production process, product reliability increases, and the parts are projected not to suffer fractures.
Circular Economy
The supply provided by ME Elecmetal includes a steel-reuse percentage in the mantles, which are used again in the subsequent campaign, achieving better utilization of this material.
After-Sales Service
Continuous support gives the client representative information about the entire process, detecting anomalies and proposing adjustments focused on continuous improvement.
“We managed to meet the client's expectations and deliver a solution in record time. The client greatly valued the speed of our response and the technical answer provided, but above all the support received from the ME Elecmetal team—a differentiating element that sets us apart in delivering integral solutions.”
ME Elecmetal presence in the crushing market
The supply of crusher liners, supported by the ME FIT Crushing program in South America, has allowed us to position ourselves as the preferred supplier in two-thirds of the market for crushing equipment, surpassing equipment manufacturers.
Out of a total of 63 mining operations considered in South America, corresponding to Large Mining, ME Elecmetal holds a 39% share in primary gyratory crushers, 25% in cone crushers, and 30% in jaw crushers, equivalent to a study of liner supplies in operation.
