Operational Challenge
Our client expresses the need to improve the campaign duration and processing of the MP-1250 secondary crushers at Concentrator C2, while maintaining the integrity of the main equipment components and ensuring no negative impacts on operational performance.
To achieve this, a study is conducted to evaluate the M7 alloy while maintaining OEM geometry and considering the use of available remaining liners in the secondary crushers.
Historical Performance as Baseline
The client used M3 ME Elecmetal alloy liners, with an average historical performance per campaign of 23 days and processed tonnage of 440,000.
Proposed Solution: Implementation of M7 Alloy
Based on the reference line defined for the tests, ME Elecmetal's proposal considers the implementation of the M7 alloy, maintaining the original geometry of the mantle and bowl profiles in the MP-1250 crushers, but incorporating an improvement in its internal composition. This new alloy features a higher manganese content compared to M3, along with additions of chromium and molybdenum, aimed at enhancing wear resistance and extending the life of the liners, without affecting the integrity of the equipment components.
The design of this solution aims to optimize operational performance through greater liner durability, allowing for extended operation cycles and increased tonnage processed per campaign. It also seeks to respond more efficiently to the high abrasiveness and hardness conditions of the ore treated at Concentrator C2, contributing to a more demanding and sustained operation.
In this context, the M7 alloy positions itself as a technical alternative that, without altering the geometric configuration of the liners, introduces significant improvements in its materiality, in line with operational efficiency and sustainability objectives.
During its implementation phase, four tests were conducted on MP-1250 secondary crushers, corresponding to four units.
Activities performed:
· Monitoring of mantle and bowl liner assemblies on the Head and Bowl Frame structures.
· Review of assemblies and verification of operation start-up in each secondary crusher.
· Initial measurements of bowl height, recorded in each unit to establish the wear baseline:
Ch1 → 22.63"
Ch2 → 23.31"
Ch3 → 22.50"
Ch4 → 22.87"
The proposed solution by ME Elecmetal also considered a technical protocol, agreed upon by both parties, which included the following elements:
· Technical support during installation: ME Elecmetal provided assistance during the installation and commissioning of the liners in the MP-1250 crushers.
· Operational Monitoring: ME Elecmetal conducted field visits and issued Campaign Operational Reports and Weekly Reports to monitor the operational variables influencing ore processing.
· Success Criterion – Duration: The test would be considered successful if the liners achieved a lifespan of 22 – 25 days of operation, under the defined operational parameters and with a processed tonnage of 600,000 TN.
· Success Criterion – Equipment Integrity: The test would be successful if the liners did not cause functional issues in the critical components of the crusher (mainshaft, upper and lower bushing, socket, and socket liner).
· Final Report: ME Elecmetal was to issue a conclusive report with recommendations to ensure sustainable operation of the wear components, suggestions for changes in operational variables, and validate the feasibility of the M7 alloy under real operational conditions.
Benefits
Processing
A 37% increase in abrasive ore processing is achieved, thanks to changes in the materiality of the liners that optimized their performance and resistance.
Availability
An additional 7 days of operation are recorded compared to the liners supplied by the OEM and with the M3 alloy, improving operational continuity and reducing downtime.
Maintainability
The lifespan of the liners is extended, reducing the frequency of annual changes by 25%. This represents an approximate total of 96 changes per year in the 8 crushing units.
Safety
Exposure to risk is reduced by 576 hours annually (25%), by decreasing the maintenance of liner changes in the MP-1250 from 128 to 96 sets per year.
Sustainability
CO₂eq emissions are reduced by approximately 38 tons per year (25%), due to the reduction in liner consumption from 128 to 96 sets annually, thanks to the longer campaign duration.
Reliability
With M3 and M7 alloy campaigns, a uniform wear profile is achieved, without critical zones on the mantle. The client confirms that ME Elecmetal liners do not cause damage to main components such as the mainshaft, bushings, eccentric, and socket assembly, ensuring operational continuity and avoiding breakages or failures in critical parts.
Performance Analysis of M7 Alloy
The main results of the tests with the new M7 alloy are detailed below.
® The table shows the accumulated processing with M7 Alloy campaign days.
MP - 1250 Crusher | Alloy | Installation Date | Removal Date | Campaign Days | Production (TMS) |
Ch1 | M7 | 10/16/2025 | 11/17/2025 | 33 | 605604 |
Ch2 | M7 | 10/27/2025 | 11/22/2025 | 26 | 412080 |
Ch3 | M7 | 10/31/2025 | 12/05/2025 | 35 | 521937 |
Ch4 | M7 | 01/02/2025 | 01/26/2025 | 24 | 567015 |
Processing Increase:
• M3 Alloy Baseline: With 440,000 tons processed on average per campaign.
• First M7 Test (Ch1): 605,604 tons processed → significant increase of 165,604 tons more compared to M3.
® The table shows tonnage projections in M7 campaigns, with a change limit to 8.5”
MP - 1250 Crusher | Initial Bowl Height | Final Bowl Height | Total Travel | Production (TMS) | Projected Production |
Ch1 | 22.63 | 8.88 | 13.75 | 605604 | 605604 |
Ch2 | 23.31 | 11.88 | 11.43 | 412080 | 520237 |
Ch3 | 22.50 | 9.94 | 12.56 | 521937 | 565986 |
Ch4 | 22.87 | 8.75 | 12.34 | 567015 | 567015 |
® The graph shows the accumulated processing with M3 and M7 ME ELECMETAL in Crushing.
Observed Operational Conditions
• Chamber Levels: The correlation between power (kW) and lubrication pressure (PSI) is a reliable indicator of the degree of filling of the crushing chamber. In the M7 evaluated campaigns, values of 59-61% chamber filling were recorded, which is below the recommended threshold for the MP-1250 model, whose optimal operation requires a minimum of 70% effective filling.
® Chamber Filling Level in M7 Campaign.
® Power (kW) vs Pressure (Psi) Variables Correlation.
• Feeder Speed (feeding to the crusher): During the M7 campaigns, it was maintained between 65% and 70%, indicating an available margin for increasing speed and optimizing chamber levels.
® Feeder Speed in M7 Campaign.
Achieved Operational Impact
+ 37% increase in material processing.
+ 7 additional days of operation.
-25% annual liner changes.
-38.4 tons of CO₂eq, direct impact on carbon footprint.
