INNOVATION.

NOT DUPLICATION.™

IMRPOVING MP1000
CONE CRUSHER
PERFORMANCE

H-E PARTS INTERNATIONAL (H-E PARTS) SPECIALIZES IN PROVIDING WEAR MANAGEMENT SOLUTIONS. H-E PARTS
LINER DEVELOPMENT PROGRAM HAS BEEN DEVELOPED TO OPTIMISE LINER DESIGNS ON A SITE BY SITE BASIS AND
INVOLVES THE ONGOING ANALYSIS OF SITE OPERATIONAL REQUIREMENTS, MACHINE OPERATING PARAMETERS
AND WORN LINER PROFILES.
Newmont Boddington (Boddington) is a mine-site located in Customizing a liner based on each sites unique application
Western Australia, producing gold and copper concentrate. allows H-E Parts to design and supply a liner that will perform
Boddington contacted the H-E Parts team when their OEM well in the specific conditions and prolong the life of the liners
supplied liners for their Metso MP1000 secondary crushers on-site.
weren’t lasting as long as expected. The initial expectation of
The objective of the Boddington liner development program
the liners was that they would withstand 630,000 – 640,000
was to reduce liner wear rates and extend time between liner
tons, but the OEM installed liners were only working to a life of
change-outs. An added complication Boddington faced was
430,000 tons. To assist Boddington with improving their liners,
extending specific liner sets to coincide with the majority of the
H-E Parts engineers performed an on-site evaluation of the
liner change-outs, reducing the unnecessary costs associated
existing liners using innovative 3D laser scanning technology.
with unexpected shutdowns.

H-E PARTS H-E PARTS H-E PARTS

OEM
STAGE ONE STAGE TWO IMPROVEMENT

LINER LIFE (TONNES) 430,000 530,000 640,000 49%

THROUGHOUT CAPACITY (TPH) N/A 1315 1670 N/A

MP1000 LINER DEVELOPMENT PROCESS
Changes to crusher liners should be based on a combination of STAGE ONE
the following;
In stage one of development H-E Parts engineers improved
Requirements of individual site-specific applications.
the liner material on three of the Metso MP1000 secondary
„„

„„Maintenance requirements as they aren’t always compatible crushers to increase the liner life to coincide with all the
with metallurgy requirements (This often requires a balance secondary crushers on-site. The material change to the
between life and performance) secondary crushers improved liner life by 23% when compared
to the previously installed OEM liners.
„„Flow on effects on other parts of the plant
The added benefit of using H-E Parts proprietary CME™ crusher
The data collected from the 3D laser scanning is sent to our liners, is that they are designed for use with H-E Parts LockLift™
dedicated team of engineers and analyzed in H-E Parts propriety safety lifters, which Boddington have taken advantage of. The
ChamberVision™ and CrusherVision™ software, enabling our LockLift™ safety lifter provides the safest means available to
engineers to predict liner shape through the full design life. remove and replace crusher liners. This allows the liner to be
lifted through the center hole of the mantle after the head
Liners are designed and tested with ChamberVision™ wear
nut is removed. All styles utilize a jacking arrangement to
simulation. This propriety chamber design and analysis method
separate the head and mantle before lifting. This guarantees a
allows for accurate benchmarking and performance estimates.
fully controlled lift takes place, while ensuring the lifting gear
ChamberVision™ allows performance of site-specific designs
is not overloaded by lifting the head along with the liner. By
to be tested pre-installation without prototyping, minimizing
removing the need to weld on lifting lugs, H-E Parts can provide
the risk of unexpected issues before liners are even cast.
customers with a safe, cost effective solution that also reduces
CrusherVision™ advanced crusher model simulation software mantle change times.
provides predictions of:
„„Throughput
„„Power draw
„„Prediction of crushed product distribution
„„Scenario testing to estimate the effects of changing
machine parameters such as speed and eccentric throw
„„Design-stage analysis tools to prevent issues such as
chamber packing and stop start feeding issues.

By combining the capabilities of the CrusherVision™ and

ChamberVision™ software, the H-E Parts team can accurately
predict crusher performance at all points in the liner life. Pre-
installation “testing” of profiles using H-E Parts simulation
software minimizes risk. Ongoing monitoring of crusher
operational and wear performance ensures that changes in
conditions are reflected in updated designs.
Once the initial designs have been validated, H-E Parts applied
site-specific demand management procedures to assist
Boddington in determining the most cost-effective liner
management policy. A tailored approach allows H-E Parts to
ensure that liner management policies are compatible with
other maintenance requirements, whether that is isolated to a
single crusher or the processing plant as a whole.
MP1000 LINER DEVELOPMENT PROCESS
STAGE TWO
With the successful improvements in stage one, Boddington engaged H-E Parts again to improve the liner profile cavity across all
secondary crushers to ensure consistent performance between sets over time. When improving the liner profile cavity, H-E Parts
engineers redistributed mantle weight to remain within the acceptable weight range. Too much weight overall can cause internal
havoc on parts such as cracking and premature failure of the sockets, socket liners and the main shaft.
The material improvements in stage one and the profile cavity improvements in stage two have led to an increase liner life of
above 700,000 tons in some cases. The average liner life across the six crushers is now regularly above 600,000 tons, with more
recent forecasts suggesting that the current stretch target of 700,000-720,000 tons will be achievable on most machines through
continuous improvement.

FEED PERFORMANCE
The stage two analysis results found that the feed performance
of the Metso MP1000 crushers were heavily influenced by
the number of operating parameters which affected optimal
efficiencies being achieved. H-E Parts technical account
managers recommended to operate the crushers in choke fed
mode as well as checking and adjusting the CSS (closed side
setting) daily as per industry best practice.
This resulted in the following:
„„Start stop event occurrences were reduced, extending
mean time between faults from 47 minutes to 120
minutes
„„Under normal operating conditions, secondary crusher
power targets were increased from 148 to 160 to ensure
the crushers were in fact operating in choke fed mode
„„During periods when crushed ore demand is low, crusher
power targets were reduced from 160 amps to 130 amps,
ensuring choke feeding was still occurring.
„„Preventing recirculation and promoting consistent and
efficient crushing due to CSS calibration.

CONCLUSION
Improving the liners performance for the Metso MP1000 has allowed Boddington to achieve a 49% increase in tonnage over the
life of the liners when compared to the OEM’s initial liners. Due to the continued success with the MP1000 liner improvements,
Boddington have awarded H-E Parts multiple long-term contracts for not only their secondary, but also their primary gyratory
crusher concaves and mantles.
H-E Parts International replacement parts are compatible with the makes and/or models of the third-party equipment described. H-E Parts International is not an authorized repair
facility of these third parties and it does not have an affiliation with any manufacturers of these third-party products. All brands, original equipment manufacturer (OEM) part numbers
or references are owned by the respective OEM entities or their affiliates. These terms are used by H-E Parts International for identification and cross reference purposes only and are not
intended to indicate affiliation with, or approval by the OEM, of H-E Parts International or its products. All parts are manufactured by, for and warranted by H-E Parts International and
are not manufactured by, purchased from or warranted by the OEM.

HEPI27MAR18 [Link]