Crusher Wear Parts Success Stories
Crusher Wear Parts Success Stories
Production Tonnage Increased by 28% Using Improved Si-Tec® Technology
Terex - Canica 2350 VSI Crusher
0050113HS Si-Tec® Ceramic Shoe
USA
2.5" Minus
2.5" Minus
"Throughput increased from 18,000 tons per set of shoes to 24,760 tons per set of shoes"
Baseline:
- 5 Shoe table running at 1085 RPM
- Feed of 550 TPH+
- Feed size of 2.5" minus (Frack Sand)
- Increase tons per hour per set of shoes
- Extend wear life of castings
- Throughput increased from 18,000 tons per set of shoes to 24,760 tons per set (28% increase)
- Fewer change outs results in increased machine up time and improved safety
Si-Tec® Ceramic Feed Disk Increases Shoe Wear Life by 41%
Cemco 70
337-7143HS Feed Disk
337-7115HS Ceramic Shoe
TN, USA
2" Minus Sand Stone
2" Minus Sand Stone
"Feed disk wear life improved 35%, while shoe wear life improved by 41%, with an increase of 1,469 tons produced"
Baseline:
- 5 Shoe table using 337-7115HS Ceramic shoes
- 130 Tons per hour using a closed circuit (recirculating load)
- Average Feed Disk wear life of 53 hours from brand X using standard high chrome
- Increase wear life of feed disk
- Improve wear pattern of shoes through Si-Tec® Feed Disk 337-7143HS
- Lower maintainance costs with fewer change outs
- Increased feed disk wear life from 53 hours to 71.8 hours over brand X standard chrome (35% improvement)
- Si-Tec® Feed Disk provided additional 18.8 hours wear life compared to Brand X
- Additional 2,444 tons of product produced with no change outs
- Increased ceramic shoe wear life from 27.5 hours to 38.8 hours using Si-Tec® ceramic feed disk (41% improvement)
- Additional 11.3 hours run time on shoes
- Additional 1,469 tons of product produced with one less set of shoes
Si-Tec® Ceramic Shoes Reduce Wear Part Cost 40%
Cemco 96
0052611HS Ceramic Shoe
USA
Clay with high silica content
Clay with high silica content
"Si-Tec® shoe wear life provided 2.25x improvement"
Baseline:
- Standard chrome four shoe table on Cemco 96
- Standard chrome shoes last 4 shifts of 8 hours
- Shoe change outs take four hours with two staff
- Shoe cost per ton of $0.095 per set
- Installation of Spokane Industries Si-Tec® ceramic Shoes
- Double wear life from standard chrome shoes
- Decrease change time and cost
- Si-Tec® wear life of 9 shifts of 8 hours (2.25x improvement)
- Change outs reduced from every 4 days to every 9 days (2.25x improvement)
- Shoe cost per ton reduced from $0.095 to $0.057 (40% Improvement)
- Reduction in change outs leads to improved safety and increased machine uptime.
Production Tonnage Increased 111% Using Si-Tec® Technology
Kolberg-Pioneer - 4500
0059311HS Si-Tec® Ceramic Anvils
Utah
"Throughput increased from 97 tons per hour to 205 tons per hour."
Baseline:
Objective:
Results:
Value delivered:
- 43”, 5 shoe table running at 1190 RPM
- Standard high chrome anvil ring
- Crushing produced high number of fines
- Recirculation rate of 40%
Objective:
- Increase production per set of anvils
- Decrease recirculation rate
- Decrease production costs per ton
Results:
- Throughput increased from 97 tons per hour to 205 tons per hour (111% improvement)
- Recirculation rate decreased to 20% (50% improvement)
Value delivered:
- Table speed reduced to 1040 RPM, reducing wear cost and machine maintainance
- Anvil ring change out improvement results in increased machine up time and improved safety
Design Improvements Reduce Wear Parts Cost per ton by 25%
Crush Boss 4156
0033035FE27 Si-Tec® Ceramic Blow Bar
Idaho, USA
Recycled Asphalt Product (RAP)
8" Minus
Recycled Asphalt Product (RAP)
8" Minus
"Production improved from 22,000 tons per set to 27,500 tons per set, a 25% increase"
Baseline:
- Horizontal impactor using four Spokane 003035FE27 Si-Tec® ceramic blow bars
- 250 Tons/Hour input
- Production of 22,000 tons per set of blow bars
- Upgrade blow bar design to improve wear life and increase machine uptime
- Reduce overall wear part costs
- Production of 27,500 tons per set (25% improvement)
- Maintained same input, output, and gradation while reducing wear parts cost
Si-Tec® Ceramic Shoes Increase Wear Life by 133%
Canica 65
00050121FE Si-Tec® Ceramic Shoes
Texas, USA
Sandstone & River Rock
2" Minus
2" Minus
"Shoe costs reduced by 60% with Si-Tec® Ceramics."
Baseline:
Objective:
Results:
Value delivered:
- 5 shoe table with standard chrome shoes
- Table speed of 1300 RPM
- 125,000 Tons Annual Production
- Standard chrome wear life of 3 X 8 hour shifts
- Two sets per week used, 520 shoes per year
Objective:
- Increase wear life of shoes by using Si-Tec ® ceramic shoes
- Reduce maintanance time for shoe change outs
Results:
- Wear life improved to 7 X 8 hour shifts (133% improvement)
- Usage reduced from 520 shoes per year to 260 per year (50% improvement)
- Shoe costs reduced by 60% with Si-Tec® ceramics
Value delivered:
- Maintenance time was reduced by 50% resulting in increased machine up-time and improved safety
Table Conversion Increases Throughput by 40%
Spokane Model 66
Tennessee, USA
Sandstone Crusher
"Recirculation rate reduced from 25% to 12.5%, a 50% improvement."
Baseline:
Objective:
Results:
Value delivered:
- 3 port rotor running at 1575 RPM with Spokane anvil ring
- 100 tons per hour input. Material backed up in rotor causing frequent production interruptions
- Output of 75 tons per hour
- Recirculation rate of 25%
Objective:
- Installation of Spokane Industries 5 shoe table fitted with Si-Tec® ceramic shoes
- Increase machine throughput
Reduce table RPM - Reduce recirculation
Results:
- 20% increase in input (100 to 120 Tons/Hour)
- 50% Reduction in recirculation rate (25% to 12.5%)
Value delivered:
- 40% Increase in throughput (75 to 105 tons/hour)
- Table speed reduced to 1150 RPM, reducing wear cost, energy costs, and machine maintenance
Table Conversion Reduces Wear Parts Cost/Ton by 80%
California, USA
1" Shot Quarry Rock
“Converting to Spokane’s open table design with Si-Tec® wear parts dramatically increased machine throughput while reducing wear parts cost.”
Baseline:
Objective:
- Anvil (ANV-80000) and 37", 5 Port Rotor configuration
- Rotor needs rebuilt every two weeks, costing up to $9,000 each replacement
- Rotor runs at 1,800 RPM, a very high amperage
Objective:
- Install 36" table, four shoe configuration with 005-0111-FE Si-Tec® ceramic shoes
- Replace standard chrome anvils with 005-2630-FE Si-Tec® Ceramic Anvils
- Decrease table RPM
- Increase machine throughput
- Reduce wear parts cost per ton
- Wear parts costs reduced 50%with Si-Tec® Technology
- 67% Increase (150 to 250 tons/hour)
- Maintenance time was reduced by 50% resulting in increased machine up-time and improved safety
- 80% Savings in wear cost per ton
- Significant energy cost savings with slower RPM
2 X Wear Life Using Si-Tec® Technology
Canica 100
005-0111-FE Ceramic Shoe
005-0143-FE Ceramic Feed Disk
California, USA
"50% Less Change outs and 25% reduction in wear parts acquisition costs."
Baseline:
- Standard chrome shoes last 2 X 10 hour shifts
- Standard chrome feed disks last 6 X 10 hour shifts
- Increase wear life of shoes by using Si-Tec®
- Increase wear life of feed disks by using Si-Tec®
- Shoes ran for 4 X 10 hour shifts - 2X improvement
- Feed disk ran for 15 X 10 hour shifts - 2.5X improvement
- 50% Less change outs resulting in increased machine uptime and improved safety
- 25% reduction in wear part acquisition cost
Si-Tec Ceramic Impeller Shoes Reduce Operation Cost Per Hour by 28%
Washington, USA
Abrassive Silicon Sand
"Wear life of Si-Tec® Ceramic Technology increased nearly four times VS standard chrome"
Baseline:
- Standard high chrome impeller shoes used in abrassive silicon sand crushing operation
- Average wear life of impeller shoes is 4 hours
- Double the wear life of shoes through Si-Tec® Ceramic Technology
- Reduce overall costs of wear parts, including maintenance and machine down time
- Wear life of Si-Tec® improved usage to 15 hours, nearly four times more than standard high chrome
- 28% Reduction in opering costs
- Improved deflection pattern improved longevity of other parts within the crushing chamber
Production Tonnage Increased 143% using Si-Tec® Technology
Mexico
Leached Ore 2.5" Minus
Leached Ore 2.5" Minus
"Anvil ring change outs reduced from 12 to 5 per year."
Baseline:
- Standard high chrome anvil ring
- 12 sets of anvils used annually
- 35,000 tons produced per anvil set
- 420,000 tons produced annually
- Increase production per set of anvils
- Decrease production costs per ton
- Production tonnage increased 85,000 tons per anvil ring set - 143% increase
- Anvil ring change outs reduced from 12 to 5 per year
- Anvil cost/ton reduced by 38%
- Anvil ring change out reduction results in increased machine uptime and improved safety