Crusher Wear Parts Success Stories

Crusher Wear Parts Success Stories

21 January 2018Clint Karlinsey

Cemco 96
0052611HS Ceramic Shoe

USA
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
Objective:
  • Installation of Spokane Industries Si-Tec® ceramic Shoes
  • Double wear life from standard chrome shoes
  • Decrease change time and cost
Results:
  • 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)
Value Delivered:
  • 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.  

31 October 2017Clint Karlinsey

Kolberg-Pioneer - 4500
0059311HS Si-Tec® Ceramic Anvils

Utah
"Throughput increased from 97 tons per hour to 205 tons per hour."
Baseline:
  • 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

17 August 2017Clint Karlinsey

Crush Boss 4156
0033035FE27 Si-Tec® Ceramic Blow Bar

Idaho, USA
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
Objective:
  • Upgrade blow bar design to improve wear life and increase machine uptime
  • Reduce overall wear part costs
Results:
  • Production of 27,500 tons per set (25% improvement)
Value Delivered:
  • Maintained same input, output, and gradation while reducing wear parts cost

27 July 2017Clint Karlinsey

Canica 65
00050121FE Si-Tec® Ceramic Shoes

Texas, USA
Sandstone & River Rock
2" Minus
"Shoe costs reduced by 60% with Si-Tec® Ceramics."
Baseline:
  • 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

02 June 2017Clint Karlinsey

Spokane Model 66

Tennessee, USA
Sandstone Crusher
"Recirculation rate reduced from 25% to 12.5%, a 50% improvement."
Baseline:
  • 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

01 May 2017Clint Karlinsey
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:
  • 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
Results:
  • Wear parts costs reduced 50%with Si-Tec® Technology
  • 67% Increase (150 to 250 tons/hour) 
Value Delivered:
  • 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

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