Crusher Wear Parts Success Stories

Crusher Wear Parts Success Stories

mt-carmel-shoes.jpg

Cemco 80 - VSI Crusher
0052717HS Si-Tec® Ceramic Shoe

USA

"Wear life for the shoes improved by 200%, going from 24 hours to 72 hours"
Baseline:
  • 6 shoe table running at 1700 RPM
  • Feed Size of 1” X 2”
  • Output size of 1/4” Minus
  • OEM standard chrome shoes - 24 hours run time per set
Objective:
  • Extend wear life of shoes while maintaining the same     finished product and output
Results:
  • The Si-Tec®ceramic shoes lasted 72 hours, more than three times the run time of standard chrome shoes
  • Maintained the same output size and finished product
Value Delivered:
  • Fewer change outs results in increased machine up time and improved safety
...

0050113hs-web.jpg

Terex - Canica 2350 VSI Crusher
0050113HS Si-Tec® Ceramic Shoe

USA
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)
Objective:
  • Increase tons per hour per set of shoes
  • Extend wear life of castings
Results:
  • Throughput increased from 18,000 tons per set of shoes to 24,760 tons per set (28% increase)
Value Delivered:
  • Fewer change outs results in increased machine up time and improved safety
...

feed-disk-cropped.jpg

Cemco 70
337-7143HS Feed Disk
337-7115HS Ceramic Shoe

TN, USA
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
Objective:
  • 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
Results:
  • 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
Value Delivered:
  • 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
...

0052611-web-small2.jpg

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.  
...

production-tonnage-increased-111-percent.png

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
...

wide-top.jpg

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
...

si-tec-shoe-sized.jpg

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
...

crushed-rock-sized.jpg

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
...

shoe-table-sized.jpg
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
...

123.jpg
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
Objective:
  • Increase wear life of shoes by using Si-Tec®
  • Increase wear life of feed disks by using Si-Tec®
Results:
  • Shoes ran for 4 X 10 hour shifts - 2X improvement
  • Feed disk ran for 15 X 10 hour shifts - 2.5X improvement
Value Delivered:
  • 50% Less change outs resulting in increased machine uptime and improved safety
  • 25% reduction in wear part acquisition cost
 ...

sand-good-sized.jpg
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
Objective:
  • Double the wear life of shoes through Si-Tec® Ceramic Technology
  • Reduce overall costs of wear parts, including maintenance and machine down time
Results:
  • Wear life of Si-Tec® improved usage to 15 hours, nearly four times more than standard high chrome
  • 28% Reduction in opering costs
Value Delivered:
  • Improved deflection pattern improved longevity of other parts within the crushing chamber
...

verticle-table-sized.jpg
Mexico
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
Objective:
  • Increase production per set of anvils
  • Decrease production costs per ton
Results:
  • Production tonnage increased 85,000 tons per anvil ring set - 143% increase
  • Anvil ring change outs reduced from 12 to 5 per year
Value Delivered:
  • Anvil cost/ton reduced by 38%
  • Anvil ring change out reduction results in increased machine uptime and improved safety
...
© 2019 Spokane Industries. All Rights Reserved.

This site uses cookies to enhance your experience.  Click "More" to learn about our use of cookies, and about our Privacy Policy.