How to manage the configuration and inventory of crusher liners under changing mineral layers

The decision of whether to reserve multiple lining plates and how to manage them for different hardness ore layers in the same mining area requires a comprehensive consideration of technical adaptability, operational stability, and overall cost. The following are suggestions based on technical analysis and operational management perspectives.

⚖️  Decision analysis: Should we reserve multiple lining plates?

The core decision depends on the range of hardness fluctuations in the ore layer and the actual impact it has on production.

Considering dimensions, it is recommended to reserve multiple lining plates/cavity types and unify lining plate standards

The degree of material fluctuation is extremely high. For example, the alternating occurrence of extremely hard and medium hard ores with compressive strength differences exceeding 100MPa in the ore layer (such as alternating dense basalt and porous limestone). Small or controllable. The hardness fluctuates within a reasonable range, or the feeding properties can be stabilized through mineral blending and pre mixing processes.

The impact on production is significant. The rapid wear of a single lining plate in hard rock layers leads to frequent unplanned shutdowns; In soft rock layers, due to insufficient impact and insufficient work hardening, there is also abnormal wear and tear. Limited. The lifespan and efficiency of the unified lining plate may fluctuate under different ore layers, but they are still within an acceptable range of operational flexibility.

The cost and complexity can accept higher inventory capital occupation and management costs in exchange for production continuity and total cost control. Pursuing inventory simplification and economies of scale in procurement, tending to adapt to changes by adjusting operational parameters such as discharge ports and feeding speeds.

Decision suggestion:

Usually, for most mining areas, it is recommended to adopt the strategy of "one main material+targeted adjustment". Select a material with relatively balanced comprehensive performance (such as Mn18Cr2 or Mn22Cr2 high manganese steel) as the standard lining plate, and optimize the replacement cycle and operating parameters by monitoring its wear data under different ore layers.

Special circumstances: Only when the hardness difference of the ore layer is extremely significant and has led to clear and quantifiable high cost or low efficiency issues with a single lining scheme (such as a sharp increase in the cost per ton of ore, frequent unplanned shutdowns), should the evaluation of two lining schemes be considered. For example, reserve materials with higher toughness and hardness for extremely hard mineral layers, and retain standard materials for conventional mineral layers.

 Inventory management strategy for stocking multiple lining plates

If it is decided to reserve, scientific management is crucial, with the goal of achieving a balance between ensuring supply and minimizing capital occupation.

Establish a data based consumption prediction model

Core: Don't guess based on experience. A database of ton ore consumption life should be established for each type of lining plate based on its corresponding specific ore layer.

Method: Record the tonnage of ore processed for each replacement of the ore layer. By accumulating long-term data, the average service life (tons/set) of each lining plate under the corresponding ore layer is obtained. By combining the medium and long-term mining plan of the mine, it is possible to accurately predict the consumption of various lining plates during a specific period of time in the future.

Implement differentiated inventory control methods (ABC classification method)

Class A (key, high-value): dynamic cone crushing wall and fixed cone rolling bowl wall. They have the highest value and the greatest impact on production. We should adopt a continuous inspection and low inventory strategy, set safety stock and clear reorder points to ensure uninterrupted supply while reducing capital occupation.

Class B (medium): such as bowl shaped bearings, spindle bushings, and other key accessories. It can be managed through regular inspections (such as monthly) to maintain moderate inventory.

Class C (low value, consumable): such as seals, ordinary bolts, etc. Batch ordering and simplified management with higher inventory levels can be adopted to ensure supply and reduce management effort.

Develop clear inventory decision-making rules

Safety stock level: To cope with sudden changes in mining plans or logistics delays, a safety stock (usually 1 set) is set for each critical lining plate. When the inventory drops to "safety stock+expected consumption within the procurement cycle", the procurement process is triggered.

Economic order quantity: Weighing between procurement frequency and single purchase cost, calculate the single order quantity that can make the total inventory cost relatively low.

Utilizing digital tools and collaborative mechanisms

System support: When conditions permit, utilize the inventory module of the Equipment Maintenance Management (CMMS) or Enterprise Resource Planning (ERP) system for management, achieving automation of consumption tracking, inventory warning, and procurement processes.

Departmental collaboration: Inventory management is not solely the responsibility of the procurement department. It requires close communication with the production planning, geology, and equipment maintenance departments to ensure that inventory strategies can dynamically respond to changes in mineral deposits and equipment operation status.

 Summary and final recommendations

In the face of fluctuations in the hardness of the ore layer, it is recommended to prioritize optimizing operations and selecting a single lining plate to cope. Reserve multiple lining plates is a backup plan for dealing with extreme situations and requires careful decision-making.

Suggested action path:

Assessment and quantification: Firstly, quantify the fluctuation range of the hardness of the ore layer, and evaluate whether the current single lining plate scheme has significant disadvantages in terms of ton ore processing cost and shutdown frequency under different ore layers.

Simulation and trial calculation: If the disadvantage is obvious, can the potential benefits of increased lifespan and reduced downtime brought by introducing the second type of lining cover the additional procurement, warehousing, and management costs.

Small scale verification: If the simulation is feasible, a small batch purchase trial can be conducted first to collect real data, verify the economy, and then decide whether to include it in regular inventory.

Building a management system: Once a decision is made to reserve, immediately establish the inventory management system described above, with data-driven and ABC classification as the core, to avoid blind stocking.