How to optimize the ton ore cost of wear-resistant parts through scientific selection and maintenance

In mining and sand and gravel aggregate production, wear-resistant accessories such as jaw plates, rolling mill walls, and plate hammers are key consumables for maintaining continuous operation. Its cost control should not only focus on the purchase unit price, but also on the core operational indicator of ton ore processing cost. This indicator comprehensively reflects the service life, efficiency, and comprehensive maintenance expenditure of accessories. Optimizing this cost through systematic selection and maintenance strategies is an important way to achieve refined operations.

1、 Establish core cost evaluation indicators: ton ore cost

The cost per ton of ore (CPT) is a direct indicator for evaluating the economic viability of wear-resistant components, calculated using the following formula:

Cost per ton of ore (CPT)=(accessory procurement cost+labor and downtime cost for replacement)/total tonnage of ore processed during the accessory cycle

The optimization goal is to reduce CPT values, which can be achieved by significantly increasing the total processing tonnage within controllable accessory procurement costs. Pursuing only low-priced accessories or solely pursuing long-life accessories may not achieve the optimal solution for CPT.

2、 Scientific selection: based on working condition matching, not just experience

Selection is the starting point for determining CPT, and should be based on an objective analysis of the operating conditions.

Refined working condition diagnosis:

Material analysis: Clarify the compressive strength, abrasion index (Ai value), quartz content, and maximum feed particle size of the ore. For example, high impact and high abrasion conditions require a balance between material toughness reserve and wear resistance.

Equipment and process parameters: Confirm the crusher model, chamber type, operating speed, discharge port setting, and expected production capacity.

Technical material selection decision:

Abandoning the idea of "universal materials": Different materials have their reasonable application boundaries. For example, high manganese steel relies on impact to achieve work hardening, which may not be as economical as medium alloy steel in low impact fine crushing positions; High chromium cast iron has high hardness but limited toughness, and there is a risk of fracture in the coarse crushing stage.

Adopting differentiated configuration: for example, in jaw crushers, materials with higher toughness (such as Mn22Cr2) can be selected for the dynamic jaw plate that can withstand complex impacts, while materials with more outstanding wear resistance can be selected for the fixed jaw plate that is mainly subjected to extrusion wear. This "one movement, one stillness" strategy helps to synchronize wear and tear and improve overall economy.

Consider composite technology: For severely worn local areas, cast in composite wear-resistant parts are used, utilizing a high toughness matrix to resist impact and a high hardness inlay to resist wear, thereby extending the overall service life.

Supplier evaluation and cooperation:

Choose suppliers who can provide material performance data (such as impact energy, metallographic reports) and conduct selection analysis based on working conditions.

Assess its ability to ensure production consistency, quality control, and key processes such as heat treatment.

3、 Systematic maintenance: ensuring performance and extending effective lifespan

Even the best accessories require proper maintenance to maximize their design performance. The core of maintenance is to prevent abnormal early failures.

Standardized installation:

Ensure good contact between the support surface: Clean the back of the frame and accessories before installation, and use special gaskets or grouting materials to fill the gaps if necessary to avoid accessory breakage due to insufficient support.

Tighten as required: Use a torque wrench to tighten the bolts in the order and torque required by the manufacturer, and re tighten them at the beginning of operation.

Optimize process operation:

Maintain uniform feeding: Avoid segregation or intermittent feeding, which can lead to local over grinding and uneven equipment load.

Set up a reasonable discharge port: avoid running under a too small discharge port for a long time, as this will intensify the lamination grinding and accelerate wear.

Effective use of iron protection device: Ensure the normal operation of the iron remover and hydraulic iron protection system to prevent damage to accessories caused by unbreakable objects.

Implement preventive inspections:

Regularly inspect the wear and tear of accessories, the tightening status of bolts, and the vibration of equipment.

Record wear data to provide a basis for predicting replacement time and the next round of selection.

4、 Establish a closed-loop system for cost tracking and continuous improvement

Data based archive management:

Establish a file for each batch/set of key wear-resistant accessories, recording their model material, supplier, installation date, replacement date, total processing tonnage, and final CPT.

Take photos of early failed components and record possible causes.

Periodic cost review and analysis:

Regularly (such as quarterly or annually) analyze the average CPT of different equipment and components made of different materials.

Compare the long-term economy of different suppliers or technical solutions, not just the initial purchase price.

Establish feedback and optimization mechanisms:

We will use the results of data analysis to provide feedback to suppliers and jointly explore the possibility of further optimizing material selection or design.

Solidify mature selection and maintenance standards into standard operating procedures (SOP), and provide training for operation and maintenance personnel.