How Metso Cone Crushers’ Constant Liner Performance Boosts Output

three cone crushers on a field

With over a century of expertise in crushing technology, Metso is the proven leader in developing high performance cone crushers that deliver exceptional productivity for aggregate operations. One of the keys to maximizing crushing productivity is ensuring consistent performance over the lifetime of the liners.

Metso’s engineered liner solutions retain their optimized profile and chamber geometry throughout extensive wear life, enabling stable, high-quality output over long periods. By maintaining constant crushing action as liners wear, Metso cone crushers boost throughput, product quality, and profits.

The Role Of Liners In Cone Crusher Performance

Cone crusher unitThe replaceable liners installed in a cone crusher play a pivotal role in proper crushing action and product sizing. As feed material enters the crusher, the liners compress the material between the mantle and bowl lining, breaking it by compression and shearing forces.

The liner profile influences the product gradation, shape, and capacity. Worn liners can result in poor crushing action and uneven wear, degrading performance. Metso utilizes an advanced Chamber Optimization Program to engineer liners that match specific feed material and operational goals.

Extensive simulation modeling and real-world testing ensure the liners are designed for optimal crushing from day one through the entire service life. Maintaining the chamber geometry and linear profile is essential for consistent performance.

Maximizing Liner Wear Life

The wear life of crusher liners is affected by many variables, including the type and hardness of processed material, the set closed side setting (CSS), the size of the chamber, and exposures to abrasive contaminants.

Metso utilizes superior alloys and casting methods along with specialized surface treatments and geometry to produce liners that withstand extended service under diverse conditions. The result is dramatically increased liner lifetimes.

Longer liner wear life provides a number of important benefits:

  • Less downtime for liner changes: Changing worn liners requires scheduled maintenance outages. Longer wear life significantly reduces the frequency of change-outs.
  • Lower operating costs: With extended lifetimes, fewer liner sets need to be purchased and installed over time. This results in major cost savings.
  • Higher production capacity: More uptime translates directly into higher throughput. Production is not interrupted as often for liner changes.

For instance, when Mexicana de Cobre replaced their previous cone crusher liners with Metso’s optimized liners, the wear life increased from 35% to 60% efficiency in producing the target <1⁄2” product. Throughout the entire service life, with the Metso liners, the crushers can handle higher throughput.

Maintaining Optimal Crushing Profile

Along with wear life, retaining the ideal profile is essential for cone crusher liners. The exact chamber geometry and liner contour direct the crushing forces to maximize performance.

As liners wear, the shape of the profile changes, impacting the size distribution, shape, and capacity of the crushed product. Off-spec material requires reprocessing, hurting productivity.

Metso utilizes advanced casting techniques and alloys that resist deformation and abrasion. The liners maintain the designed profile, shape, and clearance throughout the wear life, ensuring properly sized output.

Benefits Of Maintaining The Optimized Liner Profile

Retaining the ideal liner profile is just as important as extending wear life for optimal cone crusher performance. When the profile geometry remains constant, it provides key benefits, including:

  • Consistent product size and shape: The optimized profile ensures the proper gradation and particle shape is maintained as liners wear. This prevents inefficiencies from off-spec material.
  • Full throughput capacity: The ideal chamber shape enables maximum crushing forces and capacity. As liners wear, the crushing forces remain optimized.
  • Higher yield: When the profile is maintained, less material ends up outside the target size range, boosting sellable product yield.
  • Less rework: On-spec material requires no re-crushing, thereby improving operational efficiency.

Metso Liner Performance: Real-World Results

Metso customers around the globe have experienced remarkable gains in productivity and profitability thanks to the unparalleled performance of Metso cone crusher liners:

  • rock crusher parts on pallets ready for shipmentMexicana de Cobre: Optimized Metso liners enabled their Hydrocone tertiary crushers to produce the needed 1⁄2” feed for grinding from the start. Liner efficiency jumped from 35% to 60% fine generation, increasing throughput over the liner lifetime. Pressure also remained more stable during crushing.
  • Milpillas Mine: Replacing OEM liners with Metso’s optimized liners quadrupled the wear life from 6 to 24 months. The longer life slashed liner-change downtime from 36 hours to just 6 hours. This boosted equipment availability and enabled higher production.
  • Beira Rio Aggregates: Installing HP300 crushers with Metso liners led to a 70-80% increase in basalt production over the previous plant. Metso’s crushing solutions also improved product quality while reducing power consumption.

Optimize Your Crushing Operations With Metso Liners & Assistance From Mellott

Through advanced engineering and extensive testing, Metso has mastered the art of designing cone crusher liners that maintain their optimized profile and chamber geometry over long wear life. This enables Metso cone crushers to deliver remarkably consistent crushing performance.

Keeping output and efficiency stable over time leads to substantial gains for aggregate operations, including increased throughput, uptime, yield, and quality. Finding the ideal liner solution tailored to your specific needs requires expertise, which is exactly what Mellott can offer you.

As an authorized Metso distributor, we offer a full inventory of compatible Metso parts. Our experienced staff can assess your operation, select optimized Metso liners, and ensure proper installation and maintenance. Contact us today at 888.621.8533 or online to learn more about how Metso’s liner solutions can boost your crushing productivity and profitability.