Initially, MC06-MC05 transfer chute was equipped with Ni-Hard liners that had a service life of only 16 weeks.
This frequent need for replacement led to increased downtime and higher operational costs. The liners, subjected to heavy wear, especially in the primary wear areas of the south and north walls, often wore down to the parent metal, resulting in blowouts and extensive damage.
Ni-Hard to ZTA
The introduction of 63mm armour ZTA ceramic liners significantly enhanced the efficiency and operational lifespan of the equipment, increasing the service life by over 400%.
To address the high wear rates and frequent maintenance, we recommended upgrading to 63mm armour ZTA ceramic liners. These liners are designed to significantly enhance wear resistance and extend service life. The proposed solution included comprehensive installation of these advanced ceramic liners in the most critical areas.
- 16 Weeks inspection: After 16 weeks, the ceramic liners showed less than 5% wear, with the logo still clearly visible. This marked a significant improvement compared to the previous liners, which by this time would have required replacement.
- 32 Weeks inspection: At the 32-week mark, overall wear remained excellent, with only about 10% wear observed on the south and north walls. The improved resistance was evident, highlighting the effectiveness of the ceramic liners.
- 48 Weeks inspection: After 48 weeks, the condition of the liners was still excellent, with minimal wear. Some distinct wear zones began to appear, but the logo was still visible on the majority of the liners. Figure 5: armour Condition at 48 Weeks
- 80 Weeks inspection: At 80 weeks, the overall condition of the liners remained good. No additional work was conducted during this period, and the wear was minimal, demonstrating the long-term durability of the ceramic liners.
Service Life Evolution
The transition from traditional liners to 63mm armour ZTA ceramic liners resulted in a remarkable improvement in service life. The service life increased from 16 weeks to over 80 weeks, representing a 400% improvement with significant wear life remaining. This extension in service life reduced the need for frequent maintenance and improved safety by reducing exposure to hazardous conditions during shutdowns, while also minimizing the environmental risks associated with frequent maintenance activities.
Conclusion
The introduction of 63mm armour ZTA ceramic liners significantly enhanced the efficiency and operational lifespan of the equipment, increasing the service life by over 400%. This upgrade not only reduced the frequency of maintenance interventions but also lowered operational costs and minimized safety risks. The success of this case study suggests that similar improvements can be achieved in other high-wear applications within the mining industry, making products an excellent choice for extending equipment service life and enhancing overall productivity.
By adopting armour ZTA ceramic liners, mining operations can achieve longer-lasting protection, reduced downtime, and significant cost savings, demonstrating the value and effectiveness of products in demanding industrial environments.
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