Programas ME FIT

ME FIT Grinding

Ofrecemos soluciones integrales y técnicas para equipos de todas las marcas y tamaños, desde auxiliares hasta molinos SAG de 40’.

ME FIT Crushing

Contribuimos a la eficiencia de la etapa inicial de la conminución de mineral, enfocándonos en la mejora de los indicadores estratégicos de los clientes.

ME FIT Mine

Programa de soluciones de optimización que generan beneficios en el proceso de extracción y transporte de minerales integrando consultoría, productos y servicios.

Productos y servicios

Chancado

Proveemos componentes de desgaste con diseños y aleaciones específicamente desarrolladas para cada aplicación y ubicación dentro de cada chancador.

Molienda

Somos líderes mundiales en el diseño y suministro de revestimientos de alta ingeniería para molinos SAG, AG, de bolas, tower mills y de barras.

Medios de molienda

Gran capacidad de fabricación y diseño para todo tipo de molinos, desarrollando productos propios y sometiéndolos a ensayos y pruebas que aseguren un desempeño óptimo en operación.

Pirometalurgia

Más de 100 años de experiencia que nos validan como proveedor estratégico en la industria.

Soluciones digitales

Soluciones tecnológicas que agregan valor a los procesos mineros para la toma de decisiones y recomendaciones oportunas a clientes de ME Elecmetal.

Mining 4.0

ME Digital Lab

ME Elecmetal combina tecnología e innovación para servir a la industria minera mundial con soluciones integrales para optimizar los procesos.

The M7 alloy enabled higher ore throughput, extended liner life, and reduced maintenance requirements.

The Challenge: Increasing Campaign Life Without Compromising Operations

Our customer identified the need to improve campaign life and throughput performance in the MP-1250 secondary crushers at the C2 Concentrator, while maintaining the integrity of critical equipment components and ensuring no negative impact on operational performance.

To address this challenge, a study was conducted to evaluate the M7 alloy while maintaining the OEM liner geometry. The assessment also considered the use of the remaining liners available in the secondary crushers.

As a performance benchmark, the customer had been using ME Elecmetal’s M3 alloy liners, which historically achieved an average campaign life of 23 days and processed approximately 440,000 tonnes of ore per campaign.

The Proposed Solution

Based on the baseline established for the trial, ME Elecmetal proposed the implementation of the M7 alloy, while maintaining the original OEM mantle and bowl liner geometry in the MP-1250 secondary crushers and introducing an enhanced material composition. This new alloy features a higher manganese content than the M3 alloy, along with chromium and molybdenum additions designed to improve wear resistance and extend liner life without compromising the integrity of the crusher components.

The solution was designed to optimize operational performance through increased liner durability, enabling longer operating cycles and higher throughput per campaign. It was also intended to better withstand the highly abrasive and hard ore processed at the C2 Concentrator, supporting a more demanding and sustained operation.

In this context, the M7 alloy emerged as a technical alternative that delivers significant material improvements without modifying the liner geometry, aligning with both operational efficiency and sustainability objectives.

During the implementation phase, four trials were conducted on four MP-1250 secondary crushers.

Activities Performed

  • Monitoring of mantle and bowl liner assembly on the Head and Bowl Frame structures.
  • Review of installation activities and verification of operational start-up for each secondary crusher.
  • Initial bowl height measurements were recorded on each unit to establish the wear baseline:
    • Crusher 1 → 22.63″
    • Crusher 2 → 23.31″
    • Crusher 3 → 22.50″
    • Crusher 4 → 22.87″

In addition, the solution proposed by ME Elecmetal included a technical protocol jointly agreed upon by both parties, covering the following elements:

  • Technical Support During Installation: ME Elecmetal provided on-site assistance during the installation and commissioning of the liners in the MP-1250 crushers.
  • Operational Monitoring: ME Elecmetal conducted field visits and issued Campaign Performance Reports and Weekly Reports to monitor the operational variables influencing ore processing performance.
  • Success Criteria – Liner Life: The trial would be considered successful if the liners achieved an operating life of 22–25 days or more, under the defined operating parameters and with a processed throughput of 600,000 tonnes.
  • Success Criteria – Equipment Integrity: The trial would be considered successful if the liners did not cause operational issues in any critical crusher components, including the mainshaft, upper and lower bushings, socket, and socket liner.
  • Final Report: ME Elecmetal would issue a final assessment report containing recommendations to ensure the sustainable performance of wear components, suggestions for operational variable adjustments, and validation of the M7 alloy’s suitability under real operating conditions.

Benefits

Sustainability

CO₂e emissions are reduced by approximately 38 tonnes per year (25%), driven by a decrease in liner consumption from 128 to 96 sets annually, thanks to the extended campaign life achieved with the M7 alloy.

Safety

Both the M3 and M7 alloy campaigns demonstrated a uniform wear profile, with no critical wear zones observed on the mantle. The customer confirmed that ME Elecmetal liners do not cause damage to key crusher components, including the mainshaft, bushings, eccentric assembly, and socket assembly, ensuring operational continuity and preventing failures in critical parts.

Reliability

Both the M3 and M7 alloy campaigns demonstrated a uniform wear profile, with no critical wear zones observed on the mantle. The customer confirmed that ME Elecmetal liners do not cause damage to key crusher components, including the mainshaft, bushings, eccentric assembly, and socket assembly, ensuring operational continuity and preventing failures in critical parts.

Maintainability

The service life of the liners was extended, reducing the annual replacement frequency by 25%. This represents approximately 96 liner changes per year across the eight crushing units.

Throughput

A 37% increase in abrasive ore processing was achieved, driven by improvements in liner material composition that enhanced wear resistance and overall performance.

Availability

The M7 alloy delivered 7 additional operating days compared to both the OEM-supplied liners and the M3 alloy, improving operational continuity and reducing downtime.

Performance Results

The main results obtained during the M7 alloy trial are summarized below.

The table presents the cumulative throughput achieved during the M7 alloy campaigns:

MP-1250 Crusher Alloy Installation Date Removal Date Campaign Days Throughput (DMT)
Ch1 M7 10/16/2025 11/17/2025 33 605,604
Ch2 M7 10/27/2025 11/22/2025 26 412,080
Ch3 M7 10/31/2025 12/05/2025 35 521,937
Ch4 M7 01/02/2026 01/26/2026 24 567,015

Throughput Increase

  • M3 Alloy Baseline: Average throughput of 440,000 tonnes per campaign.
  • First M7 Trial (Ch1): 605,604 tonnes processed, representing a 37.64% increase, equivalent to an additional 165,604 tonnes compared to the M3 alloy baseline.

The following table shows projected throughput for the M7 campaigns, considering a liner replacement limit of 8.5 inches:

MP-1250 Crusher Initial Bowl Height Final Bowl Height Total Wear Travel Throughput (DMT) Projected Throughput
Ch1 22.63 8.88 13.75 605,604 605,604
Ch2 23.31 11.88 11.43 412,080 520,237
Ch3 22.50 9.94 12.56 521,937 565,986
Ch4 22.87 8.75 12.34 567,015 567,015

The chart below illustrates the cumulative throughput achieved with ME Elecmetal’s M3 and M7 alloys in the crushing process, highlighting the performance improvement delivered by the M7 alloy:

Observed Operating Conditions

  • Chamber Fill Levels: The correlation between power consumption (kW) and lubrication pressure (PSI) is a reliable indicator of the crushing chamber fill level. During the evaluated M7 campaigns, chamber fill levels ranged between 59% and 61%, which is below the recommended threshold for the MP-1250 model. Optimal operation of this crusher requires a minimum effective chamber fill level of 70%.

Chamber Fill Level During the M7 Campaign:

Power (kW) vs. Pressure (PSI) Variable Correlation:

  • Feeder Speed (Crusher Feed Rate): During the M7 campaigns, feeder speed was maintained between 65% and 70%, indicating available room for improvement through higher feed rates and optimized chamber fill levels.

Feeder Speed During the M7 Campaign:

Key Results:

Soluciones

Programas ME FIT

Productos y servicios

Mining 4.0

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