ME Elecmetal’s CMHC Alloy Significantly Decreases Wear Rates in Peruvian Mining Operations

The analyzed data reveals variations of -17% and -22%, respectively, in the SAG mill linings of two different clients.

Aligned with Customer Needs

Within the scope of supply contracts for shell and grate liners for a 40-foot SAG mill, ME Elecmetal identified an opportunity to help two of our clients enhance their processing capacity per campaign and achieve sustained productivity across various operational conditions.

As part of a continuous improvement initiative, ME Elecmetal developed the high-carbon CMHC alloy, specifically designed to address the challenges posed by variable and demanding mining environments, ensuring durability and reliability. The CMHC alloy’s technical attributes significantly reduced wear rates, helping our clients achieve their key performance indicators (KPIs) for productivity and efficiency.

By implementing this solution, ME Elecmetal helped minimize the frequency of unscheduled plant shutdowns, avoiding potential non-compliance with annual production plans and reducing the risk of additional maintenance costs. This proactive approach ensured improved performance while aligning with the long-term operational goals of our customers.

ME Elecmetal’s Solution

As part of a major maintenance initiative, complete relines of the SAG mills were executed, utilizing ME Elecmetal bolts. In line with our continuous improvement strategy, the optimized CMHC alloy was introduced, tested, and validated.

This innovative solution enabled sustainable processing of 19 million tons per campaign, a significant improvement over the previous range of 16 to 18 million tons. The CMHC alloy demonstrated its effectiveness in reducing wear and boosting performance.

The solution was rigorously tested and successfully validated in two of Peru’s largest mining operations, both of which concluded campaigns in 2024 on 40’x25′ SAG mills. These efforts were carried out in close collaboration with teams from both Chile and Peru, underscoring ME Elecmetal’s commitment to delivering superior, region-specific solutions for the mining industry.

Field results

Case 1: SAG Mill Performance with CMHC Alloy

  • The reduced accumulated fixed wear rate of the CMHC alloy for this test could have allowed for an additional 2.56 Mtons of material to be processed compared to the CM2duro alloy.
    • Final projection of CMHC campaign 23.38 Mton.
    • Wear rate reduction with an average wear index of 0.21
  • Increase of 12.3% (+2 Mton) in processing compared to the current alloy.
    • There were no restrictions on processing.
    • Ramp UP did not vary.

Case 2. SAG: Results with G1 CMHC Alloy

  • The reduction in the accumulated fixed wear rate enabled the processing of an additional 14.3 Mton.
    • Final campaign projection CMHC 16.2 Mton.
    • Wear rate reduction with a competition of 14.17 and an average Ai of 0.33
  • A 16% increase (+2 Mton) in current campaign processing.
    • G1 had no processing restrictions.
    • Ramp UP did not vary.

It is a milestone that these mining companies trust us with such a wide range of products and solutions. They receive world-class service, which demonstrates that—in a highly competitive market where short-term practices often prevail—we are able to cultivate strategic relationships with a long-term vision.

Iván Flores, Commercial Manager, ME Elecmetal South America

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