TTM-5004-B

MP SERIES CRUSHER
Crusher Liners Presentation

Crusher Liners

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The Mantle and Bowl Liner

BOWL LINER

MANTLE

Crusher Liners

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Backing Material
Standard Backing
Standard backing is a general purpose backing material used in Cone Crushers under normal
operating conditions. This backing material has a compressive strength of 16,000 PSI and a
cure time of 6 hours at 70F.

HP Backing
HP backing is an intermediate strength backing material used in Cone Crushers such as the
HP200 to HP500 and all Omnicones operating in tougher applications. This backing
material has a compressive strength of 16,500 PSI and a cure time of 5 hours at 70F.

WF Backing
WF backing is an ultra performance backing material used in such Crushers as the MP800 &
MP1000 in highly demanding applications. This backing has a compressive strength of
18,000 PSI and a cure time of 7 hours at 70F.
Note: Zinc should not be used as a liner backing material as the high temperature may
dimensionally damage the head bore!
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What Causes Liner Wear

The characteristics of the material being crushed, abrasiveness and
hardness, determines how long liners will last.
The abrasiveness of the rock being
crushed is measured as an Abrasion Index
number. The hardness of the rock being
crushed is measured as a Work Index
number.
The abrasiveness of the rock is what
wears the liner material away.
The hardness of the rock dictates how
much rock you can crush with a given
amount of horsepower.

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Abrasiveness and Hardness

Non-Abrasive Material
Canadian Kimberlite (NWT)
Ohio Limestone
Wisconsin Limestone

Abrasion Index

Work Index

0.01
0.02
0.05

5.8
13.5
14.1

0.28
0.21
0.56
0.26

10.7
6.6
17.2
11.1

0.78
0.94
0.73

14.0
7.5
12.3

Abrasive Material
Alabama Basalt
South Dakota Rhyolite
Canadian Granite (ONT)
Utah Copper Ore

Very Abrasive Material

Oklahoma Granite
Nevada Gold Ore
Arizona River Gravel

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Crushing is Done in Stages

As no one single Crusher can reduce shot rock or large gravel to
finished product sizes, crushing must be done in stages. The table below
lists the stages of crushing in a typical crushing plant.

Stage

Type of Crus he r

Approxim ate Se tting

Primary - 1st

Jaw or Gyratory

4" (100mm) to 8" (200mm)

Secondary - 2nd

Standard Cone or HSI

1-1/2" (38mm)

Tertiary - 3rd

Short Head Cone or HSI

3/8" (10mm)

Quaternary - 4th

HP Cone, Gyradisc, VSI

Less then 1/4" (6mm)

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Standard & Shorthead Crushers

Standard
Applied in the second (secondary)
stage
Normally produces products over 1"
(25mm)
6 to 8:1 maximum ratio of reduction
Usually operated in open circuit
Normally is not choke fed
Normally prepares the material for
the next stage of crushing

Shorthead
Applied in the third (tertiary) stage
Normally produces products under 1"
(25mm)
4 to 6:1 maximum ratio of reduction
Usually operated in closed circuit
Operated choke fed for best results
Normally produces the desired
products

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Standard Liner Example

The liner shown to the left

illustrates the difference
between the open side feed
opening dimension and the
closed side feed opening
dimension of an MP1000
Standard coarse liner.

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Shorthead Liner Example

The liner shown to the left

illustrates the difference between
the open side feed opening
dimension and the closed side
feed opening dimension of an
MP1000 Short Head coarse liner.

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Converting Liner Configuration

Wedge Bolts

Bowl Ring
(MP1000 only)

Bowl Liner

All MP Crushers can be converted

from a standard crusher
configuration to a short head
crusher configuration or vice versa
at anytime.
The only item that changes is the
liners.
The quantity of backing material
required will also change.

Bowl

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Open & Closed Crushing Circuits

OPEN

CLOSED

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Crusher Setting Suggestion

To optimize production, the correct cone Crusher closed side
setting must be maintained. As a "rule of thumb" a cone
Crusher operating in closed circuit should be set at:

MP Crushers
1/8 (3mm) larger than or equal to the cloth size the system is closed on

Note: The setting of a Crusher operating in open circuit is based on the wanted top size
of that product.

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Product Size vs. Setting

CRUSHER SETTING VS. PRODUCT SIZE
MP Crushers
Approximately 80% (*) of the material coming out of an MP cone
Crusher will be passing its closed side setting dimension.

Note: (*) True as long as the MP crusher is choke fed.

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Setting Compared to Power Draw

2.4

A small change in setting

results in a large change in
power draw.

2.2
2.0

Horsepower / Ton

1.8

1.7 HP / Ton @ .3" c.s.s.

1.6
1.4
1.2
1.0

.9 HP / Ton @ .35" c.s.s.

.8

There will always be a

direct relationship of
quantity of material
produced in comparison to
power being used.

.6
.4
.2
0
0"

.1"

.2"

.3"

.4"

.5"

.6"

Closed Side Setting

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Maximum Feed Size

MP Crushers
100% of the Crusher feed material should be equal to or smaller than
the liners closed side feed opening dimension

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Maximum Feed Size

Closed Side Feed Opening - 5.09
Open Side Feed Opening - 6.91

Closed side feed opening is 5.09",

maximum feed size for an MP Crusher
would be 5.09"

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Concerned About Throughput

If at some point in time, your concerned about the quantity of material
passing through your cone Crusher, you can make a capacity check to
determine actual Crusher throughput and compare it to the capacity chart
in the instruction manual.

S x W x 60
2000

TPH

S = belt Speed (FPM)

60 = 60 minutes in one hour

W = Weight of 1 foot of material

2000 = 2000 pounds per short ton

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Commit to A Liner Study

The following three exercises can be completed in the field
by anyone who is concerned about the liners that are being
used. This liner study is used to determine if the liners
being used are correct for the application.
1) Create a Liner Wear Profile
2) Calculate the Amount of Liner Utilization
3) Determine the Crushers Ratio of Reduction

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Create a Liner Wear Profile

Cut through a mantle / bowl liner from top to
bottom vertically
Trace the wear profile on paper or cardboard
Send wear profile to Metso Minerals
We scan the worn profile
We will compare the worn profile to a new
profile via computer image overlapping

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Determine Liner Utilization

Weigh the worn mantle and
bowl liner
Weigh the new mantle and
new bowl liner
Calculate the amount of liner
utilization

Note: As a rule of thumb, the amount of weight in percentage that you can expect to
utilize if the application is correct is 50%

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Determine the Ratio of Reduction

Calculate the Ratio of Reduction thats taking
place in your Crusher by:
Take samples of the feed and product
Run sieve analysis on samples
Determine sizes for 80% of feed and product
Divide F80 by P80
The result is the Ratio of Reduction

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Calculate the Ratio of Reduction

FEED

PRODUCT

Size

Cum ulative
% Passing

Size

Cum ulative
% Passing

5" (127mm)

100%

1-1/2" (38mm)

100%

3" (76mm)

55%

7/8" (22mm)

97%

1-3/4" (44mm)

28%

3/4" (19mm)

76%

1-1/2" (38mm)

22%

1/2" (13mm)

43%

7/8" (22mm)

4%

3/8" (10mm)

29%

4M (4.75mm)

13%

8M (2.36mm)

7%

Material samples are taken of the feed entering the Crusher and discharging out of
the Crusher. Sieve analysis is completed on both samples.
Example above: F80 (4.0) P80 (.79) = Ratio of Reduction (5.06:1)

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Use The Proper Liners

Use the correct liners to make your products......
Feed size to the Crusher determines the style of liners to be used (top size feed must
fit in crushing cavity)
The Ratio of Reduction should not exceed 4 to 6:1 in a short head or 6 to 8:1 in a
standard (Crusher must not be operated below it's minimum setting)

Note: A gradual decrease in product being produced usually means that the liners are
worn out (liner feed opening closes off as liners wear away)

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Keep in Mind..
To operate continuously with liners unsuited for the
operation will result in:
Uneconomical wear of the liners (poor liner wear profile)
Inefficient crushing (poor ratio of reduction)
Abuse to the Crusher (possibility of incorrect bearing alignment)

Crusher Liners

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Product Quality Keys

To maximize product quality and uniformity, the
following points must remain consistent:
Keep the Crusher feed gradation consistent by maintaining consistent Crusher
settings (all Crusher settings)
Maintain consistent feed distribution (center feeding a must)
Eliminate feed segregation
Run at a consistent cavity level (12 above the feed plate)
Operate at a consistent power draw

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Incorrect Liner Example

If Feed Size is too Large
Feed material percolates around
the feed opening
Production decreases as the feed
opening is bridged over
Volume limit is exceeded at
minimal power draw

TOO BIG!

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Incorrect Liner Example

If Feed Size is too Small
Majority of crushing takes place in the
lowest portion of the cavity
Production decreases due to a poor
ratio of reduction
Power and/or force limit of the
Crusher is exceeded at a minimal
volume level
Risk of improper bearing alignment

TOO SMALL

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Capacity Dropping Off

Typical reasons that capacity begins to drop off:
Feed opening has closed off
Extremely slabby feed
Incorrect feed distribution
Feed contains a high amount of debris
Tilted adjustment ring

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Long and Short Liners

The difference between long and short liners:
Usually, long liners will allow the Crusher to do more work than short liners (draw
more power).
The extra work will usually show up in the generation of a finer product, rather than
higher production.
Long liners may help generate a more cubical shaped product.

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Use Matched Liners!

Mixing and matching liners by accident or on purpose usually does
not work. Liners are designed to be used as a matched set. Using a
matched set of liners assures that the nip angle between the mantle
and bowl liner is correct thus giving optimum performance.
Make certain you are using matched liners
Use the correct mantle with the correct bowl liner
Use a long mantle with a long bowl liner
Use a short mantle with a short bowl liner
Use a new mantle with a new bowl liner

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Tips to Extend Liner Life

Follow these steps after new liners are installed:
Operate 50% rated power (65% amps) with a full cavity for 6 hours.
Operate 75% rated power (80% amps) with a full cavity for 2 hours.
Operate at or near 100% rated power (100% amps) from this point on.

The following items must in place:

The Crusher normally operates near full power draw
Increasing the Crusher setting in order to operate at the lighter power levels does not
effect the crushing circuit.

Note: Metso Minerals has found that when customers have followed this procedure, they
have seen as high as 30% increases in liner life.

Crusher Liners

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Tips to Extend Liner Life

Limit the quantity of water used to control dust!
Many times water is used above the Crusher to control dust.
Too much water can cause fines to be washed down the face of the mantle which can cause
premature liner wear.

* Keep a material load on the Crusher all day!

The MP head rotates quickly clockwise while operating no load.
When feed enters the crushing cavity, it rubs against the fast moving mantle and if done
frequently throughout the day (switching from load to no load), it may prevent the liners
from work hardening properly.
Liners will work harden and get tougher if you can maintain a steady feed rate to the
crusher all day long.
Note: * The MP800 is available with an Anti-Spin system that prevents the head from
turning during no-load operation.
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Storing Liners
Store liners right side up to prevent distortion of the liner (egg shaping) and keep them in
matched sets to prevent confusion at liner change time.

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Considering Thick Liners?

There must be a minimum of 1 bowl threads
engaged into the adjustment ring threads in
order to keep the bowl tight while crushing.
The potential problem when using thick liners is
a lack of thread engagement. This can lead to
thread damage and very costly repairs.
Thick liners increase the feed opening nip angle.
This can lead to percolating of the feed
material, not allowing the material to flow
properly through the crushing cavity.

Must be
proper

The additional weight of thick liners can also

lead to a Crusher balance problem.

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When To Change Liners

Liners pushed too long can and will lead to
mechanical problems with the Crusher
A thinning mantle and thinning bowl liner will flex.
Flexing liners will crack out the backing material.
Continued flexing will powder out the backing material.
The flexing deteriorates the head and bowl seating surfaces.
The seating surfaces eventually will need reconditioning as liners will no
longer stay tight.

Note: Liners need to be changed well before they are cracked, broken, loose, or have
holes in them!

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When to Change Liners

Adjustment
Cap

Adjustment
Ring

Change the liners at the same

time each time by watching
the adjustment cap height
Some customers measure the
distance between the
underside of the adjustment
cap and the top of the
adjustment ring. This creates
a reference point for the next
liner change.

Possibility # 1
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When To Change Liners

Crusher Hour
Meter

00755

Change the liners at the same

time each time by watching
the total number of crushing
hours on the liners
Some customers watch and
record the total number of
crushing hours on a set of
liners. Once established, this
creates a bench mark for the
next set of liners.

Possibility # 2
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When To Change Liners

Change the liners at the same
time each time by watching the
total tons of material that passed
through the set of liners
Some customers watch and
record the total tons of feed
material that passed through
the liners. Once established,
this creates a bench mark for
the next set of liners.

Possibility # 3
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When to Change Liners

Feed Opening Closes Off

Change the liners at the same

time by watching for a reduction
in throughput caused by the
closing off of the liners feed
opening.
The volumetric area of the liner
decreases late in liner life as the feed
opening closes off. This results in
lower throughput and a substantial
loss in salable product. An excellent
time to change liners is when a 10%
loss of product is noticed.

Possibility # 4
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Excessive Liner Utilization

Liners pushed too long can cause serious damage to the cone Crusher. A cracked, loose,
or flexing liner will deteriorate the head seating surface and the bowl seating surface.
These surfaces will eventually need to be re-conditioned; a costly maintenance repair that
drives up the cost of producing the finished product.

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Tramp Iron Passage

Tramp metal passage should be kept to a minimum as it can be damaging to the cone
Crusher. A metal detector and magnet can be added to the circuit in front of the Crusher
to minimize the risk of tramp metal passage.

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Crusher Liners