Improving Wear Life in a Copper/Gold Operation with Melbenarch's Alien Technology
Old Wear Liner System vs New Alien Design
Further Dive
A large copper and gold operation in central Australia was facing significant challenges in maintaining operational efficiency and minimising unplanned downtime. The operation’s critical Mill Feed Chute, responsible for transferring ore through the processing plant, was consistently falling short of its planned operational lifespan. The incumbent Cast White Iron liners, designed to withstand aggressive loading and crushing conditions, required replacement every 9 months — far earlier than the 12-month target for the rotable change out schedule.
This early replacement led to several operational issues:
Frequent Downtime: The need for unplanned change outs disrupted the production schedule, leading to unanticipated periods of inactivity.
Production Losses: Every unplanned downtime event resulted in a loss of approximately $3 million per day, significantly affecting the bottom line.
Increased Labor & Time Allocation: The early liner changeouts necessitated additional labor and time resources, diverting attention from more productive activities and increasing operational costs.
Supply Chain Issues: The frequent need for replacement liners strained the site's supply chain, leading to delays and logistical challenges.
The Challenge
The primary issue facing the site was the inability of the Cast White Iron liners to meet the expected wear life. The site had hoped for a 12-month operational window but was forced to replace liners every 9 months due to rapid wear caused by the aggressive nature of the mill feed.
The challenge was to identify a solution that would:
Extend the wear life of the Mill Feed Chute liners
Eliminate unplanned downtime
Reduce maintenance costs
Improve operational efficiency and productivity
The Solution - Melbenarch’s Alien Technology
Melbenarch’s Alien Technology was introduced as a solution to the wear-life issues faced by the site. Alien is a revolutionary wear material developed as a composite matrix combining industry-leading high-chrome white iron and ZTA ceramics. This cutting-edge composite material is designed specifically for applications requiring superior resistance to abrasive wear, extreme loading, and crushing forces.
The key benefits of Alien Technology include:
Extended Wear Life: Alien's advanced composite structure significantly outperforms traditional Cast White Iron liners, with enhanced resistance to wear, abrasion, and impact, making it ideal for high-impact applications.
Tailored Solutions: Alien can be custom-shaped to fit various chute dimensions, including radiused bases, ensuring a perfect fit and optimal asset usage.
Reduced Maintenance: With a substantial improvement in wear life, Alien eliminates the need for frequent and unplanned change outs, reducing maintenance costs and labor time.
Results - Operational Efficiency and Cost Reduction
Since the introduction of Alien Technology, the site has experienced remarkable improvements in operational efficiency:
Extended Operational Window: The wear life of the Mill Feed Chute has been extended to the desired 12-month interval, effectively eliminating the need for unplanned change outs. This improvement has resulted in a substantial reduction in downtime.
Increased Production Capacity: By eliminating unplanned downtime, the operation has been able to consistently meet production targets. The site is no longer losing approximately $3 million per day due to unplanned maintenance, resulting in a direct improvement to the bottom line.
Cost Savings: The reduction in maintenance costs, labor, and downtime has led to a significant reduction in operational costs. With the introduction of Alien Technology, the site is now adding millions of dollars to the bottom line annually.
Operational Impact: The increased uptime has not only improved production rates but has also optimised the overall efficiency of the site’s operations, ensuring that the plant is running at maximum capacity without interruptions.
Conclusion
The implementation of Melbenarch’s Alien Technology has proven to be a game-changer for the copper/gold operation in central Australia. By addressing the critical wear-life issues associated with the Mill Feed Chute, Alien has not only eliminated the frequent downtime but also significantly improved both production and cost efficiency.
Since adopting our Alien Technology, the operation is now benefiting from:
Increased production uptime
Lower maintenance costs
Higher operational efficiency
Millions of dollars in cost savings
The introduction of Alien Technology has clearly demonstrated its value, making it a crucial investment for mining operations looking to improve wear life and reduce costs in high-impact, high-wear applications.
Melbenarch is proud to offer Alien Technology as the solution to the most demanding wear challenges in mining operations. Our technology delivers genuine improvements in performance, extending the life of critical equipment and providing a substantial return on investment.
Contact Melbenarch Today for a Quote.
If you're facing wear issues in your mining operation, Alien Technology is the solution you need. Get in touch with Melbenarch today to learn how our advanced wear material can enhance your operations, reduce costs, and boost your bottom line.