Maximize Crusher Performance: How to Extend Cone Liner Wear Life

Extend Cone Liner Life by Up to 30%

Maximizing cone liner wear life can significantly improve maintenance costs, crusher uptime, and overall profitability. According to Curt Theisen, crushing technical support engineer at Superior Industries, producers can boost liner lifespan by up to 30% with the right strategies. Here are his top tips:

Properly Work-Harden the Liner

Manganese steel is the top choice for cone liners due to its ability to work-harden. As rock compresses against a new liner, the manganese gradually hardens, increasing from 25 Rockwell (250 Brinell) to as high as 60 Rockwell (660 Brinell).

To ensure proper work-hardening:

Start at 50% power (about 65% amps) while running a full cavity for six hours.
Increase to 75% power (about 80% amps) for the next two hours.
After this, the liners will be fully work-hardened and ready for full-capacity operation.

Keep the Cone Crusher Choke-Fed

A continuous, steady feed is key to extending manganese wear life. Choke feeding means keeping the cone head covered with at least 150mm of consistent, homogenous material. This prevents erratic head movement, which can accelerate liner wear and damage components.

Avoid running the cone empty or feeding it inconsistently. Instead, use hoppers, feeders, and surge bins to maintain a steady flow of material throughout the shift.