Ugarov Stary Oskol Technological Institute (Division), NUST MISIS, Stary Oskol, Russia:

P. F. Boyko, Head of Research Center for Innovation Repair Technologies for Mining and Metallurgical Equipment, Associate Professor, Candidate of Engineering Sciences, 410135@mail.ru

Petropavlovsk–Iron Ore LLC, Moscow, Russia:
E. M. Titievsky, Chief Machine Man, Candidate of Engineering Sciences

Stankin Moscow State Technological University, Moscow, Russia:
V. A. Timiryazev, Professor, Doctor of Engineering Sciences

NUST MISIS, Moscow, Russia:
V. U. Mnatsakanyan, Professor, Doctor of Engineering Sciences

Work faces in movable and stationary crushing cones from abrasive wear and destruction are protected by inner lining which requires periodic restoration and replacement. The costs of such repairs are determinative both in terms of time and money. Crushing liners can not be exploited until total failure. When lining wears, the width of the exit gap increases and the granulometric composition of crushed rock deteriorates. The analysis of the dimensional constraints that govern the size of the gap made it possible to determine the dependence for calculating the width of the exit gap at a certain time, taking into account the wear rate of immobile and movable lining. To determine the optimal overhaul periods, mechanisms of ultimate wear of lining are investigated. The studies show that the resistance of immobile lining is 20 to 30 % lower than the resistance of movable lining, and only 30 % of lining works to the extreme wear. When operating a crusher, lining condition should be continuously inspected. To this effect, the methods of lining wear measurement and external and internal defect detection using video endoscopy and ultrasound diagnostics are considered. In order to eliminate overloading and destruction of lining when non-crushable objects enter the working area, it is necessary to continuously monitor the load in the crushing chamber and to apply an automatic protection system to ensure removal of such objects. Improvement of the mechanical properties of the lining material (steel 110G13L) is achieved by obtaining a fine-grained structure through modification of steel with titanium and vanadium. However, the best effect is achieved with new high-manganese steel 125G18X2MNL, in which the combination of alloying elements improves the mechanical and operational properties of lining. As a result, the availability factor of the crushers KKD 1500/180 at Stoilensky Mining and Processing Plant has increased to 0.885 as compared to 0.666 before this introduction.

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