A gold mine in Australia was experiencing short liner campaign on a cone crusher operating on abrasive, fines-influenced ore. Third-party TIC liners had been trialed previously, and the site’s earlier 18% Mn liners were delivering limited days in service. The operation required longer, more predictable wear life to sustain throughput and reduce changeout exposure.
~42 days vs 36 d (TIC) and 24 d v manganese (Mn).
~540 kt vs 450 kt and 300 kt
~34% ROI
The objective was to increase days in service and tonnes per set without adding safety or availability risk. FLS benchmarked existing performance, compared TIC and non-TIC outcomes, and defined an upgrade path focused on measurable gains within a single campaign.
FLS supplied a TIC liner set engineered for the duty. The design combined titanium-carbide inserts at high-abrasion zones with an optimised manganese matrix and profile to preserve nip and manage localised wear. The upgrade was installed during planned maintenance. On-site monitoring verified wear progression and the end-of-life condition.
The first FLS TIC set ran for approximately 42 days and processed about 540,000 tonnes. This outperformed the previous third-party TIC set at roughly 36 days and 450,000 tonnes, an improvement of around 17% in days and about 20% in tonnes. Versus the earlier 18% Mn baseline of approximately 24 days and 300,000 tonnes, the improvement was close to 75% in days and up to 80% in tonnes.
Execution within a planned window helped avoid additional downtime and changeout risk while supporting steadier production.
FLS applies OEM-level metallurgy and profile engineering to target specific wear mechanisms, validated on site with measured end-of-life condition. The focus is lifecycle value: longer campaigns, fewer changeouts and more predictable throughput, delivered through proven TIC know-how, disciplined monitoring and safe execution.