Liner Wear Rate Calculation

by

Industrial Liner Wear Rate Calculator

Wear Analysis Results

Total Material Loss: mm

Hourly Wear Rate: mm/1,000 hrs

Specific Tonnage Wear: mm/100,000 tons

Estimated Remaining Life: hours (until 25mm thickness)

function calculateLinerWear() { var initial = parseFloat(document.getElementById("initialThickness").value); var final = parseFloat(document.getElementById("finalThickness").value); var hours = parseFloat(document.getElementById("operatingHours").value); var tonnage = parseFloat(document.getElementById("totalTonnage").value); var resultDiv = document.getElementById("wearResult"); if (isNaN(initial) || isNaN(final) || isNaN(hours) || isNaN(tonnage) || initial <= final || hours <= 0 || tonnage 0) ? (usableRemaining / hourlyDepletion) : 0; document.getElementById("totalLoss").innerHTML = totalLoss.toFixed(2); document.getElementById("hourlyRate").innerHTML = hourlyRate.toFixed(4); document.getElementById("tonnageRate").innerHTML = tonnageRate.toFixed(4); document.getElementById("remainingLife").innerHTML = Math.round(remainingLife); resultDiv.style.display = "block"; }

Understanding Liner Wear Rate Calculations

In heavy industries such as mining, cement production, and aggregate processing, liners are the primary protection for expensive machinery like ball mills, SAG mills, and jaw crushers. Monitoring the liner wear rate is critical for preventive maintenance and operational efficiency.

Why Calculate Liner Wear?

Liner wear isn't just about a piece of metal getting thinner. It directly impacts:

  • Throughput: As liners wear, the internal volume and profile of the mill change, affecting grinding efficiency.
  • Downtime Planning: Accurate wear rates allow maintenance managers to schedule relines months in advance, ensuring parts and labor are ready.
  • Cost Analysis: By calculating wear per ton of processed material, companies can compare different liner alloys and manufacturers.

Key Variables in the Formula

To perform an accurate calculation, you need four primary data points:

  1. Initial Thickness: The original measurement of the new liner (usually from the manufacturer's drawing).
  2. Current Thickness: Obtained via ultrasonic testing or physical measurement during a shutdown.
  3. Operating Time: The total "engine hours" or milling hours the liner has been in service.
  4. Throughput: The total mass of material that has passed through the system during that time.

Practical Example

Suppose you install a set of high-chrome liners in a SAG mill with an initial thickness of 120mm. After 3,000 operating hours and processing 500,000 tons of ore, the liners measure 95mm.

Total Wear: 120mm – 95mm = 25mm
Wear per 1,000 hrs: (25 / 3,000) * 1,000 = 8.33 mm/k-hrs
Wear per 100k tons: (25 / 500,000) * 100,000 = 5.00 mm/100k tons

Factors Influencing Wear Rates

If your wear rate is higher than expected, consider these factors:

  • Ore Abrasiveness: Higher silica content significantly increases wear.
  • Moisture Content: Wet grinding often leads to corrosive wear in addition to abrasive wear.
  • Impact Angle: In chutes and transfer points, the angle at which material hits the liner dictates whether the wear is gouging or scratching.
  • Metallurgy: Manganese steel, white irons, and rubber-composite liners all react differently to impact and abrasion.

Leave a Comment