CITIC Pacific Mining (Australia): Engineering Value Beyond Replacement - Gyratory Crusher Liner Optimization
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Author:Thomas Bai
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Published time: 2026-03-14
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At CITIC Pacific Mining's Sino Iron project in Western Australia's Pilbara region, the OEM liners for the primary gyratory crushers (ThyssenKrupp 63" x 89") lasted only 800,000 tons, causing frequent change-outs and costly downtime. Rather than simply reverse-engineering the parts, Jinyang optimized the design by analyzing wear patterns and operational data. Collaborating with Central South University on advanced metallurgy, Jinyang developed a proprietary Cr-Mo-V alloy and redesigned the liner profile. The result: service life increased to over 1.65 million tons—a more than 106% improvement. This more than doubled replacement intervals, reduced total cost per ton crushed by 30–50%, and maximized crusher availability. The success led to a long-term exclusive supply agreement and client recognition, demonstrating Jinyang's capability to deliver engineered solutions that go beyond replacement to create significant operational value.
CITIC Pacific Mining (Australia): Engineering Value Beyond Replacement - Gyratory Crusher Liner Optimization
The Challenge:
CITIC Pacific Mining's SINO iron ore project in Australia utilizes large ThyssenKrupp gyratory crushers 63" x 89". The service life of the original OEM liners was approximately 800,000 tonnes, leading to frequent change-outs, prolonged downtime, high maintenance costs, and impacts on continuous production and economic efficiency. The customer needed not just a reliable alternative liner but sought a technological breakthrough to surpass the original design's performance limits and achieve a leap in cost reduction and efficiency.
The Jinyang Solution:
Jinyang did not offer a simple copycat replacement. Our engineering team conducted an in-depth analysis of the customer's ore characteristics, crusher operating parameters, and the original liner wear patterns. We performed customized cavity profile optimization and material upgrade design. Utilizing advanced simulation technology, we redesigned the liner profile, thickness, and material composition to maximize wear resistance and service life.
Data-Driven Results:
The optimized Jinyang gyratory crusher liners delivered revolutionary improvements far exceeding expectations:
Service Life Leap: Liner service life skyrocketed from the OEM's ~800,000 tonnes to an impressive 1.65 - 1.70 million tonnes, representing a service life increase of over 106%.
Significant Economic Benefit: The extended replacement cycle, more than doubling the original, effectively reduced associated downtime, labor costs, and change-out frequency by approximately 50%. The amount of ore processed per liner set doubled, drastically reducing the liner cost per tonne of ore.
Customer Recognition: For delivering substantial economic value, Jinyang received a special performance bonus from the customer and secured a long-term exclusive supply agreement.
Customer Value & Feedback:
This case transcends the traditional "aftermarket parts" category, showcasing Jinyang's profound expertise in materials science and engineering optimization. We are not just manufacturers but solution engineers capable of creating incremental value for our clients. For global premium customers, Jinyang has demonstrated its ability to optimize the performance of existing core assets through technological innovation, delivering a return on investment that far exceeds simple part replacement. This marks Jinyang's strategic evolution in the aftermarket sector from a "supplier" to a "value-creation partner."
