Tully Sugar has a fleet of old deteriorating 4-ton low-capacity cane bins that require replacement.
Problem: Due to lower capacity than desired by the mill and frequent failures in service these cane bins require replacement to meet production, capacity, maintenance and safety requirements.
“Overall great experience working with you, flexible to accommodate our ad-hoc requests, even during this critical time of uncertainties (COVID -19 world). Much appreciated your efforts in making this project successful and delivered it on-time.”
With the installation of Bradken shoes on the sites shovels the site has improved production rates, efficiency and safety by eliminating unplanned downtime due to shoe failure and maintenance. They can now typically achieve 25k hours at this site, where the OEM tracks rarely achieve more than 15k hours.
Bradken Eclipse® Solid points resulted in a longer service life with an average of 298,700 BCM per set of points. The average life span of Bradken’s Eclipse® Solid points was 14-20 days, depending on digging conditions. This was a dramatic improvement compared to the previous competitors points that lasted only 4-8 days on average.
The Vulcabrix ZTA ceramic liners have been installed in the Flash Float Floor for 50 weeks and have more than 50% of their initial service life remaining. These preliminary results estimate the service life of the Vulcabrix ZTA ceramic liners to be 100 weeks, or an increase of 285% in service life compared to the 92% Alumina ceramic liners, enough to last at least 7 shut cycles.
The OEM crawler shoes achieved only 17,000 hours with 46 broken shoes during operation. Comparably the new Bradken crawler shoes achieved 23,000 hours with no broken shoes.
This 35% improvement in shoe life provided direct benefits to the customer in cost reductions, machine uptime and safety.
The customer was pleased with the Bradken PPS30PLB Eclipse® Solid points and the trial showed they are ideal for use on large excavators working in varied and extreme digging conditions such as double benching and digging un-shot coal. Effective penetration was maintained throughout the duration of the trial.
The liner package redesign resulted in lower costs, with a 1600% (6 weeks to 104 weeks) improvement in liner life and 24 months plus potential operational life continual service. The package processed 26 million tons of screened primary crushed ore for the sites six Ball Mills mills during its campaign.
The new liner design improved reline safety for the operation by removing a total of 60 loose steel corners liners and reducing the overall liner set mass by 19,644kgs. The reduction in parts saved 12 hours per mill reline, resulting in increased equipment availability.
Bradken collaborated with a large gold mine in West Africa and leveraged it’s expertise to provide a solution that increased the customers machine availability by 560hrs and reduced GET change-out by 50% on their 6060 Face Shovel and 6060 Backhoe machines.
Bradken has engineered a revolutionary weld overlay material that provides superior wear performance and impact resistance. Unlike traditional chromium carbide overlays, our proprietary weld chemistry creates an incredibly fine microstructure which results in substantial performance improvements when compared to existing products.