A Large Mine in Zambia - Naipu Mining High-Alloy Forged Liner Doubles the Service Life of SAG Mill

Project Background

The SAG mill of this large mine in Zambia has been using traditional cast Cr-Mo steel cylinder liners for a long time, which have the problems of short service life (1-4 months) and low grinding efficiency. Frequent liner replacement leads to high maintenance costs and serious production loss, which restricts the ore processing capacity of the mine.

Solution

Jiangxi Naipu Mining provided a customized high-alloy forged liner for the mine's SAG mill, optimized the material composition and forging process of the liner, improved the hardness and toughness of the liner, and adjusted the liner structure according to the mill's working parameters to match the ore grinding process of the mine.

Implementation Cycle

The liner was installed and put into use on January 1, 2025, with a continuous operation monitoring period of 7.2 months until the replacement on August 5, 2025.

Core Achievements

• The service life of the high-alloy forged liner reached 7.2 months, which was significantly higher than the 1-4 months of the original metal liner, and the wear resistance was greatly improved.
• The grinding efficiency of the SAG mill was improved, the ore processing capacity was increased, and the comprehensive energy consumption of the mill was reduced.
• The liner has good structural stability, no deformation or cracking during operation, and reduces the failure rate of the mill's associated components.
• The disassembly and assembly time of the forged liner is shortened by half compared with the cast liner, which further reduces the maintenance downtime of the equipment.

Customer Feedback

The mine highly recognized the performance of Naipu Mining's forged liner, and has placed a follow-up order for the supply of the liner. At the same time, it has reached a preliminary cooperation intention with Naipu Mining for the optimization of other mill wear parts, and plans to promote the application of high-alloy forged liners to the whole mine's grinding system.