Spares

 

Spares

Apart from supporting all our own new mill installations with the best spares and aftermarket support, NCP International also provides support and spares to mills of any brand.
Girth Gears
Girth-Gears
NCP International has the capability to supply new girth gears up to 16m Ø, 1500mm face width. If no drawings exist, we will re-engineer your existing gear and deliver an identical new girth gear to your site.

We pride ourselves on optimizing delivery time on new girth gears and can offer delivery from 20-46 weeks depending on the gear size.

Pinions and Pinion Shaft Assemblies
Pinions-and-pinion-shaft-assemblies
NCP International supplies pinion gears or complete pinion shaft assemblies. These gears are supplied as case-carburized or through-hardened with an AGMA 9 to 12 surface finish as per the client’s requirements. On-site measurement will verify dimensions to ensure that the gears supplied are fit for purpose.

NCP International also offers in-house gear design services should the client consider changing the existing mill’s application, operating speeds, loading or installed power.

Main Trunnion Bearing Spares
Main-Trunnion-Bearing_spares
NCP International offers new lead-bronze bearing inserts, roller bearings or other bearing spares as required. We also assist with on-site bearing inspections and wear item replacement (eg. seals, strainers, etc). Our leaded bronze inserts are of the highest spun-cast quality with quickest delivery timing.
Mill Wear Liners
Mill-wear-liners
We supply competitively priced new mill liners, as well as new Chromoly and Hi-chrome wear lining systems. Our teams can install supplied liners as per the clients prerogative. We also incorporate a design office that offers DEM and charged Trajectory Analysis. In this way, we optimize existing liner designs and improve your grinding efficiency.
Shell
Shell
NCP International offers new mill shells where required. Imported or local manufacture of shells, heads and girth gears can be expedited to ensure that delivery times are kept to a minimum. Quick change-out of mill shells is also offered
Lube System Upgrades
Lube-System-Upgrades
Poor lubrication from outdated, originally-supplied lubrication systems is the leading cause of bearing failure on mills. NCP International offers design reviews of existing lubrication systems installed at your plant. We offer new, optimized and proven lubrication systems which will increase your mill’s availability and annual production. Systems offered include main trunnion bearing lube systems, gearbox and pinion bearing lube systems as well as gear spray grease lube systems.
Gearboxes
Gearboxes
In addition to supplying spare gearboxes for our new mill supply, NCP International also supplies new spare gearboxes to match the dimensions and constraints of any existing mill installation (of any make).

We have excellent working relationships with many OEM brands and offer excellent delivery times with an engineered solution to minimize client risk.

Motors
Motors
New motors matching your existing site dimensional constraints can be supplied as operating units or as critical spares. All motor FAT’s are witnessed by our experienced site / design personnel and signed off prior to dispatch.
Heads
Motors
Spare mill heads can be newly manufactured or refurbished/re-engineered from existing heads to fit your installation.

NCP International offers market-leading turn around times.

Instrumentation Upgrades
Instrumentation Upgrades
NCP International offers a technical review of your current mill protection levels and recommendations on instrumentation and control philosophy upgrades. Please request that an engineer visit your plant to assess your current mill installation.

Quality Control

 

Quality Control

To ensure the suitability of all designs, NCPI follows stringent quality control plans that ensure each component is verified as ready for use.
  • NCPI operates in accordance with ISO9001.
  • All NDT undertaken by independent RSA NDT technicians at specified Hold Points.
  • All Hold Points are inspected by NCPI Project Engineers & QA inspectors. These include: Casting Processes, NDT, Fettling, Workpiece Set Up, Final Machining, Gear Cutting, Work-piece Run Outs, Dimensional Inspections, FAT, Sandblasting, Painting and Packaging.
  • Vendor Data Report document control management.
  • QCP’s for every component manufactured.
  • Full Manufacturing Data Report (MDR) issued on project completion.

Projects Undertaken

 

Projects Undertaken

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Large Uranium Project

Namibia
36’Ø x 19.5’, 13.5 MW SAG Mill and 22’Ø x 34’, 8.5 MW Ball Mill
Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Australia
36’Ø x 17.5’, 18 MW SAG Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Ivory Coast
32’Ø x 20’, 11.5 MW SAG Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Copper Project

DRC
Two 32’Ø x 14’, 6 MW SAG Mills

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Iron Project

Liberia
Three 30’Ø x 15’, 7.4 MW SAG Mills

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Egypt
28’Ø’ x 18’, 7 MW SAG Mill and 20’Ø x 32’, 7 MW Ball Mill
Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Mali
26’Ø x 43’, 18 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Project

Zimbabwe
26’Ø x 11.5’, 4.5 MW SAG Mill and
15’Ø x 21’, 4.5 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Guinea
24’Ø x 38’, 12 MW Ball Mill


Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Kazakhstan
Two 24’Ø x 36’, 12 MW Ball Mills

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Australia
24’Ø x 18.5’, 4.7 MW Ball Mill
Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Kazakhstan
22’Ø x 43’, 10 MW Ball Mill
Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Kazakhstan
22’Ø x 18’, 3.5 MW SAG Mill 

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Côte d’Ivoire
21’Ø x 35.5’, 7.7 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Copper Project

Peru
20’Ø x 30’, 6.5 MW Ball Mill and
16’Ø x 22’, 2.8 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

PGM Project

South Africa
20’Ø x 27’, 5.2 MW Ball Mill and
20’Ø x 30.5’, 5.2 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Lead-Zinc Project

Cuba
20’Ø x 13.5’, 2.3 MW SAG Mill and
16.5’Ø x 30’, 3.8 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Guinea
18’Ø x 31’, 4.5 MW SAG Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Australia
18’Ø x 26’, 4.5 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Platinum Project

South Africa
18’Ø x 25.5’, 4.5 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Burkina Faso
17’Ø x 25’, 3.2 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Gold Project

Liberia
17.5’Ø x 23’, 2.3 MW Ball Mill
Global Suppliers of New & Refurbished Grinding Mills - NCP International

Project

Namibia
16’Ø x 32’, 3.4 MW Ball Mill

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Project

Alaska
16.5’Ø Head and Trunnion

Global Suppliers of New & Refurbished Grinding Mills - NCP International

Chromite Project

South Africa
10’Ø x 14.7’, 6 MW Ball Mill

Design Expertise

 

Design Expertise

Process Design

  • NCPI utilize modified Bond Theory with proven Service factors established from our extensive practical experience for Ball Mill sizing.
  • SAG/AG mills are sized using a hybrid model, including published information from Barrett, Austen & Morrell.
  • NCPI has developed a Specific Energy / Breakage distribution model for accurate SAG Mill sizing.
  • This model offers more circuit detail e.g. PFD’s, PSD’s, Mass Balance, Stream products, particle size distribution prediction), covers the full comminution plant (screening milling, classification).

Mechanical Design

  • FEA Structural Analysis, Completed in house – allowable to Anglo American stress limitations (In accordance with AAC323001 specification).
  • Trunnion pad and sleeve bearing design using fluid film and FEA techniques in accordance with BS7608 specifications.
  • Gearbox Design submitted for NCPI review to AGMA 2001:C95. NCP specify a SF of between 2.0- 2.3.
  • Bearing life L10basic >52,000hrs. Pinion Bearing life L10h > = 100 000 hours.
  • NCPI Specification stipulates Couplings SF > 2.0.
  • Open gearing designed according to AGMA 6014: B15 and AGMA 321.05.

E & I Design

  • Comprehensive Electrical, Instrumentation & control system design services.
  • Expert management of VSD specialist sub-contractors and main drive motor design.
  • Detailed PLC design & implementation with precise E&I interface management.

Welcome To NCP International

 

Offering new grinding mills and complete
comminution circuits globally

Welcome To NCP International

NCP International offers new Grinding Mills to clients throughout the world.

We specialize in the supply of new grinding mills. Our designs are completed using modern FEA design techniques and 3D simulation packages. This ensures that our clients receive optimized, fit-for-purpose mill designs at the best project pricing every time. Our mill designs range from 75kW to 22,000kW.

For projects carrying constrained budgets or urgent delivery times, NCP also offers refurbished Grinding Mills to match project requirements. These mills can be refurbished back to OEM specification and be supplied with warrantees equivalent to new equipment.

NCP International also incorporates a division that specializes in after sales support for all NCP mills, as well as re-engineered spares for all other OEM mills operating in the global market.

We carry one of the largest OEM-owned stock holdings of used mills in the world. Please call us to request assistance for your project requirements.