Cone Crusher Capacity

Scheme to increase the capacity of the cone crusher

1. Keep the parameters of the tight side discharge port unchanged

In order to stabilize the output, quality and production line load of sand and gravel products, the first thing to ensure is that the parameters of the tight side of the cone crusher are unchanged, otherwise it will easily lead to an unexpected increase in the particle size of the product, which will affect the entire production line system and ultimately Yield.

For example, the tight discharge port of a device is set to 10mm. However, due to negligence and equipment wear, the parameter is expanded to 13mm, then the product with less than 10mm will be reduced by 15%, and the output of the target product will be significantly reduced. A considerable part of the sandstone producers' annual income loss in this respect is eye-catching. It is recommended that the parameters of the tight side discharge port be recommended to be checked every time the shift is changed.

2, try to continue "full cavity" operation

If a cone crusher is “satisfied” when it is “starving” due to factors such as unstable feeding, the product size and product rate will fluctuate. The cone crusher operating in half cavity is not ideal in terms of grading and needle shape.

It is recommended that the sand and gravel producers try to ensure that the cone crusher is fully operated to obtain better throughput and grain size. This is especially important for third-stage cone crushers (short-head cone crushers) that produce the final product.

3, do not feed too little

The fact that only a small amount of raw material does not reduce the burden of the cone crusher, on the contrary, too little raw material will not only damage the product yield, the grain size is poor, but also adversely affect the bearing of the cone crusher.

According to the working principle of the cone crusher, the actual power of the cone crusher should not be lower than 40% of the rated power. In order to obtain proper "load bearing positioning" and maximize productivity, the actual power of the cone crusher should be maintained between 40% and 100% of the rated power. 75%-95% of the rated power during operation is optimal. select. Affecting the operation beyond the rated power will affect the service life of the cone crusher and cause various problems.

4, the feed point needs to be aligned with the center point of the cone crusher inlet

It is recommended to use a vertical baffle to guide the feed drop point at the center of the cone crusher feed inlet. Once the drop point is eccentric, one side of the crushing chamber is full and the other side has no material or less material, which will result in lower crusher throughput, increased needle-shaped products, and large product particle size.

Improper operation Once this happens, the operator tends to reduce the parameters of the tight side discharge port and try to get the crusher to produce the product with the target particle size. However, it is easy to cause overload and adjustment ring jump on the side of too much feed. In the long run, problems such as tilting, lifting, and damage to the adjusting ring will be caused, resulting in greater production losses.

5, to ensure uniform feeding

When feeding, it is necessary to avoid the large-size stone material concentrated on one side, and the small-size stone material concentrated on the other side to ensure uniform mixing of the stone material.

Once the influence is uneven, the bulk density of the small-sized stone material tends to be compacted and blocked, which causes the adjustment ring to jump. In the face of the adjustment ring bounce caused by the blocking material, the operation operator will be forced to increase the discharge port parameters, resulting in an increase in the particle size of the product. In the long run, problems such as damage to the adjustment ring will also occur, resulting in greater production losses.

6. Minimize the retention of buffer silos and improve the efficiency of the production line

The cone crusher buffer silo is used as the “enemy of production”, and the equipment and other related equipment also need to be carefully arranged.

It is recommended that the rational use of buffer silos/hoppers, idle feed devices (conveyor belts, plate vibrating feeders) enable the operating operators to maintain the “full cavity” state of the cone crusher for a long time, and easily increase the output of the cone crusher.

7. Accurately grasp the three design limits of the cone crusher

The cone crusher has three design upper limits: throughput (capacity) upper limit, power upper limit, and crushing force upper limit.

The upper limit of the cone crusher refers to the maximum throughput of the crusher. A cone crusher that is running “full cavity” has reached the maximum throughput. If the limit is exceeded, the feed port will overflow. When the feedstock is added and the material is increased. When the crushing is finer, the actual power of the crusher will rise; as with the power, the crushing force generated between the bowl-shaped tile and the broken wall of the cone crusher will also rise as the feed amount increases and the material breaks finer. When the crushing force exceeds the upper limit, the adjusting ring will bounce and loosen.

Ideal operation When the crusher is operating at maximum throughput, the actual power and breakage rate are still slightly below the upper limit. Operating beyond the rated power and the upper limit of the crushing force will cause the cone crusher to be overloaded and permanently fatigued. This damage will irreversibly and will continue to accumulate, eventually shortening the life of the cone crusher.

8, to ensure that the operation within the upper limit of the crusher design

If the cone crusher runs beyond the upper limit of the crushing force (adjustment ring bounce) or exceeds the rated power, you can: slightly increase the parameters of the tight side discharge port and try to ensure "full cavity" operation. The advantage of "full chamber" operation is that there will be a stone-rocking process in the crushing chamber, which can maintain the product size when the discharge port is slightly larger; or reduce the feed rate, but it may be difficult to ensure good grain size.

Analysis of the cause Generally speaking, the problem of the cone crusher adjusting the loop or exceeding the rated power is caused by the jamming, the eccentricity of the feeding, the uneven feeding, the excessive fines in the feeding, the large amount of mud, the broken wall and the bowl lining. Caused by the use of the error, or simply because the operating operator set the conical crusher tight side discharge port too small.

9, monitor and try to ensure the appropriate crusher speed

If there is no proper transmission belt tension, incorrect or neglected drive maintenance, the belt will slip and the speed of the crusher will drop during work. The crusher throughput of the falling speed is sharply reduced, while the power consumption is increasing sharply, the unit energy consumption is increased, and the operating cost is increased.

It is recommended to install the speed monitoring device at the intermediate shaft and other places, connect to the PLC or directly connect the alarm device. Once the speed drop occurs, the maintenance personnel can be notified to adjust the belt, which can extend the belt life and ensure excellent productivity and energy consumption.

10. Control the fine content in the feedstock

Fine material in the feed: into the stone of the crusher, the particle size is equal to or less than the material set at the tight discharge port. According to experience, for the secondary cone crusher, the content of fines in the feed should not exceed 25%; the content of fines in the feed of the third-stage cone crusher should not exceed 10%.

Causes and effects of excessive fines are usually caused by vibrating screen problems, and the insufficient mesh diameter or insufficient screening ability may cause this problem. Excessive fine materials can lead to problems such as insufficient power utilization during the crushing process and abnormal increase in unit energy consumption.

11, the feed height should not be too large

For small and medium-sized cone crushers, the maximum suitable height for the material to fall from the feeding device to the feed port is around 0.9 meters. If the feed height is too large, the stone is easy to "rush" into the crushing chamber at high speed, causing impact load on the crusher, and the crushing force or power exceeds the design upper limit.

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