11 Tips To Maximize Cone Crusher Performance You Need To Know
Cone crusher is one of the most popular secondary crushing equipment, suitable for crushing various medium and hard materials. However, many users find that sometimes even though they are producing at full capacity, they still feel that the crusher’s production capacity is not high enough to achieve the ideal production state. Sandrock Mining shares the operating skills for improving production capacity, hoping to help you.
11 Tips To Maximize Cone Crusher Performance
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 discharge port on the tight side of the cone crusher remain unchanged, otherwise it will easily lead to an unexpected increase in the particle size of the product, which in turn affects the entire production line system and the final output.
For example: The discharge port on the tight side of a certain equipment is set to 10mm. However, due to neglect of inspection and equipment wear, this parameter is expanded to 13mm, so the products smaller than 10mm of the equipment will be reduced by 15%, and the output of the target product will be significantly reduced. Thus, many gravel manufacturers lost a great amount of annual revenue because of it.
Suggestion: It is recommended that the parameters of the discharge port on the tight side should be checked every shift.
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 discharge port on the tight side of the cone crusher remain unchanged, otherwise it will easily lead to an unexpected increase in the particle size of the product, which in turn affects the entire production line system and the final output.
For example: The discharge port on the tight side of a certain equipment is set to 10mm. However, due to neglect of inspection and equipment wear, this parameter is expanded to 13mm, so the products smaller than 10mm of the equipment will be reduced by 15%, and the output of the target product will be significantly reduced. Thus, many gravel manufacturers lost a great amount of annual revenue because of it.
Suggestion: It is recommended that the parameters of the discharge port on the tight side should be checked every shift.
3, Do not feed too little
Feeding only a small amount of raw material will not reduce the burden of the cone crusher. On the contrary, too little raw material will not only damage the product output, poor grain shape, 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 kept between 40%-100% of the rated power, and 75%-95% of the rated power in operation is the best choice.
Influence: Operation beyond the rated power will affect the service life of the cone crusher and cause various problems.
4, The feed drop point needs to be aligned with the center point of the cone crusher inlet
It is better to use a vertical deflector to guide the feed drop point in the center of the cone crusher feed port. Once the drop point is eccentric, one side of the crushing cavity is full of material and the other side is empty or less material, which will cause adverse effects such as lower crusher throughput, increased needle-like products, and oversized product particle size.
Improper operation: Once this happens, the operator tends to reduce the parameters of the discharge port on the tight side and try to make the crusher produce the product with the target particle size. However, it is easy to cause problems such as overload and adjustment ring jumping on the side with too much feeding. It will cause problems such as inclining, tilting, and damage to the base of the adjustment ring, resulting in greater production losses in the long run.
5, Ensure uniform feeding
When feeding, it is necessary to avoid the situation that large-diameter stones are concentrated on one side and small-diameter stones are concentrated on the other side, so as to ensure that the stones are evenly mixed.
Influence: Once the feeding is uneven, due to the abnormal increase in bulk density, compaction and blockage of the concentrated side of the small-sized stone are likely to occur, causing the adjustment ring to jump. Faced with the beating of the adjustment ring caused by the blockage, the operator will be forced to increase the parameters of the discharge port, resulting in an increase in the particle size of the product. In the long run, it will also cause problems such as damage to the adjustment ring, resulting in greater production losses.
6, Minminze the retention of buffer silo to improve the efficiency of the production line
As the “enemy of production”, the cone crusher buffer silo and other related equipment also need to be carefully arranged.
Suggestion: Reasonable use of buffer silo/hopper and variable-speed feeding device (conveyor belt, plate vibrating feeder) can enable operators to maintain the “full cavity” state of cone crusher for a long time, and easily increase the productivity of cone crusher by 10%.
7, Accurately grasp the three design upper limits of the cone crusher
There are three design upper limits for cone crushers: upper limit of throughput (capacity), upper limit of power, and upper limit of crushing force.
The upper limit of the capacity 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; The actual power of the crusher will increase when the crusher reaches the limit; the same as the power, the crushing force generated between the cone crusher bowl and mantle will also increase with the increase of the feeding amount and the finer crushing of the material. When the crushing force exceeds the upper limit, the adjustment ring will bounce and loosen.
Ideal run status: When the crusher is running at maximum throughput, the actual power and crushing rate are still slightly below the upper limit. If the run status is beyond the upper limit of rated power, crushing force will cause overload and permanent fatigue damage of the cone crusher. This damage is irreversible and will continue to accumulate, eventually shortening the service life of the cone crusher.
8, Ensure to operate within the design upper limit of the crusher
If the run status of the cone crusher exceeds the upper limit of the crushing force (adjustment ring jumps) or exceeds the rated power, you can do as below:
Slightly increase the tight side discharge port parameters, and try to ensure “full cavity” operation. The advantage of “full cavity” operation is that there will be a stone-beating process in the crushing cavity, so that the product grain shape can be maintained when the discharge opening is slightly larger.
Or reduce the feed rate, but this may make it difficult to ensure good particle shape.
Cause Analysis: Generally speaking, the problem of cone crusher adjustment ring jumping or exceeding rated power is caused by material jamming, eccentric feeding, uneven feeding, excessive fine material in feeding, high mud content, and wrong use of mantle and bowl liner , or simply because the operator set the discharge port on the tight side of the cone crusher too small.
9, Monitor to ensure proper crushing speed
Influence: If proper drive belt tension is not maintained, incorrect or neglected drive maintenance, belt slippage and crusher speed reduction will occur during running. The stone throughput of the crusher with a decrease in rotation speed has dropped sharply, and at the same time, the power consumption has increased sharply, the unit energy consumption has increased, and the operating cost has increased.
Suggestion: A speed monitoring device can be installed on the main shaft and other positions, connected to the PLC or directly connected to the alarm device. Once the speed drops, the maintenance personnel can be notified to adjust the belt, which can prolong the life of the belt and ensure excellent production capacity and energy consumption.
10, Control the fines content during feeding
The fines in feed: after stones enter the crusher, the particle size is equal to or smaller than the material set at the discharge port on the tight side. As a matter of experience, for the secondary cone crusher, the fine material content in the feed should not exceed 25%; the fine material content in the feed for the tertiary cone crusher should not exceed 10%.
Cause and Effect: Excessive fines are usually caused by the vibrating screen problems, which can be caused by insufficient screen diameter or insufficient screening capacity., etc. Too much fine material will lead to problems such as insufficient power utilization and abnormal increase in unit energy consumption during the crushing process.
11, The feeding height should not be too large
For small and medium-sized cone crushers, the maximum suitable height for the material to fall from the feeder to the feeding port is about 0.9 meters. If the feeding height is too tall, the stone will easily “rush” into the crushing cavity at high speed, causing impact load to the crusher, and the crushing force or power exceeds the design upper limit.
Influence: This problem can cause excessive stress or tension on the crusher components, resulting in problems such as additional maintenance costs and lower output., etc.
Factors Affect the Service Life of Cone Crusher
To buy equipment requires cost, we all hope to extend the service life of cone crusher machine, so as to increase production capacity and maximize economic benefits. So which factors will affect the service life of the cone crusher?
1) Stone powder content and stone moisture
When the cone crusher is working, if the stone powder content and humidity of the material are relatively high, it will easily adhere to the cone crusher mantle or bowl liner during crushing. After a while, it will not only reduce the production efficiency, but also get the crusher bowl liner and mantle corroded, which will reduce its service life.
2) The hardness and particle size of the stone
The higher the hardness of the material, the more difficult it is to be broken. The greater the impact load on the bowl liner and mantle in production, and correspondingly, the service life will be shortened ; when the material particle size is larger, the wear of the lining plate will be more serious, and the service life of the crusher will be more serious, which will also make the cone crusher service life shortened.
3) Quality of bowl liner and mantle
A high-quality wear-resistant part has high requirements on the casting surface . The casting part is not allowed to have cracks and casting defects such as slag inclusion, sand inclusion, cold insulation, pores, shrinkage holes, and shrinkage porosity., etc. As the core components of the cone crusher – bowl liner and mantle, their quality directly affects the capacity and life of the crusher.
As one of the leading crushers and crusher wear parts in China, Sandrock mining’s products have been exported to more than 50 countries and regions all over the world.
If you want to maximize the production capacity, please contact Sandrock to get a specific solution.
