Eleven Ways to Increase Cone Crusher Capacity

The cone crusher is one of the most popular crushing equipment. There are eleven methods to help your cone crushing capacity to a higher level.

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 is easy to cause 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, but due to neglect of inspection and equipment wear, this parameter is expanded to 13mm, then the products smaller than 10mm of the equipment will be reduced by 15%, and the output of the target product will be significantly reduced. The annual revenue lost by a considerable number of sand and gravel producers in this regard is astounding. Recommendation: It is recommended that the parameters of the tight side discharge port should be checked every shift.

2. Try to continue "full" operation as much as possible If a cone crusher is "starved" and "full" due to factors such as unstable feeding, then its product size and product rate will also fluctuate. For the cone crusher operating in half cavity, its products are not ideal in terms of gradation and needle-flake shape. Suggestion: It is recommended that sand and gravel manufacturers try to ensure that the cone crusher runs in full cavity to obtain better throughput and grain shape. This is especially important for the third-stage cone crusher (short-head type cone crusher) that produces the final product.

3. Do not feed too little Feeding only a small amount of raw materials will not reduce the burden on the cone crusher. On the contrary, too little raw material will not only damage the output of the product and cause 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 it is optimal to reach 75%-95% of the rated power in operation choose. 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 feed port. It is recommended to use a vertical deflector to guide the feed drop point at 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, trying to make the crusher produce the product with the target particle size, but it is easy to cause overload on the side with too much feeding, adjustment ring jumping. In the long run, the adjustment ring will be tilted, tilted, and the base will be damaged, resulting in greater production losses.

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 side where the small-sized stones are concentrated are prone 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. Minimize the retention of the buffer silo and 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 hoppers/hoppers and variable-speed feeding devices (conveyor belts, plate vibrating feeders) can enable operators to maintain the "full cavity" state of the cone crusher for a long time, and easily increase the volume of cone crushing by 10% .

7. Accurately grasp the three design upper limits of 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 already reached the maximum throughput. If the limit is exceeded, the feed port will overflow; When it is finer, the actual power of the crusher will increase; the same as the power, the crushing force generated between the cone crusher bowl and the crushing wall will also increase with the increase of the feeding amount and the crushing of the material to be finer. When the crushing force exceeds the upper, for a limited time, the adjustment ring will bounce and loosen. Ideal operating conditions: When the crusher is operating at maximum throughput, the actual power and crushing rate are still slightly below the upper limit. Operation beyond the upper limit of rated power and crushing force will cause overload and permanent fatigue damage to the cone crusher. This damage is irreversible and will continue to accumulate, eventually shortening the service life of the cone crusher.

8. Ensure that the crusher operates within the design upper limit of the crusher If the operation of the cone crusher exceeds the upper limit of the crushing force (adjustment ring jumps) or exceeds the rated power, you can: Slightly increase the parameters of the discharge port on the tight side, and try to ensure the "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; the feeding rate is reduced, but it may be difficult to ensure a good grain shape. Reason analysis: Generally speaking, the problem of cone crusher adjusting ring jumping or exceeding rated power is caused by material jamming, eccentric feeding, uneven feeding, too much fine material in feeding, large mud content, crushing wall and bowl lining. Caused by mistakes, or simply because the operator set the discharge opening on the tight side of the cone crusher too small.

9.Monitor and try to ensure the appropriate crusher speed Impact: If proper drive belt tension is not maintained, incorrect or neglected drive maintenance, belt slippage and crusher speed drop will occur during operation. The stone throughput of the crusher with the reduced speed drops sharply, while the power consumption increases sharply, the unit energy consumption rises, and the operating cost increases. Suggestion: You can install a speed monitoring device on the intermediate shaft, etc., and connect it to the PLC or directly 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 fine material content in the feed The fine material in the feeding material: in the stone material entering the crusher, the particle size is equal to or smaller than the material set at the discharge port on the tight side. According to 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 problems with the vibrating screen, which can be caused by insufficient screen diameter or insufficient screening capacity. 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 feeding equipment to the feeding port is about 0.9 meters. If the feeding height is too large, the stone will easily "rush" into the crushing cavity at a high speed, causing impact load to the crusher, and the crushing force or power exceeds the design upper limit.