How to improve the efficiency of cone crusher

01). Keep the tight edge discharge port parameters unchanged

If you want stable output of sand and gravel products, quality and load of the production line, the first thing to ensure is that the parameters of the discharge port of the cone tight edge are unchanged, otherwise it is easy to cause unexpected increase in product particle size, which will affect the entire production line system and final output.

For example: the discharge opening of the tight edge of a device is set to 10mm, but due to negligence of inspection and equipment wear, the parameter is expanded to 13mm, then the product of the device less than 10mm will be reduced by 15%, and the output of the target product will be significantly reduced. Quite a few of the sand and stone manufacturers lost their annual revenue in this respect.

Suggestion: It is recommended to check the parameters of the tight-side discharge port every shift.

02). Try to continue the "full chamber" operation

If a cone breaks "hungry" and "satisfactory" due to factors such as unstable feeding, the product's particle size and product rate will also fluctuate. Half-cavity running cones are not ideal in terms of gradation and needle shape.

Suggestion: It is recommended that the sand and stone manufacturers try to ensure that the cone breaks through the cavity to obtain better throughput and grain type. This is especially important for the third-level cone break (short head cone break) of the final product.

03). Don't feed too little

Giving only a small amount of raw material will not reduce the burden of cone breaking. On the contrary, too little raw material will not only damage the output of the product and have a poor particle size, but also have an adverse effect on the cone broken bearings.

According to the working principle of cone breaking, the actual power of cone breaking 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 cone breaking should be kept between 40%-100% of the rated power. Reaching 75%-95% of the rated power during operation is the best choice.

Impact: Running beyond the rated power will affect the service life of the cone and cause various problems.

04). The feeding point needs to be aligned with the center point of the cone breaking inlet

It is recommended to use a vertical deflector to guide the falling point of the feed at the center of the cone breaking inlet. Once the drop point is eccentric, one side of the crushing chamber is full of material and the other side has no or little material, which will cause adverse impacts such as lower crusher throughput, increased needle-shaped products, and super-large particle size.

Improper operation: Once this happens, the operator tends to reduce the tight-side discharge port parameters, trying to make the crusher produce a product of the target particle size, but this is easy to cause overload on the side of too much feed, the adjustment ring jumps, etc. The problem will continue to cause problems such as tilting, tilting, and damage to the base of the adjustment ring in the past, resulting in greater production losses.

05). Ensure even feeding

When feeding, it is necessary to avoid the situation where large-diameter stone materials are concentrated on one side and small-diameter stone materials are concentrated on the other side, so as to ensure uniform mixing of the stone materials.

Impact: Once the feeding is uneven, due to the abnormal increase in bulk density, the side where the small-diameter stones are concentrated is prone to compaction and blockage, causing the adjustment ring to jump. In the face of the jump of the adjustment ring caused by the plugging, the operating operator will be forced to increase the discharge port parameters, resulting in an increase in product particle size. Over time, it will also cause problems such as damage to the adjustment ring, resulting in greater production losses.

06). Minimize the stagnation of the buffer silo, improve the efficiency of the production line

Cone-breaking buffer silo as "enemy of production", the equipment and other related equipment also need to be carefully arranged.

Suggestions: Reasonable use of buffer silos/hoppers and variable-speed feeders (conveyor belts, plate-type vibrating feeders) can enable operating personnel to maintain a cone-filled "full cavity" state for a long time, and easily increase the cone bankruptcy by 10%.

07). Accurately grasp the three upper design limits of cone breaking

There are three design upper limits for cone breaking: upper limit of throughput (capacity), upper limit of power, and upper limit of crushing force.

The upper limit of the cone crushing capacity refers to the maximum throughput of the crusher. A cone crusher that is running in "full cavity" has already reached the maximum throughput. If the limit is exceeded, the feed inlet will overflow; when the feedstock increases and the material breaks finer The actual power of the crusher will increase at the same time; the same as the power, the crushing force generated between the cone-shaped bowl-shaped tile and the crushing wall will also increase with the increase in the amount of feed and the finer material crushing. When the crushing force exceeds the upper limit, The adjustment ring will bounce and loosen.

Ideal operating situation: When the crusher is running at maximum throughput, the actual power and crushing rate are still slightly below the upper limit. Running in a state that exceeds the upper limit of the rated power and breaking force will cause the cone to break overload and permanent fatigue damage. This damage is irreversible and will continue to accumulate, ultimately shortening the life of the cone break.

08). Ensure operation within the upper design limit of the crusher

If the cone crushing operation exceeds the upper limit of the crushing force (adjusting ring runout) or exceeds the rated power, you can:

Slightly increase the tight edge discharge port parameters, and try to ensure "full cavity" operation. The advantage of "full cavity" operation is that there will be a stone-rock process in the crushing cavity, so that the product grain shape can be maintained when the discharge port is slightly larger;

Reduce the feed rate, but this may make it difficult to ensure a good particle shape.

Reason analysis: Generally speaking, the problem of beating or exceeding the rated power of the cone breaking adjustment ring is caused by jamming, feeding eccentricity, uneven feeding, excessive fine material in the feeding, large mud content, broken wall and bowl lining. The error is caused, or it is simply because the operator set the discharge port of the broken edge of the cone too small.

09). Monitor and try to ensure proper crusher speed

Impact: If the proper drive belt tension is not maintained, the drive maintenance is incorrect, or the drive maintenance is neglected, belt slippage and a drop in the speed of the crusher may occur during work. The stone throughput of the crusher with a drop in rotational speed has dropped sharply, while the power consumption has increased sharply, the unit energy consumption has increased, and operating costs have increased.

Suggestion: You can install a speed monitoring device at the intermediate shaft and other locations, connect it to the PLC or directly connect the alarm device. Once the speed drops, you can notify the maintenance personnel to adjust the belt, which can extend the life of the belt and ensure excellent productivity and energy consumption. .

10). Control the fine material content in the feed

Fine material in the feed: the material that enters the crusher's stone and has a particle size equal to or less than that set at the tight-side discharge port. According to experience, for the secondary cone crusher, the fine material content in the feed should not exceed 25%; the tertiary cone crusher feed material should not exceed 10%.

Causes and effects: Excessive fines are usually caused by vibration sieve problems. Insufficient sieve hole diameter or insufficient sieving capacity may cause this problem. Too much fines will cause problems such as insufficient power utilization and abnormal increase in unit energy consumption during crushing.

11). Don't feed too high

For small and medium cone crushers, the maximum suitable height for the material to fall from the feeding equipment to the feed inlet is about 0.9 meters. If the feeding height is too large, the stone can easily "rush" into the crushing chamber at high speed, causing impact load to the crusher, and the crushing force or power exceeds the upper design limit.