A Terex MC cone crusher module that includes a feed bin with a variable speed vibrating feeder. Level indicators in both the bin and crusher hopper work to maintain a choked condition within the cone crusher chamber.
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John Flynn, of Terex Jaques, explains that quarries have numerous factors to consider when selecting cone crushers to create quality aggregate products.
Successful application of a cone crusher within a crushing circuit is measured by the amount of material passing through the cone, the power draw of the machine, the size distribution of the products coming out of the circuit and the shape of the product. The goal is to efficiently and economically produce the target products, conforming with the required specifications.
The mechanical factors that affect the production rate and quality of the material processed by a cone crusher include:
In any crushing operation, physical characteristics of the material being processed affect the output product. The material characteristics that affect the crushing process include:
A measure of the size reduction achieved for a particular crusher application is the reduction ratio. A cone crusher in a secondary crushing application will typically work with a 3.5:1 to 5:1 reduction ratio. Tertiary cone crusher configurations typically work with a reduction ratio of 2.5:1 to 4:1.
The reduction ratio is defined as the ratio of the feed size for which 80 per cent will pass (F80), divided by the product size for which 80 per cent will pass (P80). The reduction ratio for tough, high strength, damp material is restricted to the low end of the application ranges whereas a soft, low strength, dry material can be successfully crushed at the higher end of the reduction ratio.
LONG STROKE ADVANTAGES
The newer, longer stroke, high powered machines of today will outperform the machines in common use 25 years ago. A large stroke provides a greater cross-sectional area for material to pass through the crushing chamber in a given amount of time. The result is that the longer the stroke, the greater the volume of material that can be processed through a given size machine.
CRUSHER SPEED
The influence of crusher speed, or gyrations of the cone head per minute, is not as well defined as stroke. Depending on the crushing stroke, the CSS and the crushing chamber profile, the effect of increased speed can either increase or decrease the production rate of the crusher. For any combination of these, a different 'sweet spot' in speed will produce maximum throughput for a given feed.
In general, a coarse crusher, such as a secondary cone in open circuit, should be run at the low end of the speed range. As the crushing becomes finer, an increase in speed has been found to be beneficial, especially when shape is a factor. Therefore, it is recommended that tertiary crushers that are operated in closed circuit and at the higher end of the speed range. It needs to be understood that the faster the crusher runs, the faster the manganese wears. The life of other mechanical components will also be reduced. Therefore, the optimum speed for any application is the slowest speed that produces the desired production rate, gradation and shape.
LIMITATIONS ON CSS
Minimum closed side setting for any cone crusher is that setting just before the factory recommended limit of operating pressure is reached. This is the point at which the hydraulic relief system will act to open the CSS. Minimum CSS may be greater or smaller than published settings based on the conditions and crushing characteristics of the material being processed. Generally, clay or other plastic material in the crusher feed must be eliminated to prevent the formation of compacted material or 'pancakes', which are non-crushable and will cause activation of the tramp iron relief system.
PRODUCING QUALITY PRODUCT
The breakage of rock in a compression crusher can result in a percentage of flat or elongated product. However, most construction specification rock products require a cubical product. The cubicity of the cone crusher product can be improved with the proper circuit design, screen selection and crusher operating parameters.
TEN RULES FOR CUBICAL PRODUCT SHAPE
When a cubical product shape is required, the following process controls when correctly applied to the crushing circuit will minimize the flat and elongated particles generated inside the cone crusher:
1. Keep the crusher choke-fed.
Choke feed means to keep the head covered with at least 150mm of feed material. Conditions that help keep the crusher choked include surge bins, bin level sensors, adjustable speed feeders, and automation.
2. Stable, continuous feed.
The gradation of the feed material should be continuous from the maximum to minimum particle size. Do not allow 'holes' in the feed gradation (gap graded material). Use a well graded feed.
3. Keep some material smaller than CSS in feed.
Keep up to 15 per cent of feed below the CSS to encourage rock on rock attrition crushing. The small particles in the feed fill the voids between the larger particles which increase the density and promote attrition crushing, thereby improving the product shape.
While it is beneficial to retain some feed below the CSS, it is advisable to screen fines (-5mm) out of the feed to minimise compaction and avoid a tramping condition where the crusher will relieve under high pressure.
4. Restrict final stage reduction ratio to 3:1.
Feed size should be restricted so a high ratio of reduction is not attempted in one pass.
5. Distribute the feed evenly.
Crusher feed should be evenly distributed around the centre of the crushing chamber. Avoid feed segregation where the coarse new feed is on one side of the feed opening and the finer recirculated feed is on the opposite side of the feed opening.
6. Setting should be close to desired product size.
Studies have shown that the most cubical shape is achieved for those particle sizes that are close to the CSS. As the particle size gets larger or smaller than the CSS, the cubicity deteriorates.
7. Use an appropriate crushing chamber for the application.
The most efficient crushing chamber promotes continual crushing of material as it travels through the chamber. If the liners are too coarse, the material falls too far into the chamber which can lead to packing, increasing crushing pressure, power draw and inducing a bowl float or tramping condition. If the liners are too fine, the feed opening will restrict the larger lump sizes from entering the crushing chamber, resulting in reduced throughput, poor choke condition, decreased power draw and elongated product. In some cone crusher designs the feed opening will reduce as the liners wear.
8. Operate the crusher in closed circuit.
Operating a secondary cone crusher in closed circuit limits the material top size for processing in the tertiary circuit and allows the near size particles to fill the voids between the larger particles to induce attrition crushing and break flaky elongated particles. Operating a tertiary cone crusher in a closed circuit provides consistent input gradation and improves the shape by attrition crushing.
9. Operate the crusher at the correct speed for the application.
Running the crusher too fast can generate excessive fines because the material cannot fall as far with each revolution of the eccentric. The material becomes over-crushed and generates excessive crusher dust. Running the crusher too slow will coarsen the output and not allow the attrition rock on rock crushing action that leads to a cubical product.
10. Use the correct flow sheet.
Carefully analyse the complete flow circuit to balance the production. For best shape, do not mix secondary with tertiary/quaternary products.
GUIDE FOR CRUSHING CIRCUIT DESIGN
In any crushing circuit, it is good common sense to get the material to the product piles as quick as possible. This will reduce the wear and tear on the equipment and can lead to increased efficiency and capacity of the circuit because the finished product is not taking up room on the screens, conveyors, and in the crushers.
The size of the raw feed or blasted material and the specification of the final products will dictate the number of crushing stages and screens required. If there is also a shape specification, additional controls and crushing stages may be required. A low reduction ratio application may be able to get by with a jaw/cone/ screen circuit (two-stage crushing). A higher reduction ratio application may require a jaw/ screen/cone/screen/cone circuit (three-stage crushing). A large reduction ratio application may require four or more stages of crushing.
The crusher breaks down the rock to a smaller size. The screen is the 'cash register' of the crushing circuit in that it determines the final gradation of each product pile. In general, it is good practice to oversize the screen to account for changes in environmental conditions that can affect
the overall performance of the crushing circuit.
CONE CRUSHER TYPES
Cone crushers can be categorised into three main design types. With floating bowl and screw bowl cone crushers the upper frame raises to open CSS or relieve crushing pressure. The third type ' the spider-bearing cone crushers ' incorporate a shaft supported by a hydraulic piston which controls CSS and crushing pressure. Each machine type has its own features and advantages and each is best suited to particular applications. Terex, through the TC cone, Cedarapids MVP, TG cone and Jaques Gyracone, includes each of these main cone crusher types within its equipment range to ensure it can provide the best option across all crushing applications.
John Flynn is the Australia and New Zealand business manager for Terex Jaques. Visit terex.com/mps/en-aus
For more information, please visit vibrating screen feeder.
Cone crusher is one of the widely used mining machinery and equipment. With the development of the market, there are many types of cone crushers at home and abroad which have various performances. Therefore, how to correctly select the models has become one of the most concerned issues for users. And at the following introduction, we will take the three mainstream cone crushers on the market as examples to help users choose the most suitable machine by analyzing their structural characteristics, advantages and disadvantages.
Symons cone crusher is the earliest cone crusher, as well as the most widely used crusher in the world. Based on the introduction and absorption of foreign technology and according to the customer's needs, it has been developed into a modern and high-performance cone crusher integrated with high swing frequency, optimized cavity and reasonable stroke by adopting the principle of laminating crushing and the concept of more crushing and less grinding. After the optimization and improvement of the experts, Symons cone crusher has a more reasonable structure and advanced technology, and performs excellently in manufacturing, installation, use and maintenance.
It can be widely used in metal and non-metal mines, cement plants, building construction, sand making and metallurgy, etc. It is also suitable for iron ore, non-ferrous metal ore, granite, limestone, quartzite, sandstone, pebbles, etc.
However, since the Symons cone crusher crushes by reducing the size of the discharge port to control the particle size of the product, the machine is not suitable for use as ultrafine crusher or sand making.
It has the following advantages
Many types of crushing chambers: According to the site conditions, the user can choose three different chambers which have high crushing efficiency, uniform product size, well-shaped granule, uniformly worn concave and wear parts with long service life.
Dry oil seal for dustproof: It adopts a unique dustproof sealing structure which is reliable, effectively prolonging the replacement cycle of lubricating oil and the service life of parts.
Support for large crushing ratios: Key parts are manufactured by special material. The space when the crushing cone leaves the concave is large in each stroke, allowing more material to enter the crushing chamber and forming a larger discharge volume, which speeds up the passage of the material through the crushing chamber.
High output: Compared with other models, Symons cone crusher has a long broken arm with large stroke and crushing force. So it can crush much more materials in the crushing chamber effectively.
High efficiency: The main shaft of the machine has support at both upper and lower ends, which can withstand greater crushing force and larger stroke. In addition, it has a special crushing cavity shape suitable for the lamination principle, which makes the machine have higher crushing efficiency.
Low maintenance cost for daily operation: Because of reasonable part selection and structural design, long service life of parts and long crushing arm length, load on sliding bearings, gears and frames have been reduced greatly; uniform particle size of crushed products reduces cyclic load; hydraulic clearing system is easy to operate and control, reducing downtime and power consumption.
Discharge port adjustment: Symons cone crusher includes a hydraulic adjustment mechanism to quickly adjust the size of the discharge port.
Lubrication circulation system: Special light oil lubrication circulation system ensures that the oil return temperature is within60'; the new oil filtration system ensures that the transmission device is not accidentally worn, thus stabilizing the service life. This advanced and reliable double pump oil supply lubrication system ensures the temperature rise of the main shaft and copper tile, long service life, reliable operation and extended maintenance period.
Overload protection: The spring safety system is an overload protection device that allows metal objects to pass through the crushing chamber without damaging the machine.
The single-cylinder hydraulic cone crusher is developed with the world's advanced crushing technology, integrating mechanical, hydraulic, electrical and intelligent technologies. The new crushing structure, optimized laminated crushing chamber and fully automatic control system make the single-cylinder hydraulic cone crusher special with the performance characteristics that traditional cone crusher does not have.
It is widely used in metallurgy, construction, cement, water conservancy, highways, railways, mineral processing and other fields, with medium, fine, ultra-fine crushing functions.
However, the crushing force of the single-cylinder hydraulic cone is slightly insufficient, especially for crushing hard materials. Because the adjustment method is to lift and lower movable cone, the wear and tear of concave is not uniform under the condition of uneven feeding. Besides, the oil cylinder is at the bottom, leaving small space for lower parts, which brings certain difficulties to maintain.
It has the following advantages
More uniform grain size: The single-cylinder hydraulic cone crusher adopts the unique crushing cavity shape and laminating crushing principle, so that the proportion of cubes in the finished product is obviously increased, the needle-like stones are reduced, and the grain size is more uniform;
Large production capacity: The high swing frequency and large inclination of steep slope design make the throughput of the single-cylinder hydraulic cone crusher 40% larger than the ordinary cone. In addition, the feed port of the machine is also larger than the ordinary cone. So it will be destined to have a higher production capacity than the general ones;
High degree of automation: Compared with the old version of the spring cone crusher, the new single-cylinder hydraulic cone crusher can automatically adjust the size of the discharge port without stopping the machine, and can also be equipped with a computer control system for remote operation;
Good energy-saving and environmental protection: Under the same production capacity, the single-cylinder hydraulic cone crusher consumes less energy per unit hour.
Multi-cylinder hydraulic cone crusher
The multi-cylinder hydraulic cone crusher is suitable for crushing various ores and rocks of medium and or above hardness, such as limestone, iron ore, pebbles, non-ferrous metal ore, granite, basalt, limestone, quartzite and sandstone.
Its high speed, high crushing capacity and unique patented design make the finished product with an extremely high-quality cube shape, and the easy maintenance features ensure extraordinary high stability operation. It is a new generation of products that replaces spring cone crushers and newer general hydraulic cone crushers.
Its high speed, high crushing capacity and unique patented design make the finished product with an extremely high-quality cube shape, and the easy maintenance features ensure extraordinary high stability operation. It is a new generation of products that replaces spring cone crushers and newer general hydraulic cone crushers.
However, since the multi-cylinder cone crusher has small a R radius of the spherical surface, so the radius of the swing is small, causing unstable phenomena such as swaying, tipping, and flying of the moving cone, as well as problems such as poor contact between the main shaft and the bushing, and large impact force, which affects the normal work of the machine. But its processing capacity is higher, and the material smaller than the discharge port can even account for 70%~80% of the total volume.
It has the following advantages
Hydraulic motor adjusts the discharge port: The whole hydraulic operation is adopted from the insurance clearing chamber to the adjustment and locking, and hydraulic lubrication combined oil station is small in size and simple to wire.
Fixed shaft structure design: It adopts a unique structure that the main shaft is fixed and the eccentric sleeve rotates around the main shaft. Optimized transmission components and internal structure design make it strong in bearing capacity with advantages of large installed power, small size, high efficiency and low noise.
Laminated crushing chamber design: The material is crushed by the principle of laminating crushing, and the crushing efficiency is greatly improved by optimizing the equipment and cavity type; the finished material has a cubic shape, uniform fineness with high quality.
PLC+ touch screen automatic control system: The operation is more stable and reliable, easier to operate. The downtime is reduced greatly, achieving completely automatic operation.
Various crushing chamber configuration: When equipped with the medium and fine crushing chamber, only a small number of parts such as the corresponding cavity liner are needed to replace, meeting the needs of medium and fine crushing process and achieving a versatile use of the machine.
Through the above details, the three mainstream cone crushers have their own characteristics and outstanding advantages. But which one is the best suitable one, the users can also make a decision according to the following form:
TypesAdvantagesdisadvantagesSymons cone crusherSymons cone is the earliest as well as the most widely used crusher in the world; The price is cheap and most users can afford it.Maintenance is difficult; It can't be fully fed, and the processing efficiency is low; Not suitable for ultra-fine crushing and sand making.Slide to the right>>
Under the background that the world's mineral resources are in short supply and countries are robbing resources overseas, the cone crusher market will be even broader. Compared with jaw crusher and impact crusher, cone crusher has a higher demand on technology. And tiny details can affect the lifespan of the equipment.
Although there are many kinds of cone crushers and countless manufacturers available on the market, but users should choose the professional and reliable manufacturers when purchasing. In addition, through the above introduction, users can choose the cone crusher that suits them best according to their economic strength, crushed materials and target output.
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