In my estimation, 80 percent of the cone crushers in the field are not performing at their full potential because of improper feeding and use, leading to reduction in the product yield of up to 50 percent and more than doubling the cost of repairs and maintenance.
Why is this so pervasive and yet very little is done to correct or prevent it? Answers to these questions lie in the thorough understanding of the crusher design and correct use of it to crush rock so as to maximize the yield, i.e. salable product.
At the same time, by using a crusher within its design limits, the operating costs (repairs, maintenance and downtime) are minimized. After all aren’t we all looking for lowest cost per ton of desired product(s)? That being our ultimate goal, let’s look at the reasons for the crusher misuse and what can be done to correct or prevent it.
Every cone crusher design involves the choice of values for connected Horsepower (HP), Volumetric Capacity (Throughput) and Crushing Force (CF) magnitude. Different values of this ‘trio’ are selected for different sizes of the crusher before proceeding with detailed structural and mechanical designs.
The ideal design of a crusher has HP, Throughput and CF matched so they all peak at the same time for most applications, to give maximum yield. Simultaneously the application or the use of the crusher must be correct to have the ‘trio’ peak for maximum productivity.
Cone crushers are fed many different ways, i.e. a direct discharge from a belt, a feed bin, a vibrating feeder, a rock box, a chute or a combination of the above.dryer machine:http://www.hx-crusher.com/dryer_machine.html
When feed-rate control is used in combination with the rotating feed distributor, you can effectively control the horsepower draw, crushing force and volumetric capacity (for a desired reduction ratio) to have them peak simultaneously within the design limits for maximum productivity.
The older generation of cone crushers was much more forgiving in terms of the abuse they tolerated due to misapplication, overloads and poor maintenance. Modern high-horsepower, lighter-weight cone crushers introduced during the last 10 years are much less tolerant to abuse and misapplication. This is because their structural and mechanical designs carry much smaller margins of safety.
It is most important that if you want to take advantage of high performance then you must pay serious attention to the way crushers are applied or used. Most importantly you must operate them within their design limits of horsepower and crushing force.
To achieve this, proper feeding of these high-horsepower crushers is a must. In addition, an electronic ‘health monitor’ should be used to constantly monitor the vital parameters of the crusher to issue warnings or automatically take corrective actions to ensure safe operation within the design limits. With rapid advances and falling prices of technology and electronics, the pay back of the cost of such a monitor should be less than a few weeks. Inaddition to the attention that we need to pay to the cone crusher, in order to increase the product yield of other crusher machines such as hammer crusher, we should also follow the above principles.