11 ways to improve cone bankruptcy

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Maximizing the capacity of the equipment is what many sand and stone producers have come to expect. The <a href="/product/hpt-cone-crusher.html">cone crusher</a> is one of the most popular crushing equipment.

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11 ways to improve cone bankruptcy

Maximizing the capacity of the equipment is what many sand and stone producers have come to expect. The cone crusher is one of the most popular crushing equipment. Today, Xiaobian will contribute 11 kinds of tried and tested methods to help you take the capacity of the cone to a higher level. Expert summary: 11 ways to improve the ability of cone bankruptcy, each one is crucial!

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 opening of the conical breaking edge are unchanged, otherwise it will easily lead to an unexpected increase in the particle size of the product, which will affect the entire production line system and final output.

Case: For example, the tight discharge port of a device is set to 10mm. However, due to negligence and equipment wear, the parameter is expanded to 13mm, then the product with less than 10mm will be reduced by 15%, and the output of the target product will be significantly reduced. . A considerable part of the sandstone producers’ annual income lost in this respect is eye-catching.

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Recommendation: The parameters of the tight side discharge port are recommended to be checked every time the shift is changed.

Try to continue to "full cavity" operation

If a conical cone is "satiated" when it is "starved" due to factors such as unstable feeding, the product size and product rate will fluctuate. The cone of the half-cavity operation is broken, and its products are not ideal in terms of gradation and needle shape.

Recommendation: It is recommended that sand and gravel manufacturers try to ensure that the cone runs through the cavity to obtain better throughput and grain size. This is especially important for the third-stage cone break (short-head taper) that produces the final product.

Don't feed too little

The fact that only a small amount of raw material does not reduce the burden of the cone is contrary to the fact that too little raw material not only impairs the yield of the product, but also has a poor grain size and adversely affects the tapered bearing.

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

Impact: Exceeding the rated power will affect the life of the cone and cause various problems.

Feeding point needs to be aligned with the cone to break into the center of the feed point

It is recommended to use a vertical baffle to guide the feed drop point at the center of the cone feed inlet. Once the drop point is eccentric, one side of the crushing chamber is full and the other side has no material or less material, which will result in lower crusher throughput, increased needle-shaped products, and large product particle size.

Impact: Once this happens, the operator tends to reduce the parameters of the tight side discharge port and try to get the crusher to produce the product with the target particle size. However, it is easy to cause overload and adjust the ring jump on the side of the feed. In the long run, problems such as tilting of the adjusting ring, lifting, and damage to the base will be caused, resulting in greater production losses.

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Guarantee uniform feeding

When feeding, it is necessary to avoid the large-size stone material concentrated on one side, and the small-size stone material concentrated on the other side to ensure uniform mixing of the stone material.

Impact: Once the feeding is uneven, due to the abnormal increase in bulk density, the concentrated side of the small-sized stone material is prone to compaction and blockage, causing the adjustment ring to jump. In the face of the adjustment ring jump caused by the blocking material, the operation operator will be forced to increase the discharge port parameters, resulting in an increase in the particle size of the product. In the long run, problems such as damage to the adjustment ring will also occur, resulting in greater production losses.

Minimize retention of buffer silos and increase production line efficiency

The cone-breaking buffer silo is used as the “enemy of production”, and the equipment and other related equipment also need to be carefully arranged. Suggestion: Reasonable use of buffer silo/hopper, idling feeder (conveyor belt, plate vibrating feeder) can keep the operating operator to maintain the cone full "full cavity" for a long time, and easily increase the cone bankruptcy by 10%.

Accurately grasp the three design limits of the cone

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

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

Ideal operation: When the crusher is operating at maximum throughput, the actual power and breakage rate are still slightly below the upper limit. Operating in excess of the rated power and the upper limit of the crushing force will cause the cone to break the overload and permanent fatigue damage. This damage will irreversibly and will continue to accumulate, eventually shortening the service life of the cone.

Guaranteed to operate within the upper limit of the crusher design

If the cone breaks beyond the upper limit of the crushing force (adjustment ring bounce) or exceeds the rated power, you can:

1) Slightly increase the parameters of the tight side discharge port and try to ensure “full cavity” operation. The advantage of “full cavity” operation is that there will be a stone-rocking process in the crushing chamber, so that the product shape can be maintained when the discharge opening is slightly larger; 2) Or reduce the feed rate, but this may make it difficult to guarantee an excellent grain size.

Analysis of the cause: Generally speaking, the problem of the cone breaking adjustment ring jumping or exceeding the rated power is caused by the jamming, the eccentricity of the feeding material, the uneven feeding, the excessive amount of fine materials in the feeding, the large amount of mud, the broken wall and the bowl lining. The error is caused, or simply because the operator has set the taper to the side of the discharge opening too small.

Monitor and try to ensure proper crusher speed

Impact: If the proper drive belt tension is not maintained, the drive maintenance is incorrect or ignored, the belt slips and the crusher speed drops during operation. The crusher throughput of the falling speed is drastically reduced, while the power consumption is sharply increased, the unit energy consumption is increased, and the operating cost is increased.

Recommendation: It is possible to install the speed monitoring device at the intermediate shaft and other places, connect to the PLC or directly connect the alarm device. Once the speed drop occurs, the maintenance personnel can be notified to adjust the belt, which can extend the belt life and ensure excellent production capacity and energy consumption. .

Control the fines content in the feedstock

Fine material in the feed: into the stone of the crusher, the particle size is equal to or smaller than the material set at the tight discharge port. According to experience, for the secondary cone breaking, the content of fines in the feed should not exceed 25%; the content of fines in the third-stage cone-breaking feed should not exceed 10%.

Causes and effects: Excessive fines are usually caused by vibrating screen problems, and insufficient mesh diameter or insufficient screening capacity may cause this problem. Excessive fine materials can lead to problems such as insufficient power utilization during the crushing process and abnormal increase in unit energy consumption.

Do not oversize the feed height

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

Impact: This problem can cause excessive pressure or strain on the crusher components, resulting in additional maintenance costs and low yields.

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