CONE CRUSHERS

How should we do to improve cone crusher efficiency in crushing plant?

3 tips for energy efficient and productive cone crushing

It has been estimated that 5–15% of an aggregate producers’ cost can be associated with the cost of electricity. If cone crusher maintenance is neglected, the result will be a detrimental effect on productivity and an overall higher energy cost per ton of material crushed. It’s not uncommon that aggregate producers’ maintenance teams are not fully aware of the maintenance requirements of a cone crusher or its impact on energy consumption. Make sure that at least these five things are checked.

1- Cone crusher drive belt maintenance

If proper cone crusher drive belt tension and alignment is “not maintained”, the drive belts will slip at the higher power levels and the crusher will inevitably slow down. A slowing crusher will result in excessively high and fluctuating power peaks at a very low crusher throughput tonnage. Improper drive belt maintenance will result in high horsepower consumption at a low crusher throughput tonnage, this inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton).

Drive belt condition, alignment and tension should be checked on a weekly basis (40 hours). A “pulse input speed sensor” can be used to warn operations of a slowing crusher. This speed sensor will also extend drive belt life as the maintenance department will get the opportunity to service (retighten) the drive belts prior to belt failure or prior to crusher stall out.

2- Cone crusher hydraulic power unit maintenance

Improper hydraulic power unit maintenance can cause the pump and motor assembly to cycle more often than it should or worst-case scenario, to run continuously throughout the day. This inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton). It will also result in a shorter life cycle of the hydraulic power unit ancillary components, such as: the pump, motor, coupling, motor starter, pressure switches, solenoid valves, seals, packings, etc. The hydraulic power unit should be inspected on a daily basis (8 hours) for, filter condition, breather condition, leaks, loose connections or unusual noises.

3- Cone crusher discharge compartment maintenance

If the under-crusher discharge compartment is not properly maintained and material builds up on the crusher arms or the countershaft box, crushed product will be restricted from exiting the crushing chamber, this will result in a low crusher throughput tonnage at an extremely high-power level. This inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton). The under-crusher discharge area should be inspected for built-up material on a daily (8 hour) basis.

Reference; Mac. Eng. Yusuf ARMAN

Reference;

(1) Crusher — Wikipedia

(2) Crushing plant — Wikipedia

(3) https://www.quora.com/search?q=cone+crusher

(4) Cone crushers — YouTube

What are Cone Crushers used for?

How should we do to improve cone crusher efficiency in crushing plant?

3 tips for energy efficient and productive cone crushing

It has been estimated that 5–15% of an aggregate producers’ cost can be associated with the cost of electricity. If cone crusher maintenance is neglected, the result will be a detrimental effect on productivity and an overall higher energy cost per ton of material crushed. It’s not uncommon that aggregate producers’ maintenance teams are not fully aware of the maintenance requirements of a cone crusher or its impact on energy consumption. Make sure that at least these five things are checked.

1- Cone crusher drive belt maintenance

If proper cone crusher drive belt tension and alignment is “not maintained”, the drive belts will slip at the higher power levels and the crusher will inevitably slow down. A slowing crusher will result in excessively high and fluctuating power peaks at a very low crusher throughput tonnage. Improper drive belt maintenance will result in high horsepower consumption at a low crusher throughput tonnage, this inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton).

Drive belt condition, alignment and tension should be checked on a weekly basis (40 hours). A “pulse input speed sensor” can be used to warn operations of a slowing crusher. This speed sensor will also extend drive belt life as the maintenance department will get the opportunity to service (retighten) the drive belts prior to belt failure or prior to crusher stall out.

2- Cone crusher hydraulic power unit maintenance

Improper hydraulic power unit maintenance can cause the pump and motor assembly to cycle more often than it should or worst-case scenario, to run continuously throughout the day. This inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton). It will also result in a shorter life cycle of the hydraulic power unit ancillary components, such as: the pump, motor, coupling, motor starter, pressure switches, solenoid valves, seals, packings, etc. The hydraulic power unit should be inspected on a daily basis (8 hours) for, filter condition, breather condition, leaks, loose connections or unusual noises.

3- Cone crusher discharge compartment maintenance

If the under-crusher discharge compartment is not properly maintained and material builds up on the crusher arms or the countershaft box, crushed product will be restricted from exiting the crushing chamber, this will result in a low crusher throughput tonnage at an extremely high-power level. This inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton). The under-crusher discharge area should be inspected for built-up material on a daily (8 hour) basis.

Reference; Mac. Eng. Yusuf ARMAN

Reference;

(1) Crusher — Wikipedia

(2) Crushing plant — Wikipedia

(3) https://www.quora.com/search?q=cone+crusher

(4) Cone crushers — YouTube

What is Cone Crusher? What are the Samples?

How should we do to improve cone crusher efficiency in crushing plant?

3 tips for energy efficient and productive cone crushing

It has been estimated that 5–15% of an aggregate producers’ cost can be associated with the cost of electricity. If cone crusher maintenance is neglected, the result will be a detrimental effect on productivity and an overall higher energy cost per ton of material crushed. It’s not uncommon that aggregate producers’ maintenance teams are not fully aware of the maintenance requirements of a cone crusher or its impact on energy consumption. Make sure that at least these five things are checked.

1- Cone crusher drive belt maintenance

If proper cone crusher drive belt tension and alignment is “not maintained”, the drive belts will slip at the higher power levels and the crusher will inevitably slow down. A slowing crusher will result in excessively high and fluctuating power peaks at a very low crusher throughput tonnage. Improper drive belt maintenance will result in high horsepower consumption at a low crusher throughput tonnage, this inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton).

Drive belt condition, alignment and tension should be checked on a weekly basis (40 hours). A “pulse input speed sensor” can be used to warn operations of a slowing crusher. This speed sensor will also extend drive belt life as the maintenance department will get the opportunity to service (retighten) the drive belts prior to belt failure or prior to crusher stall out.

2- Cone crusher hydraulic power unit maintenance

Improper hydraulic power unit maintenance can cause the pump and motor assembly to cycle more often than it should or worst-case scenario, to run continuously throughout the day. This inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton). It will also result in a shorter life cycle of the hydraulic power unit ancillary components, such as: the pump, motor, coupling, motor starter, pressure switches, solenoid valves, seals, packings, etc. The hydraulic power unit should be inspected on a daily basis (8 hours) for, filter condition, breather condition, leaks, loose connections or unusual noises.

3- Cone crusher discharge compartment maintenance

If the under-crusher discharge compartment is not properly maintained and material builds up on the crusher arms or the countershaft box, crushed product will be restricted from exiting the crushing chamber, this will result in a low crusher throughput tonnage at an extremely high-power level. This inefficient use of connected horsepower will result in a higher energy cost per ton of material crushed (kW/hr per ton). The under-crusher discharge area should be inspected for built-up material on a daily (8 hour) basis.

Reference; Mac. Eng. Yusuf ARMAN

Reference;

(1) Crusher — Wikipedia

(2) Crushing plant — Wikipedia

(3) https://www.quora.com/search?q=cone+crusher

(4) Cone crushers — YouTube

What is the capacity of the Cone Crusher?

What are the purposes of the Cone Crusher?

Crushing action is produced by the oscillation or throw (opening & closing) between the moving mantle liner, mounted on the cone, and the stationary concave liners mounted within the upper casing of the crusher.

The mantle and concaves form the working surfaces of the crusher, as this is where the crushing action occurs.

The width of the discharge opening dictates the size of a crusher’s product output. The size of a crusher’s product output can be varied by raising or lowering the upper casing.

This adjustment varies the size of a cone crusher’s product because the gap between the mantle and concaves is correspondingly increased or decreased. Raising the concaves (bowl liner) thus increases the product’s size output, whilst lowering the concaves decreases the product’s size output.

Because the motion of the mantle is eccentric, the gap between the mantle and concaves on one side is different to the gap on the opposite side, at any given time. When the gap between the mantle and concaves is at its largest, the opposite side gap is at its smallest.

The widest gap between the mantle and concaves is referred to as the open side setting (OSS), whilst the narrowest gap is referred to as the closed side setting (CSS). Both settings are important because they describe the largest possible product size output (OSS) and smallest possible product size output (CSS). The OSS can be given as:

Eccentric motion is achieved by the lower eccentric bushing and drive arrangement at the bottom of the main shaft. The input pinion drive countershaft is supported by pinion bearings and powered by an electric motor. An external gearbox or belt drive arrangement reduces the motor speed at the crusher; typical crusher speeds range from several hundred rpm up to approx.

1000 rpm. In some cases, a clutch system may also be used to absorb shocks. The pinion on the countershaft meshes with the eccentric gear drive, or crown gear.

The inner surface of the eccentric bushing is machined off-centre from the centre-axis of the crusher. As the eccentric bushing rotates, the lower shaft oscillates in an elliptical orbit around the centreline of the crusher.

This action causes the gap between the mantle and concave liners to open and close upon each rotation of the shaft. At the upper end of the mantle this movement is very small, but as the feed falls lower, the throw increases and the crushing force also correspondingly increases.

Crushed feed falls to the bottom shell assembly and is discharged to the product conveying system for further processing. The lower casing also houses a forced lubrication and hydraulic system, which is critical for the drive arrangement and tramp release cylinders (if fitted).

Further processing may involve additional crushing stages (secondary, tertiary, quaternary etc.), milling, and other beneficiation steps to suit the product being processed.

Reference; Mac. Eng. Yusuf ARMAN

Mechanical Eng. Msc Suphi Yavuz, Başak Yavuz Makine, Technical Notes

Mining Eng. Msc Necati Yıldız, Ore Dressing and Enrichment Book

Reference;

(1) Crusher — Wikipedia

(2) Crushing plant — Wikipedia

(3) https://www.quora.com/search?q=cone+crusher

(4) Cone crushers — YouTube

What are the purposes of the Cone Crusher?

Crushing action is produced by the oscillation or throw (opening & closing) between the moving mantle liner, mounted on the cone, and the stationary concave liners mounted within the upper casing of the crusher.

The mantle and concaves form the working surfaces of the crusher, as this is where the crushing action occurs.

The width of the discharge opening dictates the size of a crusher’s product output. The size of a crusher’s product output can be varied by raising or lowering the upper casing.

This adjustment varies the size of a cone crusher’s product because the gap between the mantle and concaves is correspondingly increased or decreased. Raising the concaves (bowl liner) thus increases the product’s size output, whilst lowering the concaves decreases the product’s size output.

Because the motion of the mantle is eccentric, the gap between the mantle and concaves on one side is different to the gap on the opposite side, at any given time. When the gap between the mantle and concaves is at its largest, the opposite side gap is at its smallest.

The widest gap between the mantle and concaves is referred to as the open side setting (OSS), whilst the narrowest gap is referred to as the closed side setting (CSS). Both settings are important because they describe the largest possible product size output (OSS) and smallest possible product size output (CSS). The OSS can be given as:

Eccentric motion is achieved by the lower eccentric bushing and drive arrangement at the bottom of the main shaft. The input pinion drive countershaft is supported by pinion bearings and powered by an electric motor. An external gearbox or belt drive arrangement reduces the motor speed at the crusher; typical crusher speeds range from several hundred rpm up to approx.

1000 rpm. In some cases, a clutch system may also be used to absorb shocks. The pinion on the countershaft meshes with the eccentric gear drive, or crown gear.

The inner surface of the eccentric bushing is machined off-centre from the centre-axis of the crusher. As the eccentric bushing rotates, the lower shaft oscillates in an elliptical orbit around the centreline of the crusher.

This action causes the gap between the mantle and concave liners to open and close upon each rotation of the shaft. At the upper end of the mantle this movement is very small, but as the feed falls lower, the throw increases and the crushing force also correspondingly increases.

Crushed feed falls to the bottom shell assembly and is discharged to the product conveying system for further processing. The lower casing also houses a forced lubrication and hydraulic system, which is critical for the drive arrangement and tramp release cylinders (if fitted).

Further processing may involve additional crushing stages (secondary, tertiary, quaternary etc.), milling, and other beneficiation steps to suit the product being processed.

Reference; Mac. Eng. Yusuf ARMAN

Mechanical Eng. Msc Suphi Yavuz, Başak Yavuz Makine, Technical Notes

Mining Eng. Msc Necati Yıldız, Ore Dressing and Enrichment Book

Reference;

(1) Crusher — Wikipedia

(2) Crushing plant — Wikipedia

(3) https://www.quora.com/search?q=cone+crusher

(4) Cone crushers — YouTube

How should we do to improve cone crusher efficiency in crushing plant?

What are the purposes of the Cone Crusher?

Crushing action is produced by the oscillation or throw (opening & closing) between the moving mantle liner, mounted on the cone, and the stationary concave liners mounted within the upper casing of the crusher.

The mantle and concaves form the working surfaces of the crusher, as this is where the crushing action occurs.

The width of the discharge opening dictates the size of a crusher’s product output. The size of a crusher’s product output can be varied by raising or lowering the upper casing.

This adjustment varies the size of a cone crusher’s product because the gap between the mantle and concaves is correspondingly increased or decreased. Raising the concaves (bowl liner) thus increases the product’s size output, whilst lowering the concaves decreases the product’s size output.

Because the motion of the mantle is eccentric, the gap between the mantle and concaves on one side is different to the gap on the opposite side, at any given time. When the gap between the mantle and concaves is at its largest, the opposite side gap is at its smallest.

The widest gap between the mantle and concaves is referred to as the open side setting (OSS), whilst the narrowest gap is referred to as the closed side setting (CSS). Both settings are important because they describe the largest possible product size output (OSS) and smallest possible product size output (CSS). The OSS can be given as:

Eccentric motion is achieved by the lower eccentric bushing and drive arrangement at the bottom of the main shaft. The input pinion drive countershaft is supported by pinion bearings and powered by an electric motor. An external gearbox or belt drive arrangement reduces the motor speed at the crusher; typical crusher speeds range from several hundred rpm up to approx.

1000 rpm. In some cases, a clutch system may also be used to absorb shocks. The pinion on the countershaft meshes with the eccentric gear drive, or crown gear.

The inner surface of the eccentric bushing is machined off-centre from the centre-axis of the crusher. As the eccentric bushing rotates, the lower shaft oscillates in an elliptical orbit around the centreline of the crusher.

This action causes the gap between the mantle and concave liners to open and close upon each rotation of the shaft. At the upper end of the mantle this movement is very small, but as the feed falls lower, the throw increases and the crushing force also correspondingly increases.

Crushed feed falls to the bottom shell assembly and is discharged to the product conveying system for further processing. The lower casing also houses a forced lubrication and hydraulic system, which is critical for the drive arrangement and tramp release cylinders (if fitted).

Further processing may involve additional crushing stages (secondary, tertiary, quaternary etc.), milling, and other beneficiation steps to suit the product being processed.

Reference; Mac. Eng. Yusuf ARMAN

Mechanical Eng. Msc Suphi Yavuz, Başak Yavuz Makine, Technical Notes

Mining Eng. Msc Necati Yıldız, Ore Dressing and Enrichment Book

Reference;

(1) Crusher — Wikipedia

(2) Crushing plant — Wikipedia

(3) https://www.quora.com/search?q=cone+crusher

(4) Cone crushers — YouTube