Cone crusher is the main equipment of secondary and tertiary crushing, which can crush all kinds of medium hard and hard materials. However, many investors and operators find that sometimes even if the production is full, the capacity of cone breaking is still not high. To make sure you make the most of the cone crusher, we share 10 tips to maximize the productivity of the cone crusher to help you.

Operate at a consistent closed-side discharge setting (CSS)

Closed-side discharge setting

If you want a stable output, quality and production line load of sand and gravel products, you must first ensure a consistent closed side setting (CSS), otherwise it will easily cause the product size to become larger, which will affect the entire crushing system.

If the CSS of the cone crusher is set to 10 mm, due to negligence in inspection and equipment wear, the parameter is expanded to 13 mm, then the aggregate of the equipment less than 10 mm will be reduced by 15%, and the production efficiency of the cone crusher will be significantly reduced, which will eventually lead to Investors and operators lose part of their profits. It is best to check the settings of the crusher by a per-shift basis.

Make sure continuous “full cavity” operation

If a cone crusher cannot maintain reasonable cavity levels, the grain shape of its products will not be consistent, and the output will be affected. The proportion of flake aggregate in the cone crusher operated by half cavity will increase.

Aggregate manufacturers must ensure that the cone crusher is at reasonable cavity levels to obtain better throughput and particle size.

full cavity

Make sure not to feed too little

The hungry crusher is an inefficient crusher. Insufficient material filling in the crushing cavity will not reduce the burden of cone crushing, but it will affect productivity and machine reliability, as well as increase liner wear and product defect rates.

According to the working principle of cone crusher, the actual power of cone crusher should not be less than 40% of the rated power. In order to maximize the productivity, the actual power of the cone crusher should be kept between 40%-100% of the rated power, and 75%-95% of the rated power during operation is the best choice.

Operation beyond the rated power will affect the service life of the cone crusher and cause various problems.

Make sure the feed is evenly and vertically distributed

A vertical deflector is set at the center of the inlet of the cone crusher to ensure that the material is evenly filled from the center point.

If the feeding point is misaligned, the proportion of sheet products will increase, resulting in a low finished product qualification rate. It will also increase the wear of the liner and affect the stability of the machine.

Make sure the feed is not segregated

Segregation here means that coarse and fine particles enter different parts of the chamber.

Generally, fine particles will accumulate at the bottom of the conveyor, and coarser particles will accumulate at the top. When entering the crushing cavity, larger stones will accumulate on one side of the crushing cavity, and small stones will accumulate on the other side, which will cause the accumulation and blockage of the side where the small stones gather, and cause the adjustment ring to shake. Operators will be forced to increase the discharge port parameters, resulting in increased product particle size. A long time will also cause problems such as damage to the adjustment ring, resulting in greater production losses.

A vibrating feeder can be added in front of the cone crusher to control the feed distribution.

Reasonable use of buffer silos

Buffer silos

Reasonable use of buffer silos/hoppers and variable-speed feeding devices (conveyor belts, vibrating feeders) keep the cone crusher in a “full cavity” state, and the volume of cone failure will increase by 10%.

Operate within the crusher design limitations

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

Slightly increase the parameters of CSS, and try to ensure “full cavity” operation. The advantage of “full cavity” is that there will be a rock-to-stone process in the crushing cavity, which can maintain the product grain shape.

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

Generally speaking, the problem of conical crusher’s adjustment ring beating or exceeding the rated power is caused by material blockage, feeding eccentricity, uneven feeding, excessive fine material in the feeding, large proportion of mud, and incorrect use of liners. It may also be because the operator has made the CSS too small.

Maintain a proper crusher speed

If the proper drive belt tension is not maintained, the motor is not maintained correctly or neglected, then the motor belt may slip and the crusher speed may drop during work. The throughput of the crusher with reduced speed will also decrease, and the power consumption will increase sharply, increasing operating costs.

The speed monitoring device can be installed on the intermediate shaft and other positions, connected to the PLC or directly connected to the alarm device. Once the speed drops, the maintenance personnel can be notified to adjust the belt, which can extend the life of the belt while ensuring excellent productivity and energy consumption.

Control the proportion of fine materials

Fine material: The material entering the crusher is equal to or smaller than the crusher’s closed-side discharge setting.

Too much fine material is usually caused by the problem of the vibrating screen, which may be caused by insufficient screen hole diameter or insufficient screening capacity. This will lead to insufficient power utilization and abnormal increase in energy consumption during the crushing process.

According to experience, for the secondary cone crusher, the proportion of fine material in the feed should not exceed 25%. For the tertiary cone crusher, the proportion of fine material in the feed should not exceed 10%.

Limit the height and the speed from which the feed material drops

Stone box with steps
(Stone box with steps)

For small and medium-sized cone crushers, the maximum distance from the feeding equipment to the top of the crusher is about 0.9 meters. If the feeding distance is too large, the stone will easily impact the crushing cavity at high speed, causing impact load on the equipment, resulting in additional maintenance costs and low output.

In order to avoid these problems, the feeding speed should be reduced. Steps can be set in the chute or stone box to reduce the falling height.

You can contact us for more problems and solutions encountered by cone crushers in aggregate processing.

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