Summary: There are several factors that will affect the performance of the crusher, thereby affecting the entire circuit. Here are some ways to help you avoid production losses....

Everyone wants to make the most of their equipment, and jaw crusher operators are no exception. There are several factors that will affect the performance of the crusher, thereby affecting the entire circuit. Here are some ways to help you avoid production losses.

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Avoid Bridging

Continuous bridging of the feed zone of the jaw crusher is a common problem.

Bridging refers to stones that prevent water from entering or moving down to the crushing chamber. This may be because there is only one stone larger than the feed opening, or many stones of average size cross each other and block the feed of the crusher.

Bridging can result in major production losses that are often overlooked. Note that the bridging of the feed area of ​​the primary crusher is relevant, as it may take several minutes to resolve the problem (large rocks are removed, broken, or directly into the chamber). If it happens ten times a day, it will quickly cause one hour of production loss.

If this happens, for example, in one of our crusher models, the C130 has a working capacity of 352 short tons per hour (stph). Assuming a price of $12 per short ton, the daily loss can easily amount to 4000 dollars.

Through strict control of the blasting grid to avoid the generation of excessively large materials, bridges can be avoided, truck loader operators are trained to separate the oversized materials in the pit, as well as the primary crushing equipment operators, by changing the feeder speed and using the installation in the hydraulic hammer in the area visualizes the material flow to the crusher and controls the speed and direction of the stone.

Apply the Correct Jaw Mold Shape

Having a suitable jaw die shape can increase production capacity by more than 20%; otherwise, it will cause losses.

There are many types of rocks, and there are differences in crushability, wear resistance, and flake shape. Choosing the best combination of fixed jaw and movable jaw mold shapes will help optimize production when crushing difficult-to-process materials. Rocks with lower crushability require closer occlusal angles to maintain the designed bearing capacity. Highly abrasive rocks require thicker, heavier, and longer-life jaw molds to avoid production losses caused by frequent replacements. The flake rock needs a tooth-shaped jaw mold to crush it into more cubes to avoid stopping by bridging and belt cutting along the crushing circuit.

Monitor the Condition of the Jaws

In addition to being a key component affecting machine performance, the jaw plate of a jaw crusher also serves to protect the front frame and the swing jaw. Wear is usually caused by an increased crushing angle, loss of tooth profile, reduced CSS to compensate for potential laminar effects, and other factors, resulting in production losses. This is why the crusher needs to be monitored throughout its life cycle.

Since excessive wear can result in a 10-20% reduction in output, it is very important to find the best time for jaw rotation or replacement from a cost and benefit point of view.