Cone Crusher Applications

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All You Need To Know About Cone Crusher Applications


The amount of material moving through the cone, the machine’s power draw, the size distribution of the products coming out of the circuit, and the shape of the result are all factors to consider when using a cone crusher in a crushing circuit. The objective is to create the items you want to produce with the least amount of effort and expense economically while observing the necessary standards.

The following mechanical components can affect the rate of production and the quality of the product produced by cone crushers:

1. Cone head diameter
2. The slope of the crushing chamber (angle)
3. Cone stroke of the head.
4. Gyrating speed.
5. Manganese liner profile
6. The setting of Closed side (CSS).
7. Crushing force, measured by operating pressure.
8. Applied power
9. Control of feed

The output product of any crushing operation is influenced by the physical qualities of the material being treated. The following are some of the material qualities that affect the crushing process:

1. Abrasiveness
2. Compressive strength
3. Bulk density
4. Friability
5. Plasticity
6. Feed gradation
7. Moisture content

The reduction ratio can measure the measure of size reduction achieved in an individual Cone Crusher Applications. Cone crushers in secondary crushing applications are typically equipped with the 3.5:1 5-to-1 reduction ratio. Tertiary cone crushers generally operate with a reduced rate that ranges from 2.5:1 up to 4:4. This ratio has been the proportion of feed which 80 percent will be able to pass (F80) divided by the size of the product with which 80 percent will pass (P80). The reduction ratio for hard, damp, high strength material is limited to the lower end of the range, whereas you can effectively crush a soft dry, low strength material in the upper portion of this reduction.

What are the Advantages of Long Stroke?

The more modern longer-stroke high-powered machines of today are more efficient than those used twenty years ago. Large strokes provide a greater area of cross-sectional that allows the material to go across the chamber within the specified time frame. As a result, the more time the length of the stroke; it can crush more material in a particular size machine.

Crusher Speed

The effect on crusher speed or the gyrations of the cone’s head in a minute isn’t as clear as stroke. According to the crushing stroke and the CSS and crushing chamber’s shape, the effects of increasing speed may either enhance or decrease the crusher’s productivity. In each of the above, a particular “sweet spot” in speed can result in maximum throughput for the feed. Generally, a coarse one, like secondary cones within an open circuit, should be used at the lowest part within the range. When the crushing gets more fine, increasing the speed is proven advantageous, specifically when the shape of the crusher is an issue, so it is suggested to use tertiary crushers run in closed circuits and at the top limit within the speed spectrum. It is important to recognize that the faster the crusher operates, the more quickly manganese wears. The lifespan of the other mechanical components may also decrease. Thus, the optimal speed for any particular application is the one that produces the desired rate of production as well as the desired shape, gradation, and form.

What are the limitations of CSS?

For all cone crushers, the lowest dose-side setting will be the one that is close to the point at which the factory’s suggested limitation of the operating pressure is reached, and this is the time where the CSS is opened through the hydraulic release mechanism. Based on the specific circumstances and the crushing characteristics of the material to be treated, the minimum CS can be larger or less than the published specifications. The plastic or clay debris in the crusher teed must be removed to prevent the formation of compacted materials called ‘pancakes,’ which are inelastic and trigger the tramp iron rebellion system.

Producing Quality Product

The rock breaking during the compression crusher could result in a proportion of the elongated or flat product. However, most construction specifications rock products need a unidirectional product. The cubit of cone crusher products is improved by the right selection of the circuit design screen and operating parameters of the crusher.

What are the ten rules for Cubical Product Shape?

If a cubical form is required, the following controls will minimize the amount of flat and elongated particles produced in the cone crusher when properly applied to the crushing circuit.

1. Make sure that the crusher isn’t working too hard

Choke feeding requires filling the crusher head up with at least 193 meters of material for feed. Overload Wis. Bin level sensor, variable speed feeders, and mechanical elements help keep the crusher clear of obstructions.

2. A stable and consistent feed

The feed material must be graded continuously from the largest to the smallest particle size. Make sure there are no gaps in feed grades (gap grades). Make sure to use a reed that is graded properly.

3. Keep certain elements of the stream less than CSS

For the sake of facilitating rock-on-rock attrition crushing, Keep at least 15 percent of the feed under the CSS. Small particles in the feed fill in the spaces between bigger particles, increasing their density and encouraging attrition crushing leading to a better-shaped product. Although it is beneficial to include some feed below the CSS, remove any (-5mm) files from the feed to prevent tramping and compaction conditions where the crusher is released when pressure is high.

4. Limit the reduction rate 

To 3:1 and limit the feed size to ensure that a large reduction ratio is not achieved in one go.

5. Distribute the feed evenly

Distribute the feed of the crusher evenly across the center of the chamber. Separation occurs in the feed when coarse feeds are put on the one end of the feed opening, and smaller recirculated feeds are placed on the opposite side.

6. The setting must have the closest proportions it is to the intended size of
the item

According to research, particle dimensions that are similar to CSS attain the best cubical shape. The cubicity of particles diminishes when they are bigger or smaller than CSS.