To make sure that your crusher is delivering the desired product, and maximizing its efficiency and productivity, there are a few potential issues that you should be alert to. At Sandvik we have researched the factors that – if not properly addressed – can cause cone crushers to perform below their optimal level.
The primary contributor to poor crusher performance is crushing chamber selection. If the fit between the mantle and concave – in combination with the eccentric throw setting – is incorrect, then the optimal reduction ratio cannot be achieved. Sandvik have found that the wrong crushing chamber set-up can cause a loss in your reduction ratio of up to 40%.
Poor feeding conditions can also be a factor. Any kind of irregularity in the feed – whether from segregated feed, a misaligned feeder, or blockages or packing in the chamber – can cause performance to drop by up to 30%. Uneven distribution of material in the chamber means that the Hydroset – the mechanism that exerts an upward force on the mantle – cannot maintain even pressure. Depending on the type of irregularity, poor feeding conditions can either cause fluctuations in pressure over time, or in different parts of the chamber. Any fluctuation in pressure means that the optimal force will not be delivered consistently so, of course, crusher performance declines.
These are the two main causes of sub-optimal crushing performance, but losses in the reduction ratio can also be caused by selecting the wrong mantle or by having a poor chamber profile or design. Surprisingly, selecting the wrong alloy has no effect when it comes to the reduction ratio (although this will affect the life of wearable parts in your crusher). This graph summarizes the common problems affecting productivity:
