The primary crusher is the most important component of a mining plant. It helps reduce the size of the large rocks. the smaller pieces are processed through a range of site components like belts, screens and secondary crushers to get the result you want. Nearly all components of a crushing site are dependent upon the primary crusher. It is essential to select the appropriate one that meets your requirements.
These guidelines will assist you to determine which primary crusher best suits your project's aggregate requirements. We'll start with the objective before proceeding to the model refinement. Then, we'll put in the primary crusher.
Define the reason for the primary crusher
The first step in selecting the appropriate mill liners foundry is to find the intended purpose of its use. This is the very first step in making a decision and could take some time and some guidance. The two most crucial elements to consider are the kind of material you are using and the size of the feed that will be crushed.
Also, you should take into consideration the content of your material's moisture as well as the production target amount, discharge grade, and the long-term strategy for the site. Let's examine the different types of primary crushers in order to know their purpose.
Jaw crushers
The jaw crusher is the primary crusher utilized in mineral processing plants. It is comprised of two jaws situated in an "V" configuration. One side is fixed and the other moves to crush large rocks and break them down into smaller pieces. It's portable and can be moved to other processing plants when needed. Jaw crushers are ideal to crush abrasive materials.
Jaw crushers create the most coarse material because they break rock in its natural lines of weakness. This makes jaw crushers the ideal primary crushers for preparing materials to be further processed.
Gyratory crushers
Gyratory crushers are ideal to produce large quantities of material (which is usually around 1,000,000 tonnes annually). They operate on the same principle similar to jaw crushers however, instead of an "V" alignment there is a circular gap utilized. The crushed material is pressed between an oscillating mantle as well as a fixed conical box. Gyratory crushers are ideal for reducing the dimensions of rocks that are granular like granite, and are able to handle many feed particles such as slabby rock (which jaw crushers are unable to accept due to the shape of the feed opening).
Impact crushers
The impact crusher works by pushing feed material against the plates. This reduces its size. They are effective in processing materials like limestone with better shape than some of the mentioned crushers.
Impact crushers are used when the shape of the material is a crucial necessity. The crushing action breaks materials in its natural cleavage planes and results in a better product quality in terms of shape. The only disadvantage is that the impact of crushing can lead to excessive wear costs in the long term.
The capacity of the primary crusher and its ability to accept materials with no blockages are possibly the most significant aspects of the equipment. Larger primary crushers tend to be more expensive, and therefore the cost of investment calculations are essential to determine which crusher is required to reduce materials into smaller sizes.
Assessing the fit and function of your primary crusher
Once you have decided on the type of crusher that you want, it is time to analyze the machine's performance. Simulations are an excellent instrument for this. Simulations can be used to determine the way that crusher liners will function and the impact it has on the downstream load. There are numerous software programs that simulate the process of aggregation that can give you a good idea of the crusher's real-world performance.
Based on the results, running a simulation can impact crusher recommendations. If you have long-term plans, it is better to make use of a stationary model instead of a portable one. The concept drawing includes specifics about the site of crushing like the elevation of the site and topographic map.
Conceptual drawings can give you a clear idea of how the primary crusher will fit alongside the other components in the site. In order to increase their capacity, primary crushers will need to have screens and conveyors upgraded.
The correct installation of the primary crusher
The final step is to make sure that the primary crusher is set up correctly. The process can be complicated and confusing depending on the circumstances. To ensure a successful installation, contact your manufacturer for technicians to help with the installation. From project management all the way up to the performance audit, having an experienced technician to help you out will give you added reliability and optimise site configuration from the beginning.