Three ways to increase crushing output

Two-step optimization of the crushing circuit: first to optimize the performance of the equipment, and second to optimize the overall performance of the circuit.

Optimizing a piece of equipment includes a comprehensive inspection of the equipment to maximize process and mechanical performance. It is best to start with the crushing cavity of the crusher. During the life cycle of the mine, the production target of a single crushing section can be greatly adjusted. Ore properties also exhibit a high degree of variability. If the wear parts of the crusher are not designed for these changes in operating conditions, production will be reduced and maintenance will be more expensive. Once the crushing chamber is optimized, the entire concentrator benefits from extended liner life, improved product gradation and reduced energy consumption.

In addition to the crushing chamber, optimizing the entire crushing circuit is a good overall approach to increase production. To understand how the entire loop operates as a single process, two things need to be determined: where the bottlenecks are in the system and where the available capacity is. Once bottlenecks and sections with additional capacity are identified, a plan to remove the bottleneck and utilize the additional capacity needs to be proposed.

For example, if the secondary crusher is identified as the bottleneck, and the fine crusher has spare capacity, the screen size for inspection screening can be increased to allow the coarse material to enter the next process faster.

Overall, this solution redistributes the workload to devices with greater capacity. However, every process adjustment has an impact on other processes. Consider consulting an expert to take a holistic view and ensure that the various processes work together in the best possible way. Options for improving profitability through crushing circuits can include: changing blasting techniques and pre-processing strategies. These solutions can be measured, controlled and tracked using specialized instruments such as SmartTag ore trackers and VisioRock lumpiness imaging analyzers.

Technology is constantly improving, and crushers are no exception. The new generation of crushers can significantly improve crushing capacity, final product gradation, crushing ratio, and can better control the width of the feed opening when adjusting the crusher discharge opening. With the new crusher, you can expect a dramatic increase in processing plant production and improved operating costs in the crushing section. In addition, downstream equipment such as shakers, conveyors and mills may also benefit. In conclusion, when considering replacement of new equipment, it is important to assess whether the required capital expenditure can be compensated by the added value of the new technology.

Sometimes, existing equipment cannot meet new production demands and additional capacity is required. At this point, you need to consider integrating other devices. There is always something to be gained by consulting a team of experts. The PRO and Crusher Applications team can work with you to identify the best opportunities for additional capacity, as well as the equipment you need to meet current and future production needs.

Then, it's about balancing the budget with the desired outcome. The correct answer depends on your situation. To see the solution from a holistic perspective, start with a comprehensive factory review. Whichever option is chosen will have an impact on your overall operation and will require a cost-benefit analysis. Our team can help you with this!