Abstract
Cone crushers are used in the aggregates and mining industries to crush rock material. The pressure on cone crusher liners is the key factor that influences the hydraulic pressure, power draw and liner wear. In order to dynamically analyze and calculate cone crusher performance along with liner wear, a series of experiments are performed to obtain the crushed rock material samples from a crushing plant at different time intervals. In this study, piston die tests are carried out and a model relating compression coefficient, compression ratio and particle size distribution to a corresponding pressure is presented. On this basis, a new wear prediction model is proposed combining the empirical model for predicting liner wear with time parameter. A simple and practical model, based on the wear model and interparticle breakage, is presented for calculating compression ratio of each crushing zone along with liner wear. Furthermore, the size distribution of the product is calculated based on existing size reduction process model. A method of analysis of product size distribution and shape in the crushing process considering liner wear is proposed. Finally, the validity of the wear model is verified via testing. The result shows that there is a significant improvement of the prediction of cone crusher performance considering liner wear as compared to the previous model.
Highlights
Cone crusher performance is usually defined by the terms particle size distribution (PSD), capacity and particle shape
A wear model for the prediction of cone crusher performance is presented, which is able to be improved in order to better represent the actual process
This work will be useful for future dynamical optimization of the crushing plant, which can serve to increase plant insensitivity to variations, such as wear and malfunctions
Summary
Cone crusher performance is usually defined by the terms particle size distribution (PSD), capacity and particle shape. While the cone crusher is working, the mantle moves around the axis of the crushing chamber. As the mantle swings between the closed and open sides, the rock material is squeezed and crushed between two liners. When rock material is getting crushed in the crushing chamber, there is pressure on the liner, which leads to more serious liner wear over time. Cone crusher performance is affected by gradually deteriorating performance over time [1,2,3]. This will affect the PSD curve and the flakiness index curve [4,5]. In order to compensate the working process of liner wear and enhance its working performance, it is meaningful for studying the impact of liner wear on cone crusher performance
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