The importance of crushers working with a full chamber

Feeding is one of the most important stages in rock crushing in mining. Working with a full chamber represents one of the vital processes for success in this stage of the operation and in the final result of the quarry.

In this article, the Máquinas Furlan team answers 7 questions about operating equipment with a constant load. This is a preventative measure: unstable power supply wears out parts prematurely. When the equipment's performance is affected, production also drops.

Furlan recommends working with a full chamber and, in the parts, improving the steel alloys.

Check it out.

1. Why is it important to work with a full chamber when feeding crushers?

The main purpose of a full chamber is to prevent irregular or punctual wear caused by the impact of the stones. With the chamber full, a 'protective bed' is formed with the material being crushed. This material rubs against the parts, but does not have the harmful effect of the impact.

The tendency is for uniform wear, thus obtaining better use of all contact and wear parts.

2. What could be causing the crusher to not work with the chamber full?

The most common are the lack or insufficiency of material in the feed. An undersized feeding system is detected when we monitor conveyors or feeders in operation.

We also find types of feed spouts that are inadequate for the distribution and/or flow of the material. In addition, we deal with situations where there is poorly regulated equipment or unstable electrical power.

3. What types of parts tend to show irregular or premature wear?

The greatest wear occurs mainly on the mantle and lining of cone crushers. Next, the jaws in jaw crushers, the linings of VSI vertical shaft impact crushers, the rollers of roller mills, among others, stand out.

This is clear when we observe the mantle and lining, for example, of a crusher that has not been fed consistently. The wear appears quite irregularly.

4. This type of case occurs in the generation of which final products?

In aggregates with the generation of dust, gravel, stone 1, stone 2, among others.

We can also mention products with granulometry for agricultural purposes.

5. In addition to monitoring the power supply, is it correct to think about improving the resistance of the parts?

Yes. Here at Furlan, the main practice in this regard is the development of special metal alloys. Each application requires a personalized analysis, which includes the type of equipment and the material to be processed.

It is also important to adopt specific heat treatments on the parts, improving resistance, tenacity, wear and hardness, among other factors.

We talk more about the quality of the parts in this post .

6. In terms of production costs, what is the amount invested in castings?

When operating a plant, we have expenses with electrical energy, human resources, fuels, lubricants, maintenance, components and cast wear parts, which are periodically replaced due to wear.

This wear varies according to the hardness and abrasiveness of the rock. In the operation, castings can represent up to 30% of the final cost per ton of the processed product.

Therefore, we must always focus on optimizing processes that reduce costs.

7. And what about plant maintenance and the search for reducing downtime for adjustments?

The fact that castings consume about a third of the budget shows the importance of top-quality wear parts.

Successive equipment shutdowns to “turn over” or replace wear parts impact costs due to hours of non-production. A stopped plant is one of the biggest “ghosts” in mining.

In addition, we think about the efficiency of the plant and the safety of the operators.

Furlan Machines has a complete line of equipment

Máquinas Furlan will soon complete 62 years of operations. Currently, it is one of the leaders in the supply of mining equipment, accessories and steel castings for wear and replacement.

The fact that we manufacture more than 150 models of equipment – ​​including crushers, conveyors and feeders – allows the development of an integrated project, which focuses, in a very assertive way, on the operation of the quarry or mining company.

This is important because the efficiency of a plant lies in its ability to produce continuously without interruptions. Therefore, the perfect adjustment and operation of the equipment, in addition to adequate, well-planned and executed preventive maintenance, are of fundamental importance to extract maximum performance from the equipment.

Contact us here and schedule a conversation with our team to learn more about your plant or mining project.