Discussion on the Mineral Sizer Mechanism and Application
The crushing mechanism of Mineral sizer
The working principle of Mineral sizer is that crushing teeth are installed on two relatively rotating shafts. The torque on the two shafts is transmitted to the crushing teeth, which exert a force on the material to break it down. The transmission system of Mineral sizer uses gear rotation and hydraulic couplings to eliminate overload loads. Therefore, its frame and transmission parts have a simple structure, low height, light weight, and are convenient for installation, transportation and maintenance.
The crushing requirements for raw coal in the coal system are different from those in metal mines. After raw coal is mined (especially in large open-pit mines), the particle size is very large and the production volume is high. The main purpose of crushing is to facilitate transportation, improve transportation efficiency and reduce transportation costs. Mineral sizer happens to have high processing capacity, a large feeding port and no over-crushing, resulting in uniform product particle size.
The technical performance of Mineral sizer
The drive unit features dual drive. The prime mover can be a three-phase asynchronous motor or a hydraulic motor. The liquid coupling ensures smooth transmission and provides overload protection. The unique gearbox design not only transmits large power but also has a long enough service life. The service life of the gearbox can reach 20,000 hours. On the side walls of the box, there are wear-resistant plates and comb-shaped plates.
The shape of the comb-shaped plate matches the shape of the teeth, and the material is the same as that of the teeth. The Primary mineral sizer adopts 3-tooth, 4-tooth and 6-tooth structures. The teeth can be made into two types: integral shape and sleeve teeth, and the material is special wear-resistant material. The Secondary mineral sizer adopts a dovetail slot-installed crushing tooth plate, which can be disassembled individually for convenient maintenance.
The performance characteristics of Mineral sizer
Low load and long service life
The additional dynamic load on the bearings of the crushing shaft caused by the dynamic imbalance of the crushing shaft is very low compared with that of impact and hammer crushers. Apart from the gravity of the equipment itself, the additional dynamic loads on the foundation are only the balancing impact force generated during material crushing and the centrifugal force caused by the pressure imbalance of the low-speed rotating crushing shaft.
Therefore, the additional dynamic loads borne by the foundation supporting the mineral sizer are very small. Therefore, the service life of the bearings and the fatigue life of the shafts have been greatly enhanced.
Control the output particle size with low wear
The particle size of the product is controlled by the gaps between the teeth of the crusher and between the crushing teeth and the side comb teeth. It will not discharge ores with overly large particle sizes. During operation, it generates less dust and is more suitable for the crushing of crushed stones, coal and coke.
Materials smaller than the output particle size in the feed will not be further crushed but will be directly discharged after entering the mineral sizer, only materials larger than the qualified particle size are crushed. The reason why Mineral sizer has low wear is that small-sized materials are allowed to fall directly through the machine between the roller teeth, which reduces wear.
Protective function
In addition to the protection function of eliminating shock loads through hydraulic couplings, Mineral sizer also has safety pins installed on the couplings. When iron blocks or other unbreakable materials enter the crushing chamber and cause the gear rollers to get stuck and unable to be crushed, the safety pins of the couplings are cut off to achieve mechanical protection. When repairing, only the safety pin needs to be replaced.
Long working hours and strong adaptability
It can operate continuously for 24 hours a day in harsh open conditions. By adjusting the length of the crushing cavity, various different demands and production capacities can be adapted. It is small in size and easy to use underground, which can significantly reduce the construction cost of the surface crushing station. The special gear tooth structure makes it suitable for dry ore, wet ore, mud ore and sticky ore without clogging.
High productivity and high crushing strength
High production capacity, up to 14,000 hours, high crushing strength, capable of crushing materials with a compressive strength of up to 300MPa. mineral sizer can concentrate all loads and pressures within the machine, thus eliminating the need for a bulky chassis, saving space and reducing manufacturing costs.
The number of rings and teeth of the gear teeth installed on the axle can be determined according to the particle size requirements of the product and the nature of the material. During the material crushing process, the crushing method of mineral sizer is shearing crushing, which requires less force. Coupled with its screening effect, it only crushes the ore that needs to be crushed, thus consuming less energy.
Advantages over traditional crusher
Mineral sizer breaks materials by using the advanced “shearing principle”, while traditional crushers break materials by the principle of impact and extrusion. Because the shear force is much smaller than the extrusion force, the weight of the parts that need to be repaired and replaced is much smaller. The inherent property of the ore itself is that its compressive strength is 610 times higher than its shear strength. Traditional crushers need to apply a huge squeezing force to the material to break it down, while mineral sizer only needs to use a force of 16-1/10 of that of a traditional crusher to break the material.
This determines that mineral sizer outperforms traditional crushers in all aspects of comprehensive performance, such as: low energy consumption, controllable product particle size, small equipment volume, light weight, high working efficiency, high reliability, simple equipment structure, convenient maintenance, low dust, low noise and low pollution during operation.
The application situation of mineral sizer
Mineral sizer is mainly used for coarse crushing and second-stage crushing operations. It can be used to crush surface rocks in open-pit mines and extract rock and mineral materials such as ores, coal, limestone, clay, iron ore, gold ore, copper ore, lead-zinc ore, nickel ore, talc and coke.
Applications under different conditions
Metal mines
Mineral sizer is widely used in uranium mines, gold mines, gold-bearing bauxite mines, nickel mines, copper mines, lead-zinc mines and other metal mines.
Coal mines
Coal mines are the largest users, accounting for approximately 50% of the total. In China, they are mainly used in newly-built large-scale coal mines.
Non-metallic minerals
Mineral sizer is more suitable for crushing heavy calcium carbonate, clay minerals, gypsum minerals and other materials. It does not have the problem of clogging the feeding port and discharge port.
Municipal engineering
Mineral sizer can also be used to process urban waste and garbage as well as various hard-to-break materials such as glass and old tires.
Conclusion
In addition to being widely used in the crushing and processing of Mineral raw materials, mineral sizer can also be used to process urban waste, garbage, used glass, tires and other hard-to-break materials. With the development of human production and life, the types and quantities of materials that need to be crushed and processed are becoming increasingly complex and large. Mineral sizer is bound to play a new role in the crushing field, make new developments.
The outstanding superiority of Mineral sizer is bound to have a positive impact on the design, production management and maintenance of crushing plants. In simple terms, compared with traditional crushers, the use of mineral sizer requires a smaller factory height and area, and simplifies auxiliary facilities. This will inevitably significantly reduce infrastructure investment, operation and maintenance costs, labor costs, wear and tear costs, and power consumption costs.
