Feeder Breaker Heavy-duty Continuous Crushing System for Open-pit Mines
Application Conditions
Feeder breaker is mainly used for raw coal crushing in open-pit coal mines, and is also widely used in mining, metallurgy, building materials, coal and other industrial sectors. The equipment is mainly used under hoppers and bins with certain storage pressure, to uniformly and continuously crush, screen and transport various bulk materials over short distances. It can complete heavy-duty operations in harsh environments and has strong adaptability to changes in material size composition, temperature, viscosity, frost, rain, snow and frozen materials. The feeding amount is uniform, accurate and reliable. It can be installed horizontally or inclined, with a maximum upward conveying inclination angle of 15°.
Feeder breaker is an organic combination of material conveying and material crushing. It provides a combination of original feeding, crushing and discharging on the same horizontal plane, forming a heavy-duty continuous crushing system with continuous horizontal material flow crushing.
Product Structure Forms of Feeder Breaker
Feeder Breaker is mainly composed of a heavy-duty conveying section and a crushing section. According to different material characteristics and process requirements, the equipment structure mainly includes the following two types:
Combined with Heavy-duty Apron Feeder
The heavy-duty apron feeder is used as the bottom conveying unit and matched with the crushing module, specially designed for high-strength and large-size materials.
Combined with Heavy-duty Scraper Conveyor
The heavy-duty scraper conveyor is used as the conveying carrier and combined with the crushing mechanism, which is more suitable for continuous transportation of sticky or easily frozen materials.
Modular Design
In addition to the complete equipment integration, according to the upgrading and modification requirements of some mining customers, the conveying section or crushing section can also be designed and manufactured separately.
Differences Between Heavy-duty Apron Feeder and Heavy-duty Scraper Conveyor
Structural Differences
Apron conveyor consists of conveyor frame, drive device, track chain (tank chain), pans and other components. Its structure is relatively complex and the cost is higher. Scraper conveyor consists of sprocket, chain, scraper, frame, guiding mechanism and other components. Its structure is relatively simple and the cost is lower.
Conveying Method Differences
Apron conveyor transports materials through movable conveying pans. The pans move back and forth on the frame to transport materials from the feed inlet to the discharge outlet. Scraper conveyor transports materials by scraping them from the hopper onto the conveying line through scrapers, and then moves forward through chain traction.
Application Range Differences
Apron conveyor has low speed and high torque, and is suitable for conveying materials with large particle size, uniform particle size and low viscosity, such as ore, cement and coal. Due to the faster conveying speed of scraper conveyor, it is suitable for conveying and collecting low-temperature and high-viscosity materials, such as coal mine materials, coal slime, coal slag and ash.
Crushing Section
The crushing section mainly consists of crushing drive, crushing tooth roller and crushing box.
The crushing drive mainly consists of explosion-proof motor, small pulley, connected narrow V-belt and large pulley. This part is the power source of crushing. During equipment installation, it must be ensured that the axis lines of each device are on the same horizontal plane (allowable deviation is less than 0.5mm).
The crushing tooth roller mainly consists of tooth roller shaft, tooth roller bearing, tooth roller sleeve and movable tooth head. The rotating crushing tooth roller crushes the horizontally conveyed materials. During the use of feeder breaker, the wear condition of crushing teeth should be checked to avoid excessive wear of crushing teeth causing oversized product size.
The crushing box supports and fixes the crushing tooth roller and crushing drive.
The adjustment section of the crushing roller mainly consists of hydraulic cylinder, hydraulic gear pump, hydraulic station and folding box. Specifically, the hydraulic station drives the hydraulic cylinder to lift or lower the crushing tooth roller, realizing intelligent adjustment of whether it participates in crushing.
Pre-screening (Optional)
The receiving section adopts static screening method, and the non-receiving section adopts dynamic screening device. The non-receiving section adopts sine disturbance screening method to prevent any material blockage (including uncrushable iron objects).
The static screening grate bar screen adopts rails fixed on the conveying box. This method is suitable for screening large particle size materials.
Calculation of Conveying Capacity of Scraper Conveyor on Feeder Breaker
Q=3600*F*ψ*Y*V
Q: Conveying capacity
F: Maximum cross-sectional area of the load (F=B*H+B*1/2B*tana*0.5)
ψ: Filling coefficient of the load
Y: Bulk density of the load
B: Width of scraper conveyor trough
H: Depth of scraper conveyor trough
V: Speed of scraper chain
a: Angle of repose of material
Structure of Feeder Breaker Scraper Conveyor
The traction chain of Feeder Breaker adopts mining round link chain connected by rectangular connecting links. It is hardened to improve the toughness and impact resistance of the traction chain, with good wear resistance and long service life. It is convenient and quick to use, and the operation is very simple.
The round link chain is manufactured entirely from 23MnNiMoCr, and the overall strength meets national standards.
Conclusion
Feeder Breaker, with its unique advantages of integrated feeding, crushing and conveying, as well as its strong adaptability to harsh operating conditions, has become an indispensable high-efficiency equipment in modern open-pit mines and heavy industrial material handling.
Whether you need to handle high-viscosity materials, large-size raw coal, or achieve high-capacity output in limited space, reasonable equipment selection and accurate parameter configuration are the key factors for successful project implementation.
Are you looking for a Feeder Breaker solution suitable for your mine?
Welcome to contact our technical expert team. We will provide a customized efficient and durable continuous crushing system solution according to your material characteristics, capacity requirements and site conditions.
