Mineral Sizer For The Coal Mining Industry
Introduce
Mineral sizer is a widely used crushing equipment in industries such as coal, metallurgy, mining, chemical engineering, and building materials. It is particularly suitable for crushing raw coal or coal containing gangue in large coal mines and coal preparation plants.
Compared with other crushing machines, Mineral sizer has a greater crushing force. Its unique design effectively ensures the safe and smooth operation of the equipment, providing more reliable safety guarantees for operators.
In addition, after the optimization of the new Mineral sizer’s tooth shape, it adopts tensile-shear force selective crushing, making the production process more efficient and energy-saving, and ensuring a relatively ideal output effect.
What is a mineral sizer
The surface shape of the Mineral sizer roller can be divided into primary toothed rollers and secondary toothed rollers. The tooth shape can be configured according to the customer’s needs. It can be adjusted for production based on the required size of the material and is suitable for brittle and soft materials. The Mineral sizer is applicable to industries such as sintered ore, coal, cement, silicate, glass, and ceramics. It is suitable for crushing brittle materials with a hardness of medium or below and is mainly used for coarse and medium crushing of ores.
The feed particle size of the Mineral sizer is large, and the output particle size is adjustable. It can crush materials with an anti-compression strength of ≤160Mpa. Especially in the coal industry, when the Mineral sizer is used to crush raw coal and coke, it only needs to remove iron and impurities, without the need to remove gangue, and can be directly crushed. The crushed materials by the Mineral sizer have uniform particle size and low over-crushing rate, thus simplifying the coal selection process and reducing investment and production costs.
Key Features of Mineral Sizers for Coal Mining
It has the dual functions of screening and crushing, greatly simplifying the process flow, and featuring a compact design that saves equipment and infrastructure investment.
It adopts the dual crushing principle of shearing and stretching, with two motors driven by a hard toothed gear reduction device for slow transmission. The equipment operates smoothly, with low noise, and the crushed materials have low over-crushing.
It is equipped with electrical and limit-type hydraulic coupling dual overload protection, ensuring safety and reliability.
It is equipped with side teeth plates, allowing the adjustment of the output particle size by adjusting the pads. During operation, the distance between the two tooth rollers and between the tooth rollers and the side teeth plates remains constant, ensuring stable output particle size.
It has significant advantages in handling dry materials, wet materials, and sticky materials without clogging.
It adopts a modular design, with the reducer and teeth plates configured, and the two tooth rollers can be interchanged, improving the universality of equipment components and reducing maintenance costs.
The electrical control is controlled by PLC, achieving program control of the operation process of the crusher and its feeding and discharging equipment, with a high degree of automation.
The tooth roller bearings and seals are lubricated centrally by grease pumps, ensuring reliable operation, and being convenient and fast.
Advantages Over Other Crushers
Compared with traditional crushers such as jaw, cone or impact crushers, mineral sizers have many advantages and are especially suitable for mining and material recovery applications. The following is a brief overview of its main advantages based on its design and performance characteristics:
Handle viscous and clayey materials
Mineral sizers are good at handling moist, sticky or clayey materials (such as clay, shale, and coverings) without clogging, while jaw, cone or impact crushers often get clogged. Its dual-axis, low-speed, high-torque design and serrated roller design can prevent material accumulation, while the side scraper comb sometimes aggravates material accumulation.
Reduce the output of fine powder
Compared with impact or jaw crushers that may produce excessive fine powder, mineral sizers can produce more stable products with lower fine powder content. This reduces excessive grinding, optimizes downstream processes, and minimizes dust generation, making it an ideal choice for less-than-ideal fine powder applications.
Compact design, lower infrastructure costs
The mineral sizer takes up little space and has a low height, making it an ideal choice for space-constrained applications such as underground mining. Compared with cone crushers or jaw crushers, they require less civil engineering work and have lower capital and installation costs.
Energy-saving and highly efficient
The mineral sizer operates at low speed and high torque, consuming less energy than high-speed crushers such as impact crushers or cone crushers, thereby reducing operating costs and increasing the return on investment.
Maintenance is easier and safer
The sizer has fewer moving parts and a lower drum speed, thereby reducing wear and failure. The features such as detachable wear sections, replaceable crushing teeth and hydraulic clearance adjustment make maintenance simpler, without the need for complex lifting equipment or disassembly of the main shaft, which is different from other crushers.
Strong material processing capacity
They can handle a wide range of materials, from soft coal to hard rocks (such as iron ore, copper, gold, granite) and hard clays, with a compressive strength as high as 250 MPa. This versatility makes it suitable for primary and secondary crushing in various mining applications.
Applications in Coal Mining
Primary Coal Crushing
Application scenarios
It is installed at the initial stage of the material conveying system, near the starting point of raw coal conveying in coal mines, or in the unloading area of large coal distribution terminals.
Main functions
Raw coal often varies in size, and some can even reach a diameter of several meters. Using primary mineral sizer for primary crushing can break it down to a range of tens of centimeters, enabling the raw coal to smoothly enter conveying equipment such as belt conveyors and avoiding conveying blockages caused by overly large blocks.
Advantages and features
When dealing with high-moisture coal, it will not be as prone to material adhesion to the walls of the crushing cavity as in jaw crushers, nor will it cause a significant drop in crushing efficiency due to wet material adhesion as in impact crushers. Its unique crushing structure can keep the material in good fluidity during the crushing process, reduce clogging and adhesion phenomena, thereby ensuring continuous and stable crushing operations and improving overall production efficiency.
Secondary Crushing in Coal Preparation Plants
Application scenarios
It is used for further refining of already crushed coal and is usually set up before the screening operation in the coal preparation plant.
Main functions
Through secondary crushing, the particle size of coal is controlled within a specific range. For instance, coal blocks that originally range from a few centimeters to tens of centimeters are crushed into particles within a few centimeters and of relatively uniform size, enabling more accurate classification based on particle size.
Advantages and features
Excessive powder will make it difficult to effectively recover during the sorting process, resulting in resource waste and also affecting the quality of the final product. By using secondary mineral sizer and adopting reasonable crushing methods and parameters, the situation where coal is overly crushed into powder can be minimized to the greatest extent.
Overburden & Waste Rock Handling
Application scenarios
It is used for volume compression of stripping layers, soft rocks or waste rocks, and is commonly found in the mining process of open-pit coal mines.
Main functions
The originally large cover layers and waste rocks are crushed into smaller blocks. The crushed materials can improve the loading efficiency of the transportation tools during transportation, reduce the number of transportation trips and costs. When stacking, they can be piled up more closely, reducing the area occupied by stacking. When backfilling, it can better fill the space of the mining area, improve the quality and efficiency of backfilling.
Advantages and features
The structural design of the equipment is compact, occupying a small space. It can be flexibly arranged at the open-pit mining operation site and adapt to complex site conditions. Meanwhile, its component design is simple, the replacement of vulnerable parts is convenient, and the daily maintenance process is straightforward, which can reduce the downtime for equipment maintenance. Moreover, mineral sizer has a strong continuous operation capability, which can meet the demand for the continuous processing of a large amount of stripping materials in open-pit mining, ensuring a smooth connection between stripping operations and subsequent processing.
In-Pit Crushing and Conveying, IPCC
Application scenarios
As the main crushing equipment in the IPCC system, it is installed near the mining area inside the open-pit mine. The IPCC system directly crushes raw coal in the mine pit and then conveys the crushed coal out of the pit through a conveyor belt. mineral sizer is the core component of this system.
Main functions
After the coal mining equipment extracts raw coal from the coal seam, it is directly sent to the mineral sizer in the mine pit for crushing. The large pieces of raw coal are crushed to the particle size suitable for transportation by the conveyor belt. The crushed coal is then conveyed to the storage or processing area on the ground along the preset route in the mine pit through the connected conveyor belt system. Realize the integrated operation of raw coal from mining to ground transportation.
Advantages and features
Placing mineral sizer in the pit for on-site coarse crushing reduces transportation costs in traditional open-pit mining, enhances operational safety, and lowers carbon emissions.
Conclusion
Mineral sizers are a game-changer in the coal mining industry, offering efficient, reliable, and versatile solutions for crushing coal and associated materials. Their ability to handle sticky, wet coal, produce minimal fines, and operate in space-constrained environments makes them ideal for both open-pit and underground operations.
