Why Is The Feeder Breaker Gradually Replacing The Hammer Break In Open-Pit Coal Mines
Open-pit coal mining is a special working environment and is widely present in domestic and international markets. In previous crushing systems, a portable simple crushing station consisting of hammer break and vibrating feeder was commonly used for crushing. However, recently, both domestic and foreign markets have been gradually replacing the small crushing stations composed of hammer break with large crushing stations composed of feeder breaker and mineral sizer. The reason for this situation is mainly influenced by the following factors:
1.Feeder breaker: Specifically designed for handling large pieces of materials, it can accept feed sizes up to 2000mm (such as extra-large frozen blocks), and through the combined effect of horizontal crushing rollers and chain plate conveyors, it can initially crush materials to less than 6 inches (approximately 150mm). Its chain conveying system can feed continuously and avoid material accumulation. It is particularly suitable for the high-capacity demand of open-pit mines (with a single-machine processing capacity of up to 3,500 t/h).
Hammer crusher: It is usually used for medium and fine crushing, with a maximum feed size of ≤ 500mm (some heavy hammer crushers can reach 1000mm). Multiple crushing stages are required to achieve the target particle size, and it is prone to clogging the screen plate for viscous and high-moisture materials (such as coal and rock mixtures).
2.Feeder breaker integrates feeding and crushing functions, directly connecting to trucks or loading equipment, reducing intermediate transfer links, and lowering material spillage and dust generation. Hammer crushing requires additional feeders and screening equipment, and the process complexity is high.
3. The processing capacity of feeder breaker can reach up to 7000 t/h at most, which is particularly suitable for the continuous crushing requirements of open-pit coal mines.
The processing capacity of hammer crushers is generally 50-700 tons per hour, and multiple units need to be connected in parallel or combined with other equipment to meet the high-yield demand.
Particle size control and overgrinding issues
4. The feeder breaker reduces the crushing of materials through the mutual synergistic effect of the chain plate and the crushing toothed roller, and the output particle size is uniform, which is suitable for subsequent conveying or washing. Improve the qualification rate of materials and reduce the scrap rate of products.
Hammer crushing is a high-speed impact crushing method, which can easily cause the proportion of raw materials with a diameter of ≤ 5mm to reach 85%, increasing dust pollution and the difficulty of subsequent processing.
5.Feeder breaker adopts low-speed toothed rollers, which have low energy consumption, long service life of vulnerable parts and long maintenance intervals
Hammer crushing relies on high-speed rotating hammer heads, which consume a lot of energy, wear out the hammer heads quickly, and the maintenance cost accounts for more than 40% of the total equipment cost.
At present, the feeder breaker specially developed by our company for open-pit coal mines has accounted for 93% of the domestic market. It has achieved full certification in foreign countries such as mongolia, indonesia, and russia, and has been recognized by customers. We have a professional technical team, strict product quality control, and skilled workers. Our high-quality partners for purchased parts ensure the advantages of our products, such as good quality, favorable prices, and low operation and maintenance costs. We welcome domestic and foreign customers to visit our company for inspection and investigation, establish cooperative relations, and create a bright future together.
