Why is the toothed roller spacing on the mineral sizer so important for efficiency
Introduce
In mining operations, the crusher is an extremely important component. Especially in the beneficiation process, the production cost of the crusher will account for nearly 40% of the total beneficiation cost.
Therefore, in the design and manufacture of crushers, it is necessary to actively conduct performance analysis of the crushers and optimize their mechanical structure to effectively increase the productivity of the crushers.
Mineral Sizer is a relatively new type of crushing equipment. Compared with traditional crushers, it has a simpler structure and less over-crushing phenomenon, and can achieve good results in the production of coarse powder of limestone, coal, etc.
The influence of tooth roller spacing on crushing efficiency
Material crushing effect
Too large spacing
If the spacing between the toothed rollers is set too large, when the materials pass between the rollers, the pressure and shear force they receive are insufficient, making it difficult for them to be fully crushed. For some materials with higher hardness or larger block sizes, they may only be simply compressed or pushed aside, unable to achieve the expected crushing size, resulting in larger particle sizes of the crushed products, which does not meet the production requirements and thereby reduces the crushing efficiency of the mineral sizer.
Insufficient spacing
When the spacing between the toothed rollers is too small, although it can enhance the crushing effect on the materials and make the particle size of the crushed products finer, it is also prone to causing blockages of materials between the toothed rollers. Especially for materials with high humidity or certain stickiness, they may form accumulations between the toothed rollers, hindering the normal operation of the toothed rollers and reducing the continuous operation of the mineral sizer, thereby affecting the crushing efficiency. Moreover, an insufficient spacing will also aggravate the wear of the toothed rollers, shorten their service life, and increase the maintenance cost of the equipment.
Production capacity
Too large spacing
A larger spacing between the toothed rollers means that the amount of material passing between the rollers per unit time may increase, which to some extent improves the processing capacity of the mineral sizer. However, due to insufficient material crushing, more processing procedures may be needed later to meet the qualified particle size requirements. Overall, the overall production efficiency may not necessarily be high.
Insufficient spacing
A smaller spacing between the toothed rollers will limit the speed and quantity of material passing through, reduce the processing capacity of the mineral sizer per unit time, and lead to a decrease in production capacity. Moreover, to avoid material blockage, the feed speed may need to be reduced, which further affects production efficiency.
Fragmentation energy consumption
Too large spacing
Due to the inability of the materials to be fully crushed, multiple cycles of crushing are often required to meet the requirements, which increases the energy consumption during the crushing process. Moreover, when the materials cannot be effectively crushed, the useless work done by the toothed rollers also increases, leading to an increase in energy consumption.
Insufficient spacing
Although it can achieve a better crushing effect for the materials in one pass through the toothed roller, at this time, the toothed roller needs to overcome greater resistance to compress and crush the materials. The operating load of the mineral sizer increases, and the motor needs to output more energy, resulting in a significant increase in energy consumption. Moreover, frequent material blockages and cleaning operations will also indirectly increase the energy consumption of the mineral sizer.
Mineral sizer VS Traditional crusher
The mineral sizer is a new type of crushing equipment, which has extremely obvious advantages compared to traditional jaw crushers and hammer crushers.
Due to the structural flaws of jaw crushers and gyratory crushers, the above-mentioned crushers have a higher probability of getting clogged during operation and are prone to causing the crushed minerals to have over-crushed defects.
Compared with hammer crushers, the mineral sizer has a lower crushing efficiency. While impact crushers have a higher production efficiency, their complex structure and high cost are disadvantages. The mineral sizer is mainly used for crushing minerals such as coal and limestone, and has a wide application prospect in domestic mines.
In the new era, efforts should be made to actively carry out the design and optimization of the mineral sizer to meet the constantly increasing usage demands.
The working principle of the Mineral Sizer
The mineral sizer is widely used in coal mines and can achieve excellent crushing results. The mechanical structure of the mineral sizer consists of two crushing tooth rollers at its core. The two tooth rollers in the mineral sizer each have an independent motor reducer, and there is a synchronous gear at the rear.
During the relative rotation of the two tooth rollers, the crushing teeth shear and compress each other to achieve the crushing operation of the materials. This not only improves the crushing efficiency but also avoids the occurrence of over-crushing defects.
The structural composition of Mineral sizer
Driven unit
The mineral sizer is driven by two motors, which are coupled through a coupler, a reducer, and a self-aligning drum-shaped gear coupling to drive the two toothed rollers to rotate. During the relative rotation of the two toothed rollers, a crushing chamber is formed.
Toothed rollers
The surface of the toothed rollers is arranged with high-strength wear-resistant tooth plates, which are tightly connected to the roller body through bolts, facilitating later replacement and maintenance.
Roller bearings
At both ends of each toothed roller, offset roller bearings are equipped. The bearing seats are made of cast steel and can withstand the huge radial and axial forces generated during the crushing process. They can also reduce the vibration and impact during the operation of the mineral sizer through the elastic buffer device between the bearing seat and the frame.
Frame
The frame, as the supporting skeleton of the entire equipment, adopts an integral welding structure and has sufficient rigidity and stability.
Protection device
The overload protection device can cut off the power transmission when the crushing chamber encounters non-crushable materials, preventing the core components from being damaged.
Toothed roller gap adjustment device
The toothed roller gap adjustment mechanism can precisely adjust the distance between the two toothed rollers through manual or hydraulic methods to meet the crushing particle size requirements of different materials.
Selection of tooth profiles for the toothed rollers
In the mineral sizer, different tooth profiles and roller tooth arrangement schemes can achieve different crushing effects. The settings for the tooth profiles and roller tooth arrangements in the mineral sizer mainly include the following several schemes:
Primary mineral sizer toothed roller
The surface of the toothed roller is equipped with irregular multi-angled tooth shapes. The roller teeth present a contour with concave and convex edges, and the edges of adjacent roller teeth are adapted to the outer circle of the toothed roller, forming an interlaced meshing space. The tooth layout adopts an orderly array arrangement.
The roller teeth are distributed regularly along the axial and circumferential directions of the toothed roller, making the material subjected to the crushing force more evenly, and helping to obtain regular-shaped crushed products.
When paired with the matching toothed rollers, the roller teeth fit each other, and the maximum particle size of the crushed material is determined by the distance between the top of the roller teeth of the cooperating toothed rollers and the surface of the other roller, ensuring the controllability of the crushing particle size.
Secondary mineral sizer toothed roller
The surface of the secondary crushing tooth roller is equipped with multi-angled triangular teeth. Each tooth block has regular edges, and the spaces between the teeth form an appropriate biting space for material crushing.
These spaces are coordinated and compatible with the outer circle contour of the tooth roller. The tooth layout is arranged in an equidistant array, with an orderly distribution method, which helps to finely crush the materials and facilitate obtaining more uniform particle sizes of the crushed products.
Due to the detachable tooth plate (with dovetail groove installation), during actual operation, in combination with the action between the teeth, the maximum particle size of the crushed materials is determined by the distance between the tooth tips of the cooperating tooth rollers and the surface of the other roller, ensuring controllable crushing particle size and facilitating adjustment and maintenance of the tooth structure according to requirements.
Summary
Mineral Sizer, as an efficient new type of crushing equipment, its core working component is a double toothed roller. The spacing between the toothed rollers is the key parameter determining its crushing efficiency. In practical applications, the spacing needs to be precisely adjusted according to the material characteristics (such as hardness, moisture content, and particle size requirements) to maximize the performance of the equipment.
