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There are several factors that affect crusher performance and thus the whole circuit. Here are a few things that can help you avoid production losses.

Avoid bridging

Continuous bridging in the feeding area of jaw crushers is a common problem.

WHAT IS IT?

Bridging means stones blocking the flow from entering or moving down in the crushing chamber. It can be caused by just one stone that is larger than the feed opening, or then many average-sized stones of crossing against each other and blocking the crusher’s feed.

WHY IT IS A PROBLEM?
HOW TO PREVENT BRIDGING?

Bridging can be avoided by implementing a tight control of the blasting grid to avoid generating oversize material, training the truck loader operator to separate the oversize material at the pit and the primary crushing plant operator visualizing the flow of material to the crusher and controlling the stones’ speed and direction by varying feeder speed and using the hydraulic hammer installed in the area.

Apply the proper jaw die profile

There are many kinds of rocks, differing in crushability, abrasiveness, flakiness, etc. Choosing the best combination of fixed and movable jaw dies profiles will help to optimize production when crushing difficult material. A Rock of low crushability requires a closer nip angle to keep the capacity as designed. A highly abrasive rock requires thicker and heavier jaw dies that last longer, thus avoiding loss of production due to frequent stops to replace them. Flaky rock requires toothed jaw dies to crush it into more cubical pieces, avoiding stops due to bridging and belt cutting along the crushing circuit.

Having the appropriate jaw die profile saves more than 20% of production capacity that would otherwise be a loss. Let’s use the same example scenario as in the first one with the C130 model. We would have approximately a 70 stph reduction in production, in other words, a decrease of USD 4000 to 8000 in revenue for one day.

To summarise, an Impact Crusher has more versatility than a Jaw and Cone Crusher since it can simultaneously perform primary and secondary duties. 

We're big fans of Impact Crushers as wastes recyling because they produce excellent results for our customers and have thus far; been unbeatable as a total machine solution. 

Want more information on Crushing Solutions or a Consultative approach to choosing your next machine? We can help by providing a profitability calculator, production forecast and a full costing run down.