Crusher capacity is significantly affected by the properties of the material being crushed. Here are some of the key material properties that affect crusher capacity:
Crushability: Harder materials with lower crushability require more energy to break down, resulting in a reduction in throughput. For example, changing the crushability of the feed material from 70% to 20% can result in a 25% reduction in throughput and also require 45% less energy. This highlights the interconnected nature of crusher parameters, where changing one element affects the others.
Abrasiveness: Highly abrasive materials cause increased wear and tear on crusher components, requiring frequent maintenance and potentially resulting in reduced capacity. Selecting the right wear-resistant material is critical to optimizing crusher performance. For example, manganese steel is a common choice due to its work hardening properties. However, the sources do not provide specific recommendations for limestone.
Moisture Content: Excessive moisture can cause material to stick and clog in the crusher, reducing capacity and efficiency.
Fines in Feed: A high proportion of fines in the feed can impair crushing efficiency. If fines exceed 10% of the crusher capacity, it can negatively affect performance.
Size Distribution: The size distribution of the feed material also affects crusher capacity. The maximum feed size should be within 60-80% of the crusher inlet opening to ensure bridging and optimum performance.
Bulk Density: Materials with higher bulk densities will typically result in lower crusher output capacity, as a given volume of material will weigh more.
Shape: The shape of the feed material can also affect crusher capacity. For example, elongated or flaky particles may not be crushed as thoroughly as cubic particles.
Sources emphasize that crusher capacity is a complex interaction of various factors. Understanding material properties, selecting the appropriate crusher types and settings, and ensuring proper feed control are critical to maximizing crushing efficiency and minimizing operating costs.
