Characterized by the optimized combination of crusher speed, eccentricity, and cavity profile, Nordberg HP100 cone crusher is has proved revolutionary in providing higher capacity, better product quality and suitability to a wider range of applications.
Nordberg HP100 cone crusher a unique combination of crusher speed, throw, crushing forces and cavity design. This combination is renowned for providing higher capacity and superior end-product quality in all secondary, tertiary and quaternary applications. Field proven for years, HP series cone crushers are built to perform.
Increasing the stroke, the power and the retaining force while improving crusher body design and weight to withstand the force are principles of kinematics. A higher density in the crushing chamber improves the inter-particle crushing action, resulting in superior product shape, high reduction ratio and high capacity.
In a size-class comparison, Nordberg HP100 cone crusher a higher output capacity, higher density in the crushing chamber and better reduction ratio, producing higher on-spec yield end products with the same energy consumption. Nordberg HP100 cone crusher is equipped with the latest high-efficiency motors, making it efficient and ecological crushing machine.
Nordberg HP100 cone crusher produces finer products by limiting crushing stages, which lowers your investment cost and saves energy. This is achieved through a combination of optimized speed, large throw, crushing chamber design and increased crushing force. The efficient crushing action of Nordberg HP100 cone crusher gives it the best power utilization per cone diameter.
Designed for your needs, Nordberg HP100 cone crusher is safe and easy to maintain. Fast and easy access to all the main components from the top and dual-acting hydraulic cylinders significantly reduce downtime.
Accessibility from the top of the crusher to the principal components, easy access for liner maintenance, mechanical rotation of the bowl for removal with a simple press of a button, and no backing compound on liners make Nordberg HP100 cone crusher safe to maintain.
Nordberg HP100 cone crusher delivers less downtime and increased operator confidence. Dual-acting hydraulic tramp-release cylinders are used to let the crusher pass tramp iron and to provide a large clearing stroke if needed. The double accumulator combination provides better reactivity of the hydraulic system.
With Metso IC70C you can control maintenance, setting modifications, production follow-up and data extraction. All parameters can be adapted to your plant characteristics, and you can easily do all this close to the crusher or remotely from the control room.
You set the goals and Metso IC70C helps you reach them. It allows you to monitor the feeding, change the settings automatically depending on the load or liners wear, and select the product size distribution according to your preference of coarse or fine aggregate production.
A Cone Crusher is a compression type of machine that reduces material by squeezing or compressing the feed material between a moving piece of steel and a stationary piece of steel. Final sizing and reduction is determined by the closed side setting or the gap between the two crushing members at the lowest point. As the wedge or eccentric rotates to cause the compression within the chamber, the material gets smaller as it moves down through the wear liner as the opening in the cavity gets tighter. The crushed material is discharged at the bottom of the machine after they pass through the cavity.
A Cone Crusher will deliver a 4:1 to 6:1 reduction ratio. As we set the closed side setting tighter to create a finer output, we also reduce the volume or throughput capacity of the machine. Generally speaking, multiplying the closed side setting by two is a good guide to the top size of the gradation exiting the machine.
The technology that makes a MSP Cone Crusher outperform competitive cones on the market is the combination of all of the factors of performance i.e. balanced eccentric, higher speeds, fulcrum point position, and stroke. By using sound engineering with years of field testing a truly tried and tested new Cone Crusher has emerged.
A balanced eccentric coupled with a fulcrum point ideally placed over the crushing chamber yields highly effective compression crushing. This allows higher eccentric speeds to maximize performance without disruptive forces. The eccentric stroke is designed to work with the eccentric speed and fulcrum position to produce higher yields and minimize recirculating loads. The torque and resultant crushing forces are as effective as virtually any Cone Crusher on the market.
Spiral bevel gears provide the turning force to the eccentric. The spiral gear is mounted on a sturdy countershaft of the Cone Crusher, which rides in bronze bushings. The gears are precision cut for quiet operation. Misalignment problems are eliminated.
The MSP Cone Crusher features one of the largest volume displacements by a crusher head. When there is a large volume of material displaced this way, it means that more material is crushed in each cycle, more material can be fed to fill the larger void left when the crushing head recedes, and more material flows through the crusher due to the larger throughput and gyrating cycles allowing material to drop further. The benefits of high efficiency, greater crushing force and high capacity coupled with the durability the market expects are the reasons why this design is the best way to increase your productivity and profitability.
Sleeve bearings make removal and installation of the MSP Cone Crusher head and main shaft simple. The tapered main shaft fits into a large opening at the upper end of the tapered eccentric bushing. The shaft does not require precise alignment. It can be inserted from a vertical position and will self-align.
With the MSP Cone Crushers automatic hydraulic overload relief system, the crusher immediately opens in the event of an overload. This action reduces the crushing pressure, allowing the obstruction to pass through the chamber. After the chamber has been cleared, the hydraulic control system automatically returns the crusher to its original setting. Shock loads on the crusher are reduced for longer component life.
MSP Cone Crushers are built to make your operations run more smoothly and easily. Its simple and easy to read control panel provides you with the necessary information to properly run your crusher. For example, the MSP Cone Crusher shows you the exact cone setting to allow the operator to stay on top of a critical set point.
To enhance your Cone Crusher's life and maintain optimal crushing capacities, an automatic liner change reminder is included for your convenience. When the new mantle and liners are installed, the automated reminder is reset. As the crusher operates, the system will track production capacities and calculate the liner wear rate. When the cone liners reach the maximum wear point, it sends a flashing reminder to 'change cone' on the cone setting meter. After the wear parts are changed, simply reset the automated reminder system and continue efficient, reliable crushing.
The MSP Cone Crushers are built heavier than most competitive Cone Crushers. The extra weight means lower stress on the machine, which results in longer operational life. There is no question that the proper use of mass makes for more durable crushers. Additionally, a broad array of manganese liners is offered for each size MSP Cone. A unique and patented feature allows the Liners to fit without the use of any backing material. Improved Chamber matching with crusher feeds virtually eliminates any trial and error.
All these factors combine to give producers more effective compression crushing. This reduces liner wear, which reduces wear cost and allows higher yields, resulting in decreased overall cost per ton of finished product.
In the Symons principle, which is utilized by the MSP Cone Crusher, each cycle is timed so that the feed material and the upward thrust of the crushing head meet at the moment of maximum impact. The optimum speed of gyration and the large eccentric throw produce two important results: 1) the rapidly closing head catches the falling feed material and delivers the extremely high crushing force and 2) on the other side of the chamber the rapidly receding head allows material to fall freely to the next point of impact or exit the chamber. The combination of superior crushing force and free flow of material in the MSP Cone Crusher results in production levels that are unsurpassed and means lower power consumption per ton.
Ten years of testing went into the final combination of speed, stroke, and head angle to deliver the most efficient use of power. Greater efficiency delivers lower power consumption, reduced cost per ton, less maintenance and higher profits.
The power input imparted by the driven eccentric results in a bearing force in opposition to the crushing force at a point on the lower portion of the main shaft. The bearing force as it is transmitted to the main shaft provides the required moment to crush the rock. The distance between the bearing force and the fulcrum point is called the force arm. The longer the force arm, the greater the momentum, which produces a greater crushing force.
Crushing loads are distributed over a large spherical bearing. The socket liner keeps full contact with the crushing head ball and carries all of the vertical component and part of the horizontal. The long force arm, represented by the main shaft, reduces the load transmitted through the eccentric bushing.
Capacities and product gradations produced by Cone Crushers are affected by the method of feeding, characteristics of the material fed, speed of the machine, power applied, and other factors. Hardness, compressive strength, mineral content, grain structure, plasticity, size and shape of feed particles, moisture content, and other characteristics of the material also affect production capacities and gradations. Gradations and capacities are most often based on a typical, well-graded choke feed to the crusher. Well-graded feed is considered to be 90% to 100% passing the closed side feed opening, 40% to 60% passing the midpoint of the crushing chamber on the closed side (average of the closed side feed opening and closed side setting), and 0 to 10% passing the closed side setting. Choke feed is considered to be material located 360 degrees around the crushing head and approximately 6 above the mantle nut. Maximum feed size is the average of the open side feed opening and closed side feed opening.
Minimum closed side setting may vary depending on crushing conditions, the compressive strength of the material being crushed, and stage of reduction. The actual minimum closed side setting is that setting just before the bowl assembly lifts minutely against the factory recommended pressurized hydraulicrelief system.
Overall, industry acceptance of the Symons principle and performance, the McLanahan Cone Crusher works to deliver lower recirculating loads at higher tonnage rates with lower maintenance costs by combining:
A general rule of thumb for applying Cone Crushers is the reduction ratio. A crusher with coarse style liners would typically have a 6:1 reduction ratio. Thus, with a 34 closed side setting, the maximum feed would be 6 x 34 or 4.5 inches. Reduction ratios of 8:1 may be possible in certain coarse crushing applications. Fine liner configurations typically have reduction ratios of 4:1 to 6:1.
The difference between the volume displaced by the crushing head when it is fully closed and fully open is called the displacement volume. A large displacement volume results in greater capacity because:
In order to maintain the maximum levels of capacity, gradation, and cubical product, a Cone Crusher must be choke-fed at all times. The best way to keep a choke-feed to the ConeCrusher is with a surge bin (or hopper) and feeder that are located prior to the crusher. Choke-feeding is almost impossible to achieve without a hopper and feeder.
There are a number of different criteria to consider when selecting the right chambers for your crushing needs. However, the one that must always be considered isthat you have a well-graded feed to the chamber. A well-graded feed is generally thought to be 90 to 100% passing the closed-side feed opening, 40 to 60% passing the midpoint, and 0 to 10% passing the closed-side setting.
One thing you should never do is place a new concave liner in a crusher with a worn mantleor place a new mantle in a crusher with a concave liner. Why? If you have properly selected the replacement component, you will change the complete profile of the Cone Crusher by mating new and worn components. The receiving opening will tend to close down, restricting the feed from entering the chamber and causing a reduction in tons per hour.
If the liner is wearing evenly throughout the chamber, you should consider changing out the manganese when it has worn down to about 1" (2.5 cm) thick at the bottom. At about 3/4" to 5/8" (1.9 to 1.6 cm) thick, the manganese will crack, causing the backing material to begin to disintegrate. This, in turn, will cause the liners to break loose. If this should happen, continued operation could destroy the seat on the support bowl or the head of the Cone Crusher.
McLanahan Symons Principle (MSP) Cone Crushers utilize a combination of improved factors of performance, which are enhanced by the Symons Principle of crushing, as well as the latest hydraulic features and electrical features that create a modern, efficient, reliable and durable Cone Crusher that ultimately leads to a faster ROI. MSP Cone Crushers are designed to make your operation run more smoothly and easily, as well as ensuring lower operating costs and minimal downtime so that MSP Cone Crushers are more frequently fully operational and processing optimal amounts of material.
Efficiency can be defined by the ratio of the work done by a machine to the energy supplied to it. To apply what this means to your crusher, in your reduction process you are producing exactly the sizes your market is demanding. In the past, quarries produced a range of single-size aggregate products up to 40 mm in size. However, the trend for highly specified aggregate has meant that products have become increasingly finer. Currently, many quarries do not produce significant quantities of aggregate coarser than 20 mm; it is not unusual for material coarser than 10 mm to be stockpiled for further crushing.
The Powerscreen 1150 Maxtrak Pre-Screen is a high performance, medium sized track mobile rock crusher with an independent pre-screening system. At the heart of the Maxtrak is the Automax cone crusher with hyd...
The Powerscreen 1300 Maxtrak is a portable cone crushing plant which is ideally suited to secondary applications such as taking an all in feed from a primary crusher. Based around the 1300 Automax cone crush...
The Powerscreen 1150 Maxtrak is a high performance, medium sized track mobile cone crusher. At the heart of the Maxtrak is the Automax cone crusher with hydraulic setting, tramp release, and unblocking system. ...
The high performance Powerscreen 1000 Maxtrak portable rock crusher has been designed for direct feed applications without pre-screening on clean rock. At the heart of the Maxtrak is the Automax cone crusher w...
The Powerscreen 1500 Maxtrak cone crusher is one of the largest mobile cone crushers available on the market. Specifically developed for users requiring higher tonnage, the plant can accept an all in feed from...
Suitable for even your toughest applications, our cone crushers are built using direct customer input and feedback, making them the most reliable and maintenance friendly options on the market. We give you speed flexibility of speed for the versatility and productivity that you need. Revolutionise your mining projects with the Raptor Cone Crusher.
Our line of Raptor Cone Crushers is the most diverse product line on the market, including a broad range of sizes and features. For mining applications, we recommend the R500 to the R2000, though we also offer smaller crushers that are typically used in aggregates. We designed each model using industry feedback. You can be sure that no matter which model you need, the most common industry crushing concerns have been addressed to give you better results at a decreased cost.
Raptor Cone Crushers employ advanced overload sensing technology to detect crushing force overload. If desired, our advanced automation system can take the necessary corrective action. The same advanced automation system can be used to optimise crusher performance with feed control, setting adjustment and monitoring of critical lubrication and hydraulic parameters. This mean improved efficiency and lower cost for your business.
Because of its large head diameter of 1.5 m (59.06 inches) and ideal eccentric motion, the Raptor 500 cone crusher can accept feed that is up to 25 percent larger than can be accepted by competitive cones with less throw or similar head diameter, while producing more material of desired cubicity and gradation. With a maximum diameter of 3.75 m (148 inches) and weight of 50,274 kg (110,833 lbs), the crushers size gives you flexibility for multi-site crushing opportunities. The Raptor 500 cone is built with a rigid three-arm frame and integral countershaft box mounted inside one of its three arms which reduces your maintenance time, improves the reliability of the gear and pinion and simplifies the backlash adjustment.
The Raptor 900s 1.8m (70-inch) head diameter and integral countershaft built into the four-arm mainframe means the 900 is not only large, but its one of the most robust crushers in its size range. Like all Raptor models, the high pivot point and large crushing stroke offer better crushing action throughout the crushing chamber. The 900 leaps forward, improving throughput and acceptance of larger feed size. The crushers higher pivot point and larger crushing stroke provide the most productive 1.8m (70-inch) head diameter cone ever manufactured, resulting in better, higher output for your business. The dynamics of the 900 allow more crushing to take place from the first nip at the feed opening and continuously throughout the chamber, until the material exits the parallel zone.
Previously our largest cone crusher on the market, the Raptor 1100 breaks productivity barriers and features an integrated countershaft in a three-arm mainframe for unmatched durability. Whether accepting coarse feeds, intermittent feeds, high yields or simply high throughputs, the Raptor 1100 uniquely combines proven and modern technology in an excellent machine to meet your needs. The Raptor 1100 eccentric is a nodular iron casting, providing a high strength material with excellent machinability and surface finish critical to bearing longevity under high performance crushing conditions.
The Raptor 1300 Cone Crusher includes many exciting new features. One such is the integral countershaft assembly, which reduces maintenance time along with improving the reliability of the gear and pinion. The crushers spiral bevel gearing is the best combination of durability and reliability while minimizing gear noise, and is engineered to maximise resistance to pitting and breakage. Our new double acting tramp release and clearing cylinders reduces stress in the main frame lower flange with a multi-functional design. The increased throw and high pivot point crushing action ensures maximum throughput and application of connected horsepower and coupled with increase bowl travel production is increased while operating costs are lowered.
The Raptor 2000 Cone Crusher is a maximum capacity cone crusher for the most demanding high tonnage applications. The machine has been successfully applied in the most demanding crushing applications with full power consumption. With many industry-leading features such as fail safe hydraulics, integral countershaft assembly, enclosed counterweight assembly with replaceable non-contacting T/U seal arrangement and ductile iron eccentric, the Raptor 2000 is designed to meet the demanding needs of your high capacity and high demand mineral processing business. Specific features include: spiral bevel gearing, new double acting tramp release and clearing cylinder, along with new easy access to critical load carrying bearings offers a cone crusher design that will exceed previous expectations for cone crusher performance. Add to all this the features of significant eccentric throw and high pivot point crushing action and direct drive at 2500 hp with a variable speed option, and you wont find a crusher that matches the Raptor 2000 Cone Crusher.
FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.
Cost-effective aggregate production begins with employees who are knowledgeable about the maintenance requirements and operational parameters of the cone crushers they operate. There are certain proven methods and practices industry experts use to ensure a smooth crushing operation. This article presents key tips that will help you maximize your cone crushing operation.
1. Operate at a consistent closed-side discharge setting. Producing a consistent product quantity, quality, uniformity and attaining a balanced circuit begins with operating the cone crusher at a consistent closed-side discharge setting. If a crusher is allowed to operate at a wider-than-optimum setting for even a short period of time, the result will be less product and an increase in oversized material.
Keep in mind that oversized product almost always creates circuit flow problems within the aggregate plant. An example of the effect that crusher setting has on the product gradation is as follows: If the target crusher setting is 3/8 in. (10 mm) but the setting is not checked and it wears open to 1/2 in. (13 mm), then the end result is a 15 percent decrease in the minus 3/8-in. (10 mm) material size. This is a substantial decrease in productivity.
Most aggregate producers would be amazed at the revenue lost each year due to the simple fact that crushers are not being operated at consistent closed-side settings. The crusher setting should be checked on a per-shift basis.
2. Operate at a consistent choke-fed cavity level. If a crusher operates at varying cavity levels throughout the shift, the result will be an inconsistent product shape and inconsistent production rate. Operating a cone crusher at a low cavity level (half cavity) will result in a significantly coarser product gradation, and this low cavity level will also produce more flat and elongated product particles.
Efforts should be made to operate the crusher at a proper choke-fed cavity level, as the favorable end result will be increased crusher throughput tonnage and a more cubical-shaped product. This tip is particularly important for the tertiary (short head) crushers in the circuit, as they produce the vast majority of an aggregate operations salable products.
3. Do not trickle feed the crusher. Trickle feeding a cone crusher should be avoided because it not only results in poor productivity and poor product shape, but it can also adversely affect bearing alignment within said crusher. Due to the operational characteristics of a cone crusher, when crushing, it should never be operated below 40 percent rated horsepower. To obtain a proper loaded bearing alignment and to maximize productivity, the crusher should be operated above 40 percent rated horsepower yet below 100 percent rated horsepower of the drive motor.
A power draw of 75 to 95 percent is a great target range to stay within while crushing. Excessive power peaks, particularly above 110 percent rated horsepower, should be avoided as this could lead to premature crusher failure.
4. Ensure the feed is evenly distributed. The incoming feed material should be directed on a vertical plane into the center of the crusher. When the incoming feed is not directed into the center of the cone, one side of the crushing cavity could be quite full while the opposite side of the cavity could be low or empty. This will always result in a low crusher throughput tonnage, the production of more flat and elongated product particles and oversized product.
This typically prompts crusher operators to tighten the crusher setting in order to get the crusher to make the smaller product size that they are trying to produce. This in turn can result in an overload condition in the form of adjustment ring movement on the side of the crusher that is heavily loaded. Over the long term, this can cause the adjustment ring to become tilted on the main frame, resulting in an even larger loss of productivity.
5. Ensure the feed is not segregated. All incoming feed material should be well mixed and homogeneous. A segregated feed condition exists when large stones are directed to one side of the crushing cavity and small stones are directed to the opposite side.
The side of the crusher receiving the small stones will have a higher-than-normal bulk density, and this can lead to something known as packing or pancaking. This in turn leads to adjustment ring movement on the side of the crusher receiving the smaller feed stones. Adjustment ring movement forces the operator to open the crusher setting to avoid this overload condition. This results in the production of oversized product due to the increase in crusher setting. In addition, segregated feeding and the resultant adjustment ring movement can lead to a tilted adjustment ring, resulting in larger loss of productivity.
6. Minimize surge loading for a more efficient circuit. Surge loading of any crusher is a production enemy. Surge piles or feed hoppers, along with variable-speed feeding devices, can be used to provide a better and more consistent feed control to the crusher. This allows the operator to run the crusher at a very consistent cavity level for extended periods of time. Providing better crusher feed control for the cone crusher through the use of surge piles, hoppers and variable-speed feeding devices such as belt conveyors or vibrating pan feeders can easily increase crusher productivity by a minimum of 10 percent.
Regarding the volume limit, each crushing cavity has a volumetric limit that determines maximum throughput, and a choke-fed crusher is operating at its volumetric limit. The volume limit is exceeded when feed material overflows the top of the crusher. As for the horsepower limit, each crusher has been designed to operate at maximum power draw, and power draw will increase as the feed rate increases and as the feed material is crushed finer. The horsepower limit is exceeded when the crusher draws more power than it is rated for.
Lastly, dont forget about the crushing force limit of the crusher. As with the horsepower limit, crushing forces being applied between the mantle and bowl liner increase as the feed rate increases, and as the feed material is crushed finer. The crushing force limit of the crusher is exceeded when the adjustment ring bounces, wiggles or moves on top of the main frame.
An ideal operational condition exists when the crusher is operating at its volumetric limit while still being slightly below both the horsepower limit and crushing force limit. Operating any crusher outside of its designed parameters with either excessive power draw or excessive crushing force results in a very serious crusher overload. These overloads create something known as fatigue damage, which is permanent, irreversible and cumulative. Without a doubt, frequent overloads will shorten the life cycle of any cone crusher.
8. Operate within the crusher design limitations. If you find the crusher operating in a crushing force overload condition (ring movement) or a power overload condition (excessive amperage), open the crusher setting slightly, but try to stay choke fed. The advantage of staying choke fed is the fact that there will still be rock-on-rock crushing and grinding taking place in the crushing cavity. This helps to maintain good cubical product even though the setting is slightly larger than optimum.
The other option, of course, is to decrease the feed rate to the crusher. But the downside is that product shape tends to suffer. Typical reasons for adjustment ring movement or excessive power draw are tramp events, poor feed distribution, segregation of the feed, too many fines in the feed, high-moisture content, wrong mantle and bowl liner being used or simply trying to operate at an unrealistically small closed-side setting.
9. Monitor and maintain a proper crusher speed. If proper drive belt tension is not maintained, the belts will slip and the crusher will slow down. A slowing crusher will cause incredibly high power peaks at a very low crusher throughput tonnage. Improper or neglected drive maintenance will result in a high-horsepower consumption at a low crusher throughput tonnage, and this inefficient use of connected horsepower will result in a higher-than-normal energy cost per ton of material crushed.
A speed sensor can be used to monitor the crusher countershaft speed, which will send a warning signal of a slowing crusher to the programmable logic controller, or it could be wired to simply turn on a warning lamp. When a warning is detected, the maintenance department can be dispatched to re-tighten the drive belts. When a speed sensor is used, drive belt life is extended and proper production levels can be maintained.
10. Determine the percentage of fines in the feed. Fines in the crusher feed is defined as material entering the top of the crusher, which is already equal to or smaller than the crushers closed-side discharge setting. As a rule of thumb, the maximum number of fines in the crusher feed should not exceed 25 percent for secondary crushers or 10 percent for tertiary crushers.
When there is an excessive quantity of fines in the feed, it is typically the result of a vibrating screen problem. This problem could be due to the fact that the screen is insufficient in size, or a screen that is sufficient in size yet is inefficient in operation. Re-crushing and re-handling product size material due to an insufficiently sized screen, inefficiencies due to the way the screen is set up or due to improper vibrating screen maintenance will lead to an excessive quantity of fines in the crusher feed. This will lead to inefficient use of connected crusher horsepower and a higher energy cost per ton of material crushed.
11. Limit the height from which the feed material drops. The maximum distance from which the feed material should fall from into the top of a small to mid-size cone crusher is 3 ft. When the feed material drops from a much greater distance, the stones tend to slam into the V-shaped crushing cavity with such velocity that it subjects the crusher to shock loads and extremely high stress levels. This situation is referred to as high-velocity wedging, and it can result in power overloads or force overloads or both. This action puts undue stress and strain on the crusher components, and it results in increased maintenance repair costs and poor productivity.Get in Touch with Mechanic