The picking of crushing, grinding devices is the core of stable mineral treatment plant. In today mining industry correct gear choice determines plant effect, running expenses, and metal recover ratio. Based on operation practice and sector references this article mixes technical datas from trusted machinery and show a confident standpoint on equipment selection, design criterias, and field cases.
Crushing plus milling shrink rock particle dimension for beneficiation. Main crushers such as jaw breakrs handle input up to 1200 mm & deliver output around 40–350mm. Secondary breakers, like cone machines, refine input to 10–50 mm. Last, grinding mills like ball grinders and Raymond rollers grind stone to powder, sometimes less than 75 micron. The operation is ruled by breakage principles liner profile CSS OSS tuning, and motor-power balance. Energy usage ratio and circulating load factor are vital metric in evaluation
The jaw unit apply compressive force by two jaws one fixed, one moving. Capacity varies 1–2200 t/h depends on model. The crushing ratio usually 4–6. Key specs: input opening size (150×250 mm to 1500×1800 mm), motor capacity (5.5–220 kw), discharge range (10–350mm). Site data shows wear piece change cycle 8–12 months under mid hardness rocks. Maintain include lubrication each 200 hrs and toggle audit each 500 hrs
| Model | Feed Size (mm) | Throughput (t/h) |
|---|---|---|
| PE-600×900 | 500 | 65–160 |
| PE-1200×1500 | 1020 | 400–800 |
Cone units work on laminated crush. The eccentric shaft generate gyrating squeezing ore in chamber. CSS setting controls product grading. Efficiency is raised by optimized cavity styles: coarse, middle, fine. Normal capacity 12–1000 t/h. Motor rating 30–280 kw. Oil system and hydraulic safety cut down downtime. Standard liner lifetime in granite medium hard is 600–800 hr
The ball grinder runs by impact attrition between balls & ore. Output 0.65–615 t/h. Ball charge usually 30–35% volume, spin speed 21–38 rpm depending on mill size. Energy usage 17–25 kWh/t in closed circuit. Raymond mill applied for fine powders limestone gypsum etc. Output 80–325 mesh capacity 0.8–9.5 t/h. Fan speed classifier rotation are decisive to fineness. Regular bearing oil change each 1500 hr keeps operation smooth
A gold facility treated ore with 2.8 g/t Au. Machines: one PE-900×1200 jaw unit, two PYZ-1200 cone breakers, and Φ2700×4500 ball grinder. Design throughput 200 t/h. Feed 600 mm crushed to 12 mm before milling 74 μm. Energy usage 22 kWh/t. After tweak, liner swap interval grew 9 months. Operators said average availabillity 93% over 12 month
The site processed magnetite 42% Fe. Flow: primary crush by PE-1200×1500 jaw, secondary by cone, and ball grinder before magnetic sep. Capacity 450 t/h. Ball product size 150 μm 75% passing. Plant power demand 11 MW. Logbook showed cone liner switch every 700 hr. Downtime per year under 5% in line with benchmarks
The job required 325 mesh powder for cement. Raymond mill model 4525 fitted capacity 8 t/h. Input 20 mm, product D90=45 μm. Power 23 kWh/t. Filters, fans ran under desert weather dust kept under 25 mg/m³. Maintain intervals: roller swap 10 months blower service 6 months. Client review confirmed product steady, plant reliable
Choice rely on ore hardness (Bond Index), moisture, abrasiveness index, and downstream need. Crush ratio, energy efficiency, and availability must compare. Price of spares, maintain cycle, climate adaptability are equally vital. Example: in tropic zones sealing, oil systems need better defense against wetness
Picking crushing grinding machines requires not just catalog reading but also site testing, lifecycle cost analyze. Jaw breakers stay trusted for primary stage, cone machines for second, ball grinders or Raymond mills for last grind. Field cases prove correct sizing, energy balance cut cost and raise recovery. For new processing plants, eval must combine ore property, power, local service capacity. This study shows structured approach assure sustainable profitable operations
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