Iron ore processing is tough work. The rock is very hard. It has a high Bond Work Index. This means it resists breaking. Cone crushers are vital here. They do the secondary and tertiary crushing. Correct installation is key. It ensures long life. It lowers costs. This guide helps you install SBM crushers right. We focus on practical steps. We use data from industry journals. Follow these steps for success.
You must know how it works. A cone crusher compresses rock. It happens between the mantle and concave. The mantle moves. The concave stays still. This is the crushing chamber.
Key Terms:
CSS (Closed Side Setting): The smallest gap. It sets the product size. Why? It controls the maximum particle size leaving the machine.
OSS (Open Side Setting): The largest gap. It allows intake. Why? It determines how much rock enters.
Eccentric Speed: How fast the mantle spins. Higher speed means better shape. Why? It increases inter-particle crushing.
Crushing Ratio: Input size vs output size. Standard is 3:1 to 5:1. Why? It balances energy use.
Do not rush this part. Check the site conditions. Iron ore dust is abrasive. The climate matters. High heat affects oil. Cold affects steel.
Foundation Checklist:
1. Concrete mass. It must be 3 times the machine weight. Why? To absorb vibration.
2. Flatness. Surface must be level within 1mm. Why? Prevents frame stress.
3. Cure time. Concrete needs 28 days. Why? To reach full strength.
Reference SME Mineral Processing Handbook regarding foundations. They state rigid support reduces wear by 15%.
Follow this sequence. It saves time.
Step 1: The Frame
Place the bottom shell on the gasket. Use a level. Tighten anchor bolts. Why? Loose bolts break foundations.
Step 2: The Transmission
Install the countershaft box. Check the gear backlash. It should be 0.8mm to 1.2mm for large units. Why? Too tight causes heat. Too loose breaks teeth.
Step 3: The Eccentric Assembly
Lower the eccentric into the bushing. Use plenty of oil. Why? Dry starts ruin bronze bushings.
Step 4: The Bowl and Mantle
Install the crushing surfaces. Check the seating. Use epoxy backing. Why? It fills gaps and stops cracking.
This is a common pain point. Iron ore is abrasive. It contains silica. If liners wear too fast check the feed.
The Solution:
Is the feed centered. Off-center feed causes one-side wear. Why? Rock hits only one spot.
Check the chamber profile. Is it full. You need “choke feed”. Why? Rock on rock crushing reduces liner wear.
Select the right alloy. Use High Manganese steel (Mn18Cr2). Why? It hardens under impact.
Background:
A large mine in Brazil had issues. They processed hard hematite. Capacity was low. They used old crushers.
Equipment List:
1. SBM HST315 Single Cylinder Cone Crusher.
2. Feed size: 250mm.
3. Output size: 35mm.
The Fix:
We installed the HST315. We optimized the CSS to 30mm. We set the eccentric speed to 330 RPM.
The Result:
Throughput went up 40%. Energy use dropped 15%. The client manager said “The SBM unit is stable. Maintenance is easy. We saved money on power.”
Bad shape hurts downstream value. Flaky rock is bad for concrete. It is bad for grinding mills.
The Solution:
Increase the speed. Faster spin improves shape. Why? It causes more impacts per second.
Fill the chamber. Run a high level. Why? It forces rocks to break each other.
Check the CSS ratio. The reduction ratio might be too high. Why? Too much squeezing makes flakes.
Use these numbers for iron ore. They are based on field tests.
| Parameter | Value Range | Notes |
|---|---|---|
| Eccentric Speed | 300 – 350 RPM | Higher for fines |
| Motor Power | 160 – 315 kW | Depends on model |
| Crushing Ratio | 3 – 5 | Standard range |
| Oil Temp | 38 – 45 °C | Inlet temperature |
| Vibration | < 3 mm/s | Safety limit |
Background:
The site is hot. Dust is everywhere. The ore is very hard Magnetite. The old crushers overheated.
SBM Solution:
We used the SBM HP Series Multi-cylinder cone. We added a heavy-duty oil cooler. We used a dust seal system.
Design Logic:
The multi-cylinder design clears tramp iron fast. Why? Hydraulic release is quick. The dust seal protects oil. Why? Clean oil saves bearings.
Customer Feedback:
The site supervisor reported “No overheating this summer. Liner life increased by 400 hours. The SBM support team was great during setup.”
Do not calculate every penny. Look at the big picture. Good maintenance saves huge money.
Daily Checks:
Check oil pressure. It must be stable. Why? Low pressure means leak or pump fail.
Listen to the noise. Smooth hum is good. Clanking is bad. Why? Loose parts cause damage.
Weekly Checks:
Check the belt tension. Loose belts slip. Why? Slipping loses power.
Inspect the liners. Look for uneven wear. Why? It shows feed problems.
Cost Tip:
Replace liners before they wear through. Why? It protects the expensive shell.
Here are answers to things you might ask.
Q1: How often should I change the oil?
A: Change it every 2000 hours. Or change if it gets dirty. Test the oil often. Why? Clean oil extends bearing life.
Q2: What if metal (tramp iron) gets in?
A: SBM crushers have hydraulic release. The cylinder lowers. The iron passes through. Then it resets. Why? To prevent the shaft from breaking.
Q3: Can I increase the capacity later?
A: Yes. You can change the cavity type. You can change the eccentric throw. Why? This adjusts the volume of the crushing zone.
Installing a cone crusher is a science. You need precision. You need the right steps. Iron ore demands the best equipment.
Selection Summary:
For hard rock use SBM HP series. Why? It has high force.
For high capacity use SBM HST series. Why? It is efficient.
Always follow the manual. Check your foundation. Monitor your oil. Your plant will run smooth. Your profits will grow.
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