Common problems and optimization strategies for large quartz sand cone
crushers: improving production capacity and particle quality
The cone crusher is the core equipment for the fine crushing process in
large-scale quartz sand production lines (with a daily processing capacity of ≥
3000t). It receives the coarse crushed material (particle size ≤ 300mm) from the
jaw crusher and crushes it to a precise particle size of ≤ 50mm (requiring
needle like content ≤ 12% and production capacity compliance rate ≥ 90%),
directly affecting the subsequent grinding efficiency and finished sand grading.
In actual production, the equipment often suffers from insufficient production
capacity, poor particle shape, and uneven wear of lining plates, which seriously
restricts the efficient operation of the production line. This article combines
the high hardness and high abrasion characteristics of quartz sand to sort out
high-frequency problems on site, analyze the causes, and provide practical
optimization solutions.
1、 On site high-frequency issues and analysis of their causes
Through on-site research on quartz sand production in multiple locations, the
core problems of cone crushers are concentrated in three points: firstly, the
production capacity is below the rated value (mostly below 70%), which is mainly
caused by improper adaptation of the crushing chamber type and imbalanced
spindle speed control; The second issue is the poor particle shape of the
finished product (over 20% needle like), which is caused by insufficient
crushing force and disordered material crushing trajectories; The third issue is
uneven wear of the lining plate (unilateral wear exceeding 10mm), which is often
caused by uneven feeding load and unreasonable eccentricity setting. These
issues are interrelated, such as uneven wear of lining plates, which will
further exacerbate particle deterioration and production capacity decline.
2、 Practical optimization strategy for problem solving
Problem 1: Insufficient production capacity - dual optimization of cavity
type and speed
The poor adaptability of traditional standard cavity types is the main cause
of low production capacity when facing high hardness materials of quartz sand,
such as insufficient crushing space and long material retention time. Suggest
replacing the "high-efficiency and high-energy chamber type", increasing the
crushing chamber volume (more than 25% higher than the standard chamber),
optimizing the gap gradient between the moving cone and the fixed cone, and
reducing the probability of material blockage. Simultaneously precise control of
spindle speed, dynamically adjusted according to material particle size: when
processing 200-300mm coarse materials, the speed is controlled at 180-200r/min
to enhance crushing impact force; When processing 100-200mm intermediate
materials, adjust the speed to 200-220r/min to balance the crushing efficiency
and particle shape. Paired with a variable frequency speed regulation system, it
can adapt to the feeding load in real time, avoid overload or no-load operation,
and increase production capacity to over 92% of the rated value.
Problem 2: Particle shape difference - crushing force+precise trajectory
control
Insufficient crushing force can lead to material "squeezing deformation"
rather than "precise crushing", resulting in a large number of needle like
particles. It is necessary to check the pressure of the hydraulic system to
ensure that the working pressure is stable at 18-22MPa, activate the pressure
compensation device, and automatically supplement the pressure when the pressure
drops by more than 1MPa to ensure sufficient crushing force. To address the
issue of disordered material crushing trajectories, optimize the eccentricity
parameter: when dealing with high hardness quartz sand, adjust the eccentricity
to 12-15mm to enhance the coherence of the crushing trajectory; Simultaneously
calibrate the coaxiality of the moving cone and the fixed cone, with a deviation
controlled within 0.3mm, to avoid one-sided force on the material. In addition,
a grading and screening device is installed at the discharge outlet to timely
separate unqualified needle shaped particles, recycle and break them, and
improve the qualified rate of finished particle shape.
Problem 3: Uneven wear of lining plate - coordinated adjustment of feed and
eccentricity
Unbalanced feeding is the core cause of unilateral wear of the lining plate.
It is necessary to install a "circular feeder" at the feeding port to evenly
distribute the material along the circumference of the crushing chamber and
avoid local overload. At the same time, control the particle size of the feed
and strictly prohibit the mixing of large pieces of material exceeding 300mm. A
pre screening screen can be added at the front end of the feed to remove
excessive impurities. Unreasonable eccentricity setting can also exacerbate
uneven wear. When unilateral wear occurs, adjust the eccentricity deviation
appropriately (controlled within 0.5mm), and regularly (every 500h of operation)
flip or replace the lining plate to balance the wear amount. The lining plate is
made of high chromium alloy composite material (hardness HRC63 or above), and
the surface is coated with plasma welding wear-resistant layer. The service life
can be extended to more than 2000 hours, reducing the frequency of
replacement.
3、 Daily operation and maintenance guarantee measures
Daily monitoring of production capacity, particle size, and liner wear status
is required; Clean up residual materials in the crushing chamber every week and
check the pressure and oil quality of the hydraulic system; Monthly calibration
of spindle speed, eccentricity, and coaxiality; Conduct comprehensive
maintenance on the moving cone, fixed cone, and transmission system every
quarter. Through the above optimization and operation, the production capacity
compliance rate of the cone crusher can be stabilized at over 90%, the needle
like content of the finished product can be controlled within 10%, the service
life of the lining plate can be extended by 2 times, and the stable and
efficient operation of the fine crushing process in the large-scale quartz sand
production line can be guaranteed.