10 Tips for Maximizing the Efficiency of Your Mobile Crusher
Mobile crushers have revolutionized aggregates production by delivering unparalleled flexibility and productivity gains to mining/quarrying operations. Propelled by strong independent tracks or tires, these self-contained units autonomously move between job sites for continuous processing.
Despite advancements, many mobile crusher operators fail to maximize equipment potential through neglecting effective optimization practices. This article outlines 10 effective methods to maximize value and productivity from any mobile crushing unit through efficient operation, predictive maintenance and process optimization.
1. Commission Pre-Crushing Screens
Installing pre-screening ahead of mobile crushers retains oversized refuse for re-crushing, improving size reduction uniformity. Vibrating grizzly feeders prevent damage from tramp metal ingression while advancing only suitably sized feed smoothly into the crusher. This preserves hammer/mantle life spans and reduces fines generation.
2. Automate Lubrication Systems
Manually greasing daily bears hazards and wasted downtime versus automated systems reliably maintaining lubrication schedules according reduced intervals. Sensors signal technicians for oil conditioning before breakdowns. IoT systems optimize grease types/intervals customized to operating severities.
3. Program Crusher Settings
Crusher settings regulate product size distributions but manually adjusting burdens operators. Integrate telemetry detecting settings remotely from control rooms for consistent, centralized “autofine-tune” control maximizing size/shape specifications. IoT further forecasts optimized settings based on production variances.
4. Inspect Wear Components Routinely
Undetected hammer/mantle wear exaggerates before failures, diminishing outputs. Schedule daily inspections identifying component life percentages remaining for timely replacements versus gambling on extended lifespan risks. Thermography enables predictive monitoring of heat signatures pinpointing component weaknesses.
5. Set Crusher Chamber Clearances Correctly
Crusher settings directly influence throughput, power draw, maintenance needs and product shape/size distribution. Integrated telemetry allows remote monitoring and adjustment of opening clearances based on changing material properties for consistent compliance to specification. Close monitoring ensures settings are reset promptly if drift occurs due to liner wear.
6. Apply Processing Theory
Crusher capacities disproportionately decline with increasing feed hardness/abrasiveness. Subject representative material samples to laboratory crushing/ABA tests characterizing constraints. Leverage Bond Work Index figuring optimizing crushing circuits, preventing over/under crushing through regulating crushing stages and settings.
7. Improve Conveying Capacity
Dimension conveyor belts, chutes, transfer points and stockpile areas generously according to the crusher's maximum rated throughput to avoid bottlenecks forming. For continuous crushing operations, clearing overflowing stockpiles and belt build-ups must occur promptly to maintain uninterrupted feed. Modular, variable-speed conveyors handle fluctuating demands.
8. Conduct Maintenance Blitzes
Comprehensive planned shutdowns systematically refresh components exceeding design lives to restore nameplate capacities. Thermography scans detect fatigue areas, while electrical tests uncover loose contacts. Ultrasonic thickness measurements track structures for timely weld/bolt repairs before failing catastrophically.
9. Minimize Downtime
Unplanned stops hemorrhage revenues while ongoing maintenance curtails. Stock critical spare parts on-site or near suppliers for express deliveries. Practicing set change-out procedures shortens repair times. Mobile technicians’ rapid responses to electronic fault alerts via IoT systems limits disruptions.
10. Train Operators Continuously
Skilled operators optimize settings understanding relationships between variables. Routine hands-on training transfers processing knowledge with simulators re-enacting scenarios. eLearning courses upgrade skills on conveying, crushing theory and new control systems. Competency assessments verify educational effectiveness for consistent, safe crushing operations.
Maximizing efficiency demands developing exhaustive optimization routines through performance tracking, planned preventative maintenance programs and operator enrichment. Technology elevates production insight while streamlining controls for unmanned processes. With diligent execution of proactive optimization practices, mobile crusher fleets reliably satisfy material demands for decades ahead.
