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    Wear Parts For Cone and Jaw Crushers

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    Ragab Abulmagd
    This document discusses factors to consider when choosing wear parts for cone and jaw crushers. It examines properties of the rock material being crushed as well as operational parameters. Different types of crushing chambers and jaw plates are presented along with their advantages and applications. Special liners are discussed that can increase liner life and improve reduction. Common wear problems and solutions are outlined. The importance of preventative maintenance and using genuine parts is also emphasized.

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    © All Rights Reserved
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    Wear Parts For Cone and Jaw Crushers

    Uploaded by

    Ragab Abulmagd
    1K views40 pages
    This document discusses factors to consider when choosing wear parts for cone and jaw crushers. It examines properties of the rock material being crushed as well as operational parameters. Different types of crushing chambers and jaw plates are presented along with their advantages and applications. Special liners are discussed that can increase liner life and improve reduction. Common wear problems and solutions are outlined. The importance of preventative maintenance and using genuine parts is also emphasized.

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    Wear Parts for Cone and Jaw Crushers

    Original Title

    Wear Parts for Cone and Jaw Crushers

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    This document discusses factors to consider when choosing wear parts for cone and jaw crushers. It examines properties of the rock material being crushed as well as operational parameters. Different types of crushing chambers and jaw plates are presented along with their advantages and applications. Special liners are discussed that can increase liner life and improve reduction. Common wear problems and solutions are outlined. The importance of preventative maintenance and using genuine parts is also emphasized.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views40 pages

    Wear Parts For Cone and Jaw Crushers

    Uploaded by

    Ragab Abulmagd
    This document discusses factors to consider when choosing wear parts for cone and jaw crushers. It examines properties of the rock material being crushed as well as operational parameters. Different types of crushing chambers and jaw plates are presented along with their advantages and applications. Special liners are discussed that can increase liner life and improve reduction. Common wear problems and solutions are outlined. The importance of preventative maintenance and using genuine parts is also emphasized.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The document discusses factors to consider when choosing wear parts for crushers, different mantle types for hydrocone crushers, advantages of heavy choke mantles, preventive maintenance practices and special liner solutions.

    Factors that should be considered when choosing wear parts include the castability of the wear part, abrasiveness of the rock material, risk of high impact loads, work index of the incoming material, acceptable degree of expansion during work, type of crusher, type of crushing (coarse or fine), size of incoming rock material, and operational parameters of the crusher.

    Advantages of using a heavy choke mantle include enabling smaller settings which results in more reduction and less circulating load and better shape in smaller fractions. Disadvantages include lower throughput, especially with new liners.

    Wear Parts for

    Cone and Jaw Crushers

    Quarry Academy 2005

    How to choose wear parts?


    z

    Castability of wear part?

    Abrasiveness of rock material (AI)?

    Risk of high impact loads during service?

    Work index (WI) of incoming material?

    What degree of expansion during work can be accepted (and


    expected)?

    Type of crusher?

    Type of crushing (coarse/fine)?

    Size of incoming rock material?

    Operational parameters for the crusher?

    Any tests made on other wear materials?

    Quarry Academy 2005

    Crushing chambers for Hydrocones

    Quarry Academy 2005

    Mantle Difference between A and B

    A
    B

    Quarry Academy 2005

    Mantle A or B
    A-Mantle:
    z Used with small setting and small throws.
    z Used wrongly means that large enough
    setting can not be obtained. Piston in
    bottom position.

    B-Mantle:
    z Used with large setting and large throws.
    z Used wrongly means poor utilization at
    the end of the A-dimension.

    Quarry Academy 2005

    Utilize the
    Travel length!

    Heavy Choke (HC) - Mantle


    Advantages:
    z Enable smaller settings
    More reduction means less
    circulating load and better
    shape in small fractions (5-8).
    z Larger feed opening
    Marginal stones enter.
    Disadvantages:
    z Lower throughput
    Especially with new liners.

    Quarry Academy 2005

    Wear problems
    z Crushing chamber selection Concave and mantle
    z Feed distribution

    Quarry Academy 2005

    Preventive maintenance
    z Wrong feed arrangement
    9 Higher power usage = higher load on bearing
    9 Lower capacity
    9 Higher wear in the crushing chamber
    9 Less reduction
    9 Worse shape of final product
    9 Higher cost

    Quarry Academy 2005

    Special Liners 3C
    3C includes:
    z Crushing Technology Solution
    z After market Business
    z Production Time
    Increased customer value:
    z Longer liner life
    z More reduction
    z Correct setting

    Report results to
    Crushing Technology Group

    Quarry Academy 2005

    Special Liners
    Problem:
    z Low capacity in the end of liner
    life.
    Action:
    z More vertical in the top section
    by machining
    Result:
    z No premature liner change
    50% increase in liner life.
    z Full capacity all through the
    liner life.

    Quarry Academy 2005

    Special Liners
    Problem:
    z Wear on support ring when
    running at large settings
    Action:
    z Machining in the bottom
    section to make more space
    from the support ring
    Result
    z No wear on support ring

    Quarry Academy 2005

    Special Liners
    Problem:
    z When changing only concave
    ring the edge creates low
    capacity
    Action:
    z Remove the edge by machining maintaining nip angle
    Result:
    z No capacity problem
    z No need for cutting

    Quarry Academy 2005

    Special Liners
    Problem:
    z High wear and not enough
    reduction
    Action:
    z New patterns for both mantle and
    concave optimizing feed opening
    and thickness
    Result:
    z More reduction, %<1/4
    z Liner life increase with 40%

    Quarry Academy 2005

    Special Liners
    Problem:
    z Customer wanted to run at
    90mm setting
    Action:
    z Machine off material to allow
    larger setting with new liners
    Result:
    z Crusher sold
    Customer satisfied

    Quarry Academy 2005

    Special Liners
    Problem:
    z Ski slope on mantle creating high
    pressure, large setting and low
    capacity
    Action:
    z Optimizing crushing point by
    machining
    Result:
    z Full capacity and maintained
    setting, all through the liner life
    z Increase in life up to 100%
    depending on application

    Quarry Academy 2005

    Quarry Academy 2005

    Wide Wave (WW)

    Heavy Duty (HD)

    1
    1
    1
    1
    1

    1
    1

    1
    3

    1
    1

    3
    6

    Sharp Tooth (ST)

    1
    1
    1
    1
    1

    Coarse Corrugated (CC)

    Corrugated (C)

    JM 806
    JM 907
    JM 1206
    JM 1108
    JM 1208
    JM 1211
    JM 1312
    JM 1511
    JM 1513

    Wide Teeth (WT), Z

    Jaw Plates for the Jawmaster

    1
    1
    1
    1
    1
    1
    2

    Wide Teeth (WT), Z


    z General applications
    z Abrasive rock
    z Less in stock due to that
    the Z-plate can be fitted on both sides

    Quarry Academy 2005

    Corrugated (C)
    z Laminar material
    z High amount of fines
    z Small setting
    z Cubical product

    Quarry Academy 2005

    Coarse Corrugated (CC)


    z Laminar material
    z Abrasive material
    z High amount of fines
    z Large setting

    Quarry Academy 2005

    Sharp Tooth (ST)


    z Increased nip action
    z Laminar material
    z Abrasive material
    z Large amount of fines

    Quarry Academy 2005

    Heavy Duty (HD)


    z Extremely abrasive material
    z Increased liner life
    z No demands on particle shape
    z Can be combined with CC or ST for improved particle shape

    Quarry Academy 2005

    Wide Wave (WW)


    z Extremely flaky material
    z Less abrasive material
    z Muddy material
    z Good particle shape

    Quarry Academy 2005

    Improvements
    z New ST jaw plates for
    large crushers
    z One piece

    z Angled teeth to reduce cheek plate wear

    Quarry Academy 2005

    Study of Wear Profiles


    z Heavy Duty (HD)

    z Wide Teeth (WT), Z

    z Please report to Crushing Technology Group

    Quarry Academy 2005

    Manganese steel
    History:
    z 1880 Sir Robert Hadfield 12% Mn, 1% C
    z Hardening by deformation
    z Strmhard increased the Mn- och C-content.
    Important parameters when casting manganese:
    z High quality scrap Impurities means lower quality
    z Casting temperature Decides grain size
    z Heat treatment Time enough to get to center of casting
    z Water quenching Low thermal conductivity. High carbon and
    chromium content means more carbides. Thick castings means
    risk of cracking.

    Quarry Academy 2005

    Manganese steel
    To choose from Sandvik alloys: M1, M2 and M7
    z Soft and abrasive material M2, M7
    z M2 and M7 have less significance in fine crushing
    z Try and see Please report to Crushing Technology Group
    Pirates promote 24% manganese steel.
    z The manganese content do not show the wear resistance.
    z Mn-content expand the austenite zone, enabling higher
    carbon and chromium content.
    z Higher Mn, Cr och C-content increase wear resistance
    marginally but also increase the cracking risk substantially.

    Quarry Academy 2005

    Wear Problems - Summary


    1. Choose the correct standard crushing chamber
    Both mantle and concave
    2. Make the feed distribution as good as possible
    Here is a lot to gain, rebuild if possible
    3. If there still is a problem with the wear profile
    Contact the 3C-group
    4. To boost liner lifetime even more
    Try a different manganese alloy

    Quarry Academy 2005

    The capacity is too low?


    z Make sure the crusher is choke fed
    z Increase the eccentric throw
    z Select a coarser crushing chamber
    z Reduce the moisture content

    Quarry Academy 2005

    The product size is too coarse (or the


    circulating load is too high)
    z Reduce the C.S.S.
    z Reduce the throw to enable a finer C.S.S.
    z Select a finer crushing chamber
    z Increase eccentric speed

    Quarry Academy 2005

    The product contains too much fines


    z Increase the C.S.S.
    z Reduce the throw for a more gentle crushing
    z Select a coarser crushing chamber
    z Reduce the amount of fines in the feed

    Quarry Academy 2005

    The product shape is not acceptable


    z Make sure the crusher is choke fed with a
    minimum of stops for idling
    z Select a C.S.S. that is close to the product size
    with high demands on cubicity
    z Reduce the reduction ratio, i.e. reduce the top size
    of the feed
    z Reduce the lower fraction limit of the feed a little
    in order to add some fines

    Quarry Academy 2005

    The crusher is packing


    z Reduce the reduction ratio
    z Reduce the amount of fines in the feed.
    z Avoid dirt or moist in the feed
    z Adjust the feeding arrangement for even
    distribution (and central feeding of Hydrocones)
    z Avoid segregated feed
    z Inspect the crushing chamber for uneven wear

    Quarry Academy 2005

    Excessive wear at the bottom part of the


    crushing chamber
    z Select a finer crushing chamber in order to move
    the crushing work upwards

    Quarry Academy 2005

    Uneven wear around the concave ring


    z Adjust the feeding arrangement for even
    distribution (and central feeding of Hydrocones)
    z Avoid segregated feed
    z Use a distributor for MF and finer crushing
    chambers

    Quarry Academy 2005

    Too short liner life


    z Try the M1+ material for the mantle and concave
    z Try the M1+ material only for the mantle

    Quarry Academy 2005

    We know what we are talking about!


    z Manganese steel????
    9 Cold work hardening + toughness

    z Manganese content????
    9 heat treatment + alloys + solving carbon + cooling&carbides

    z Thicker manganese????
    9 tramp iron protection + risk of carbides + shape of profile

    z Tonnes or hours = money????


    z Surface finish????
    9 It does matter!

    z Machining????
    9 It does matter!

    z Experience in design, manufacturing & process????


    9 >10000 years

    z Sandvik quality and development????


    9 Tooling and Material Technology

    Quarry Academy 2005

    Preventive maintenance
    z Warranty policy
    9 Design, material or manufacturing
    9 Report to Sandvik Rock Processing within warranty time
    9 Used according to maintenance manual and in appropriate
    applications.
    9 Service and repair carried out by SRP authorised personnel
    9 Use Sandvik Rock Processing genuine parts

    Quarry Academy 2005

    Preventive maintenance
    z Parts policy
    9 Genuine Parts = optimal safety and economy
    9 Latest design and quality
    9 10 years supply of parts

    Quarry Academy 2005

    Preventive maintenance
    z Storage of parts
    9 Check corrosion protection regularly
    9 Place wood under heavy components
    9 Seals and gaskets shall be stored under dark, dust free and
    dry conditions, preferably at room temperature.
    9 Bushings should be kept standing
    9 E.g. dust seal ring should be stored flat

    Quarry Academy 2005

    Proactive Elements for Success:


    z Availability of Parts
    9 Operational cost, process, performance

    z Reliability of Parts
    9 Effective maintenance, operational cost, uptime

    z Maintenance
    9 Operational cost, uptime

    z Process
    9 Desired product, minimise waste, utilise plant, adopt to changes

    z Performance
    9 Capacity, uptime, quality

    Quarry Academy 2005

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