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Some ways to reduce the energy consumption of metal crushers
In order to ensure the efficient operation of a metal crusher, the bulk material must meet specific comminution requirements. The material's strength should not exceed the maximum capacity of the crusher. Furthermore, during the crushing process, it is essential to prevent non-grindable items such as iron pieces from entering the crushing chamber, as they can cause damage and reduce efficiency. When mixed materials are processed, variations in their strength can lead to uneven crushing. Stronger materials may resist being crushed, which reduces the likelihood of achieving the desired particle size for weaker materials. This imbalance also causes uneven stress on the crusher’s liner, leading to irregular wear and potentially affecting the machine's performance.
To enhance the crusher's efficiency, improve component durability, and maximize the benefits of lamination and crushing, it is crucial to maintain consistent material strength throughout the feeding process. According to the concept of lamination and crushing, when the bulk material occupies more than 40% of the crushing volume, it can be fully engaged in the lamination process. Additionally, under full feeding conditions and with a uniformly filled hopper, when the material filling degree reaches 55%, the requirements for effective lamination and crushing are fully met.
The lamination and crushing method significantly contributes to energy savings in the crushing equipment. To achieve optimal energy efficiency, the feeding material must meet the necessary conditions for lamination, as previously discussed. Research shows that when the material is arranged in 6 to 10 layers, the energy consumption of the equipment decreases substantially. Typically, the uniform particle size of the feed is about half of the maximum particle size, resulting in approximately two layers of material. When the choke layer height in the shredder is 93 mm, the uniform particle size can reach 9.45 mm, indicating that the number of feed layers should be around 9.8. This configuration meets the ideal conditions for the best feeding layer, enabling the crusher to effectively save energy and reduce consumption.