Our Indonesian client's head office is located in Jakarta, and its main business focuses on coal mining and processing. The site we visited this time is the second-largest coal mine project under the client's portfolio. Due to the fact that the previously used crushers could not meet the actual production requirements in terms of processing capacity, the client decided to purchase a new mineral sizer to replace the old equipment.
Around July 2024, the client contacted our company through the internet. After thoroughly understanding the client's actual needs, our technical department had an efficient and in-depth communication and discussion with the client for over three months. Through repeated technical demonstrations and scheme optimization, we finally tailored a feasible solution for the client and successfully helped the client increase the processing capacity of coal.
The mineral sizer equipment purchased by the client has been successfully installed and put into actual use. It has been nearly a year since then, and the operation is in good condition, earning high recognition from the client.
At the end of July, we went to Indonesia to visit our clients and visited the client's coal mine site. The main purpose was to conduct on-site inspections of the mineral sizer that we had previously supplied and installed, to ensure that the equipment was operating in good condition and to collect the client's feedback.
On the site, our technical team carefully inspected every component of the mineral sizer, from the feed inlet to the discharge outlet, paying no attention to any detail. Through on-site communication with the client, we learned that this equipment had performed stably over the past year, meeting the client's expectations in terms of processing capacity and significantly improving their production efficiency.
Crushing teeth
Squeezing effect
When the mineral sizer is in operation, the material enters the crushing chamber. The primary toothed ring rotates along with the toothed rollers, coming into contact with the material and exerting a squeezing force on it. Under this powerful squeezing force, the structure of the material is disrupted, and it begins to break down into smaller particles.
Shearing and tearing effect
The special shape and distribution of the primary toothed ring enable it to produce shearing and tearing effects on the material during its rotation.
Increasing the number of crushing operations
As the initial stage of the crushing process, the primary toothed ring can perform the first crushing on the material, making it easier to handle in subsequent crushing operations.
The side teeth plate
Removing adhered materials
The side teeth, through their unique tooth shape angle and installation position, form a cooperation with the rotating crushing teeth during the operation of the mineral sizer. They can promptly remove the adhered materials on the surface of the crushing teeth, such as wet sticky materials and fine powder lumps, thus avoiding the accumulation of materials that would reduce the effective working area of the crushing teeth, and maintaining the continuity and efficiency of the crushing process.
Enhancing equipment wear resistance
The side teeth are made of wear-resistant alloy material, featuring excellent wear resistance and impact resistance. During their continuous cooperation with the crushing teeth, the side teeth can withstand the friction, compression from the materials, and the impact force when in contact with the crushing teeth. Even in harsh working conditions such as crushing hard materials or continuous operation for a long time, they can reduce their own wear, thereby extending the service life and reducing the frequency of component replacements.
Improve overall performance
The side teeth do not operate independently but form a complementary cooperative relationship with the crushing teeth. The crushing teeth are responsible for crushing the materials through actions such as squeezing and shearing, while the side teeth are responsible for "cleaning" the crushing teeth and assisting in maintaining the material flow state inside the crushing chamber. This cooperative effect reduces problems such as equipment blockage and load fluctuations caused by material adhesion, thereby enhancing the overall operational stability, crushing efficiency and processing capacity of the mineral sizer.
Crushing beam
Participating in crushing
As a part of the crushing components of the mineral sizer, the crushing rod directly participates in the crushing process of the materials. It can work in conjunction with the toothed rollers to increase the intensity and effect of crushing, allowing the materials to be subjected to more thorough compression, shearing and tearing during the crushing process, thereby more efficiently crushing the materials into the desired particle size.
Stable crushing structure
From the perspective of the structural stability of the mineral sizer, the crushing beam plays a role in supporting and stabilizing the entire crushing structure. The crushing beam can connect and fix various crushing components, ensuring that the equipment maintains a stable structure during operation, reducing problems such as component loosening and displacement caused by vibration and impact, and ensuring the normal operation and service life of the mineral sizer.
Adjusting the crushing particle size
The crushing beam can also play a certain role in adjusting the crushing particle size. It works in conjunction with the adjustment mechanism, by changing its position or state, indirectly influencing the gap between the toothed rollers or the passage of the materials, thereby achieving the adjustment of the crushing particle size to meet the requirements of different production processes for the particle size of the materials.
Wear-resistant liner
Protective equipment
The wear-resistant liner is typically installed at the critical areas where the mineral sizer comes into direct contact with the materials, such as the inner wall of the crushing chamber and the side of the toothed roller. It serves as the first line of defense, bearing the impact, friction and compression from the materials, preventing the main structure shell and frame of the mineral sizer from being damaged due to long-term wear and extending the overall service life.
Improving wear resistance
The wear-resistant liners are made of special materials with high hardness and wear resistance, such as high manganese steel, wear-resistant cast iron, and composite alloys. Their wear resistance is much higher than that of the ordinary steel of the equipment body. By using the liners, the ability of the equipment to resist wear in the contact area with the materials can be significantly enhanced, reducing the frequency of equipment shutdown and maintenance due to wear.
Maintaining stability
As the mineral sizer operates, if the main components are directly worn out, it may cause structural deformation, affecting the material crushing path or the cooperation accuracy of the toothed rollers. The uniform wear of the wear-resistant liners can maintain the stability of the internal structure of the mineral sizer, ensuring that the material crushing process follows the designed parameters, and avoiding the reduction in crushing efficiency or the unqualified particle size caused by the deformation of the components.
Reducing maintenance costs
Compared to directly replacing the main components of the mineral sizer, the wear-resistant lining plate is a wear-prone part. The replacement process is simpler and the cost is lower. When the lining plate wears to a certain extent, it can be replaced separately without requiring major repairs to the equipment body. This reduces maintenance time and costs, and improves the overall operational efficiency of the mineral sizer.
