Introduction

From primary crushing in large open-pit mines to secondary and tertiary crushing in concentrators, mineral sizer plays a crucial role in every process. The ability to break down large minerals into smaller and more manageable fragments is crucial to the overall productivity and profitability of the mining business. Blockage can lead to unexpected downtime, reduce throughput, increase maintenance costs and lower the efficiency of the entire production line. The unique design structure of Mineral sizer makes it less prone to clogging during the crushing process.

Core Structural Advantages

Open-Throat Design

For traditional crushers such as jaw crushers and cone crushers, their crushing cavities are usually closed or semi-closed. The jaw crusher is a type of crusher where materials enter a relatively narrow and enclosed crushing space from the top feeding port. Under the squeezing action of two jaw plates, the materials are crushed. The closed or semi-closed design restricts the flow of materials. When the processing volume is large, materials will accumulate at the feeding port, especially when processing materials with irregular shapes and high moisture content that tend to stick to each other.

Mineral Sizer adopts an Open-Throat feeding port and crushing area. Materials can directly enter the crushing area and quickly disperse upon entry without accumulating at the entrance. Even when processing large quantities of materials, subsequent materials can continuously enter, maintaining efficient crushing operations.

Special Tooth Profile and Geometry

Mineral Sizer differs from traditional crushers that rely solely on extrusion for crushing. It mainly adopts the crushing principles of shearing, stretching and bending. When dealing with sticky materials, the traditional extrusion crushing method is prone to compacting the sticky materials, forming hard-to-break lumps, which in turn can lead to blockages. When Mineral Sizer processes minerals with high viscosity, the toothed roller, through shearing and stretching, causes cracks in the material during the force application process.

The tooth tip design and spacing of Mineral Sizer enable the tooth tips to quickly embed into the material when it enters the crushing area, grasp the material, and through the rotation of the tooth roller, use the pulling force generated by the spacing between the teeth to tear and crush the material. During the rotation of the toothed roller, it exerts a pushing effect on the material, preventing it from remaining on the tooth surface and leaving no opportunity for adhesion.

Working Principle: Active Clearance and Transport

Simultaneous Crushing and Self-Cleaning

The crushing rollers of Mineral Sizer usually rotate continuously at a relatively low linear speed. Unlike some high-speed crushers, the lower linear speed ensures that the force on the material within the crushing area is more uniform and stable. The high-speed rotating hammer heads of the hammer crusher exert a huge impact force on the materials in an instant. Although it can quickly crush the materials, it is also prone to making the crushing process uncontrollable, and the materials may be over-crushed, generating a large amount of fine powder. The low-speed operation mode of Mineral Sizer allows the material sufficient time to come into contact with the toothed rollers, gradually subjected to forces such as shearing, stretching and bending, achieving smooth crushing.

Wear-resistant plates are installed around the inside of the housing,and comb shaped wear plates are installed on both sides of the housing to prevent excessive material from adhering to the crusher tooth rollers.

Efficient Material Transport Mechanism

In Mineral Sizer, the rotation of the toothed rollers causes the material to be subjected to the effect of centrifugal force, which is thrown to the outside of the toothed rollers. The combined force of gravity and the rotating centrifugal force enables the material to pass through the crushing area rapidly, making the distribution of the material in the crushing area more uniform and avoiding the accumulation of material in a certain area.

The crushed product has uniform particle size and no overly large or small particles will appear. Under the action of gravity and the thrust generated by the rotation of the toothed roller, they can be quickly discharged through the gap at the bottom of the toothed roller. Compared with other crushers, such as some jaw crushers, the materials may remain in the crushing chamber for a longer time after being crushed, which can easily lead to re-aggregation and blockage of the materials.

Special Adaptability for Sticky/Wet Materials

Throughput Capacity

Traditional crushers are prone to frequent clogging problems when dealing with large amounts of coal with high water content and high viscosity. After adopting the Mineral Sizer, the open feeding port and crushing design enable the coal to quickly enter the crushing area and be effectively crushed, ensuring the continuity of production and improving the economic benefits of the entire coal mine.

Mineral sizer adjusts the gap between the two toothed rollers to handle materials with different degrees of stickiness and wetness as well as feed sizes. When dealing with materials with high moisture content and high viscosity, appropriately increase the crushing gap to enable the materials to pass through the crushing area more smoothly and avoid material blockage due to too small a gap. When dealing with materials with larger feed sizes, the crushing gap can also be reasonably adjusted according to the specific size of the materials to ensure that the materials can be effectively crushed.

Low Speed, Low Vibration Operation

Mineral Sizer operates at a low speed, and the linear speed of its crushing roller is relatively low, avoiding severe vibration and shock. When handling materials that also contain fine powder and mud lumps, due to the lack of the powerful impact force of a high-speed crusher, the fine powder and mud lumps will not be overly compacted. During the slow and stable crushing process, the material can remain in a relatively loose state and will not form blockages in the cavity.

Conclusion

The fact that Mineral Sizer is not prone to clogging is the result of its multiple advantages such as structure, tooth shape design, and crushing principle. Through a smooth and controllable crushing process, it effectively deals with sticky, wet and powder-containing materials.