WP-0110 Cone Crusher Attrition / Crushing Manufactured Sand by Paul Smith White Paper WP-0110

A Common Challenge: As any aggregate producer knows, it is a rare occurrence for Mother Earth to provide natural material deposit characteristics that perfectly meet 100% of the end product mix and processing requirements driven by the business needs as it related to mix designs or product sales of products like rooming granules. There is frequently an abundance of ½ x 3/16 washed or clean sized aggregate, commonly considered a surplus material. In many regions, some producers are managing inventories consisting of several hundred thousand tons of such material. This type of surplus material...

very close to the desired top size of the end product and new super-fine liners were developed. Many quickly found that when operating at a 3/8” or smaller discharge setting with a long parallel zone in the liners, the machine quickly consumed all available power and the result was often overload events. When a machine was able to perform, the quantity of #200’s was too great and created new challenges at the wash plant or with quality control on mix designs. When these issues were coupled with relatively low production in the more expensive cone crusher, the economics were simply not in favor...

Once the system has been designed and the equipment has been selected and positioned, the actual procedure itself is actually very simple, as listed below and illustrated in Figure 1: Figure 1 1. The crusher discharge setting must be calibrated and then the initial CSS set at about 0.50” 2. Start the screen and all transfer and stacking conveyors – DO NOT START THE SURGE FEEDER YET. 3. Start the under-crusher discharge conveyor; 4. Begin feeding the system and build up a load in the surge; 5. When the surge hopper is full, turn on the surge belt feeding the cone. The purpose is to immediately...