Crusher Vision has developed patented novel technology that offers the mining sector the opportunity to increase throughput, decrease maintenance costs, decrease power consumption and greatly reduces the safety concerns by implementing a system for non-disruptively measuring wear on gyratory crushers.
Crusher Vision was developed to minimize down-time when determining the closed side or open side settings in the mining sector. Crusher Vision will reduce maintenance costs, reduces power draw, increase throughput and eliminate a safety hazard when taking closed side or open side settings. Current manual methods of determining the CSS/OSS are inaccurate, dangerous and require that the equipment be shut down for at least an hour, which results in production losses. In contrast, Crusher Vision can measure CSS/OSS when the crusher is operating, but empty, allowing an operator to obtain results within a few minutes. As there is little or no downtime, readings can be taken daily with little impact on productivity. With accurate data, a mine operator can trend the mantle liner wear daily, predict mantle liner life and plan mantle liner changeouts with accuracy.
The standard method for determining wear on the mantle is to lower a galvanized steel bucket or led ball into the crusher then measuring the amount of deformation on the bucket or lead ball. This method is highly inaccurate, time consuming and poses significant physical risk to the operator.
When the system, utilized daily, the crusher tonnage or production is maintained at the forecasted numbers. Too tight of setting reduces tonnage and can adversely affect the crusher mechanics and motor amp draw. If the CSS is too large it will affect choke feeding as it cannot be maintained, and will send coarse material to the mill reducing tonnage and crusher effectiveness.
Open pit mining worldwide utilizes gyratory crushers as the primary crushing circuit that feeds the mills. In some cases, the mantles are changed approximately every seven weeks at a cost of approximately $150,000 each time. It is expected that the present technology will result in at least one less mantle change-out per year. At one large open pit mine, for one crusher, the reduction of downtime translates into increased productivity of about 780,000 tons annually, based on production of 20,280,000 tons annually. The replacement of crusher operators with the system saves a mine about $500,000 a year in North America.
Crushing equipment is the heart of an industrial material-processing system. The size reduction choice you make will have a profound impact on the profitability of your business. When the right choice is made, you should expect many years of profitable operation.
Crushers are not glamourous. They are brute force workhorses and what they do is simple, really. Size-reduction equipment in all forms is adding energy to a material to make big pieces smaller. Simple, right?
When the above costs are all accounted for, they are used to quantify the production costs related to size reduction and are expressed in cost per unit of measure production. For example, $0.50 per tph.
There are always opportunities to buy a machine at a lower upfront cost. This usually translates into paying higher operating costs over the life of the equipment. Higher service labor cost. Higher wear parts costs. Higher energy costs.
Often there is a justifiable case to spend additional capital dollars for the better machine. When evaluating crushing equipment suppliers, crusher manufacturers should quantify both costs: purchase price and operating costs. Before you purchase, ask for reference customers to visit.
Why are there so many types of equipment? Our team brainstormed this question, and we came up with more than 50 tools or machines that are used for size reduction. What we are addressing here is industrial size reduction of dry, solid materials, which are grown, mined or chemically synthesized, and need to have a physical dimension alteration to be put to use.
The variables above all affect your costs. Lets take the first question as an example. How long do you plan to operate? There are times when mines reserves, stockpiles, permits, project contract terms affect expected life.
If a project is limited by any factor, then good enough could be the best choice. As long as the equipment is safe and there are machine wear parts and service available, then going cheap may be the best choice. Another factor to consider with low-cost is limited post-sale assistance if there is some process change or major equipment problem. You dont want to be hung out to dry.
Aggregate producers typically expect to be running and profitable for many years. Always buy a crusher from an established company, develop a relationship, and expect ongoing service and personal contact. Ask before you buy about how they approach post-sale parts sales and service.
Ask the company quoting how they intend to offer service for their crusher. How many field service people do they have? Are they local, regional or too far away? Not having responsive suppliers will have a significant impact on your plant profitability.