Rumbling mechanical sound, a piece of ore weighing several tons was sent into the crusher’s “iron teeth”, instantly turned into uniform particles – this scene in modern mines are staged ten million times a day. As the “first process” of mining production, the performance of crushing equipment directly determines the subsequent beneficiation efficiency and resource utilization. Under the wave of green mining and intelligent transformation, mining crushing equipment is promoting the industry revolution with innovative technology.
1, the classification of mining crushing equipment and technology iteration
Mining crushing equipment can be divided into three categories according to the function of coarse crushing, medium crushing, fine crushing, each type of equipment corresponding to different particle size requirements. *Jaw crusher* is the dominant in the field of coarse crushing by virtue of its high capacity, and its double-plate extrusion structure can easily deal with materials with Moh’s hardness below 9; * Cone crusher* realizes high efficiency and energy-saving in the crushing stage through the principle of laminated crushing, and the hydraulic adjustment system makes the discharge particle size accurately and controllably; and * Impact crusher* is the leading crusher in the field of fine crushing by virtue of the principle of “hitting the stone”. The *Impact Crusher* has risen to prominence in the field of fine crushing by virtue of the “stone hitting stone” principle.
The introduction of intelligent sensing technology and modular design has further upgraded the performance of the equipment. For example, the PLC control system of a brand of cone crusher can monitor the bearing temperature and vibration data in real time, and the accuracy of fault warning is increased by 40%; while the quick-disassembly cutter design compresses the maintenance time from 8 hours to less than 2 hours.
2、Selection Guide: Matching the Core Elements of Demand
The selection of crushing equipment needs to take into account the three dimensions of ore characteristics, production capacity targets, and energy consumption standards. For granite, basalt and other high hardness materials, it is recommended to use “Jaw + Cone Crusher” combination, utilizing the high compression resistance of the jaw crusher and the fine control ability of the cone crusher; for limestone, gangue and other low hardness raw materials, “Heavy Hammer Crusher + Shaper” solution can not only reduce power consumption, but also reduce energy consumption and energy consumption. For low-hardness raw materials such as limestone, the “heavy hammer crusher + shaper” program can not only reduce power consumption, but also ensure that the grade of the finished product is excellent.
Case of an iron ore enterprise: the original traditional production line with a ton of power consumption of 3.2kW-h, switching to vertical shaft impact breakers equipped with frequency conversion drive, energy consumption dropped by 28%, and at the same time, by adjusting the angle of the casting head, so that the proportion of needle flake particles from 15% down to 6%, significantly improving the efficiency of the ball mill.
3、Operation and maintenance upgrade: full life cycle management strategy
Preventive maintenance has become the key to extend the life of the equipment. Take the hammer head as an example, although the initial cost of the wear parts made of high-chromium alloy is 30% higher, the service life can be more than 3 times of manganese steel parts, and the annual comprehensive cost is reduced by 18%. By installing an online oil monitoring system to the crusher, a group discovered signs of bearing micro-wear in advance, avoiding an unplanned shutdown and recovering losses of more than 2 million yuan.
In terms of intelligence, *digital twin technology* is beginning to penetrate the field of equipment management. By constructing a 3D dynamic model of the crusher, engineers can remotely simulate the stress distribution under different working conditions and optimize the liner replacement cycle, reducing spare parts inventory by 25%.
4、Future Trend: Dual Evolution of Green and Intelligent
With the advancement of the Outline for the Development of the Mining Equipment Manufacturing Industry, low noise and zero emission have become hard indicators for equipment iteration. A new jawbreaker adopts double-layer soundproof cover design, and the working noise is reduced from 110 dB to 85 dB; while the popularization of dry dust removal system makes the dust concentration in the crushing workshop stably lower than 10mg/m³.
In the intelligentization track, 5G+AI technology is reshaping the production scene. The crushing system of a demonstration base has realized autonomous decision-making: the visual recognition module automatically analyzes the particle size of incoming materials and dynamically adjusts the parameters of the equipment; when non-crushable materials are detected, the hydraulic protection device automatically unloads within 0.3 seconds, which is 5 times faster than the traditional mechanical overload protection.
From the manual crushing hammer in the steam era to today’s intelligent crushing production line, mining equipment is always the core carrier of resource development. When more enterprises focus on equipment networking, data mining, energy efficiency optimization, this efficiency revolution driven by technological innovation is redefining the value boundary of “crushing”.
