Crushing potential to full use with an optimized chamber
The typical target in chamber optimization is to maximize the wear life of the crusher wear parts. This will lead to less wear parts change-outs and less stops in production. Other targets are to increase crushing capacity and decrease energy consumption without endangering the components of the crusher, enabling our customers to operate with lower cost per ton.
Chamber optimization is especially beneficial for high-volume crushing purposes, where tailoring enables increased production. For developing optimum crusher chambers, Metso uses a state-of-the-art computer-controlled simulation software, which has been developed in-house during several decades.
By using this tool, taking into account your experiences and applying our expert-level crusher knowledge, we make sure the set production targets are achieved.
5 steps of chamber optimization:
- Data collection: The optimization process starts with data collection. Our experts perform an audit to identify primary factors of your plant such as feed gradation, material samples, power draw, foam castings of wear patterns and crusher settings. This way, we make sure all necessary factors in your process are taken into account.
- Analysis: This data is then carefully analyzed and improvement potential is identified. Our competence center network focuses on crushing process simulation, material characteristics, improvement potential and global benchmarking.
- Re-engineering: Global Metso know-how is utilized to re-engineer the needed components regarding metallurgy, simulation and chamber engineering.
- Manufacturing: Improved crusher wear parts are then manufactured in Metso’s global foundry network in order to have full control of the supply chain. This ensures consistent quality, perfect fit and high availability.
- Follow-up: After the delivery the behavior of new components is monitored intensely to see the results in capacity increase, longer wear life and lower cost per ton.
These steps are repeated for continuous long term development.
Case study: Increased capacity and huge savings in energy costs
In a recent chamber optimization project carried out by Metso at a mine site, the re-engineered crushing chamber design contained customized features to prevent pressure spikes and excessive crushing force. The concave segments were cast using three different alloys in order to achieve optimum gradient type, abrasion resistance and the ductility needed for each concave tier.
The new crushing chamber’s choke zone was set to the optimum position, and the fine-materials flow through the cavity was resolved. A higher throughput could be achieved with a smaller stroke, as well as a reduced cupping risk, thanks to the more balanced crushing chamber.
The following results were achieved:
annual electricity saving
lower and fewer
per crushed ton
more crushing capacity