The key role of metal prevention in crushing
During the ore crushing process, an accidentally mixed metal block may cause a crusher worth millions of dollars to "suddenly stop heart" in an instant. This seemingly small production detail is actually related to the lifeblood of the entire production line. As the core equipment of mining, cement, metallurgy, energy, quarrying and other industries, the stable operation of the crusher directly affects production efficiency and economic benefits. The metal prevention and control and iron protection system are the key links that cannot be ignored in guarding this industrial defense line.
The harm of metal impurities to the crusher is far more than what can be seen on the surface. When a hard metal block enters the crushing chamber and collides with the high-speed rotating jaw plate, cone crusher liner or other wear-resistant parts of the crusher, the impact force generated can reach tens of tons. This sudden stress concentration can cause cracks and fractures in the wear-resistant parts, and even cause irreversible damage such as spindle deformation.
For example, one of our customers, a large cement production company, once had a piece of excavator shovel tooth mixed with limestone raw materials, which caused the entire vertical crusher rotor to be scrapped, resulting in direct losses of more than 2 million yuan, and the indirect losses caused by the suspension of production are even more difficult to estimate. What is more worrying is that the iron overload incident may also trigger a chain reaction of equipment - the flying metal fragments may damage the conveyor belt and block the discharge port, and the crusher overload may also involve the motor, reducer and other supporting equipment. This "domino effect" makes metal prevention and control no longer a single equipment problem, but a core issue concerning the safety of the entire production system.
Modern iron overload protection technology has formed a multi-level defense system. Primary protection relies on metal detectors. These detection devices use the principle of electromagnetic induction to accurately identify mixed metal foreign matter during material transportation, trigger alarms in time and stop feeding. Secondary protection is the mechanical protection device of the crusher body, such as the iron overload release mechanism of the hydraulic jaw crusher. When unbreakable objects enter, the hydraulic system can automatically increase the discharge port to discharge them to avoid equipment damage. The third-level protection is reflected in the intelligent monitoring system, through vibration sensors, temperature monitoring and current analysis.
Building a comprehensive metal prevention and control system requires both technology and management. On the technical level, in addition to conventional metal detectors, the iron removal device in the raw material field is also crucial. The permanent magnetic self-unloading iron remover can continuously and automatically remove iron pieces from the upper material of the conveyor belt, while the metal detection and pneumatic flap linkage system can accurately remove the iron-containing material segment. After a certain alumina plant put seven iron removal processes into the crushing line, the annual incidence of iron overload accidents dropped from 17 times to zero. The management level needs to establish standardized processes: metal screening before raw materials enter the site, regular equipment inspection system, iron overload emergency plan drills, etc. Particularly noteworthy is employee training. Many iron overload accidents are caused by operators ignoring or misjudging alarm signals.
Some of our customers will also ask, "The wear-resistant parts of the crusher produced by your company have a tensile strength of more than 1500MPa. Are you also afraid of metal falling into the crushing process?" Of course, our high-crystalline nano-compound wear-resistant parts are also afraid of metal foreign bodies entering the equipment. Especially for the cyclic crushing of Cone Crusher, if the metal block enters the cone crusher for the first time, it may collide with the cone lining once or several times and be discharged. After screening, the conveyor belt puts the iron block into the crusher again. After multiple collisions, even the strongest wear-resistant parts cannot guarantee no problems. This is why metal prevention and control is particularly important.
Of course, here we also want to say to the users of the crushing industry that in addition to the necessary equipment maintenance, it is also very important to choose high-quality wear-resistant parts for crushers. Take the wear-resistant parts we produce as an example. Under the same working conditions, if your original cone lining can be used for 50 days, then our wear-resistant lining can be guaranteed to be used for more than 100 days. This can effectively reduce your downtime and replacement time, reduce production losses, and help your company save money.
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