Implementation of optimized compressive crushing in full scale experiments

Commonly used at the coarser end of the comminution process, cone crushers often operate as the final crushing stage in the aggregate industry, or as the supplier of feed material for HPGRs or ball mills in the mining industry. As such, the performance of cone crushers undoubtedly affects the performance and efficiency of the overall process. The aim of this study is therefore to implement theoretical optimizations of compressive crushing for two different applications.Three different prototypes of crushing chambers have been manufactured based on the conceptual designs obtained from theoretical optimizations. Tested in full scale experiments, the results for these prototypes (designed for aggregate production and mining operation) were subsequently compared to the measured data for the corresponding reference crushing chambers. The performed analysis suggests that the performance of cone crushers can be improved in terms of product yield as well as reduction ratio.

► Size reduction and particle shaping should be separated in aggregate applications. ► More size reduction with single particle crushing should be applied in mining. ► The balanced product yield of the aggregate reference can be improved by 5%. ► The relative production of 0–4 mm in the mining reference can be improved by 20%.