Around our offices at ELRUS, we often share stories and discuss the state of the industry, reflecting on the successes and failures of our acquaintances. We noticed common themes in our observations that we believe are valuable to share and discuss.
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Many of us didn't initially plan to be in this industry. Some entered due to family connections, while others started with summer jobs that turned into careers in crushing and screening. We endured the dust, changed screens, fixed belts, and shoveled conveyors. Our persistence, care, and innovative ideas propelled us to supervisory roles, allowing us to oversee entire processes. We learned the intricacies of handling rocks and became "rock stars."
We've found that this business is challenging! There is no "Crushing University" or "Gravel College" for mastering efficient rock crushing. Furthermore, the scarcity of high-quality gravel pits and quarries complicates meeting stringent specifications. It’s understandable why many in this field lose their hair – it's akin to making a silk purse from a pig’s ear.
During our discussions, we identified common attributes among the successful in our field – those who advanced to managerial roles or thrived as contractors while others faltered. Over our 40 years in this business, we believe that the most successful share these characteristics.
1. They have robust measurement systems and use them to drive improvement
To differentiate between cost and price and to understand throughput and improvements, you need accurate data from measurement systems. The most successful ones measure:
- Production per day of in-spec materials
- Downtime per day/shift/month/year by reason
- Manganese wear life in tons, days, and hours
- Screen media wear life in tons, days, and hours
- Revenue per hour of operation
- Detailed maintenance records
Successful operators track additional metrics to analyze operating practices, especially where feed quality varies. Ultimately, good measurement systems support continuous operational improvement and profitability in capable hands.
2. They understand that cost and price are different considerations
Price is the amount spent to acquire something, such as $750,000 for a cone plant. Cost, however, is evaluated over time or units of operation. If the cone plant lasts fifteen years, the capital cost is $50,000/year. If it produces 1,000,000 tons annually for fifteen years, the cost per ton is $0.050/ton.
A different cone plant priced at $650,000 may only last twelve years, making its capital cost $54,167/year. With the same annual production rate, the cost per ton is $0.054/ton. Although the price is lower, the cost/ton produced is higher, as is the annual cost.
This analysis applies to every operational expense, from crusher cost to screen media quality, emphasizing that a lower price does not equal a lower cost of operation.
3. They understand throughput
Throughput is not merely production per hour or day; it’s the sellable, in-spec material's dollar value at the end of a financial period (month/quarter/year).
Consider Two Operations:
- Operation A produces 400 tons/hour on average and relocates its spread five times a year, losing 20 working days annually.
- Operation B, producing the same 400 tons/hour, only loses 10 working days to relocations annually.
At $5.00 per ton, the annual difference in throughput is $200,000 over the life of the spread, which significantly impacts the bottom line.
4. They implement good ideas
The most successful operators are open to new ideas, willing to examine and improve their production processes. They experiment, evaluate, and adopt beneficial ideas.
An example from the field:
Crushing rocks larger than 12” in sand and gravel operations is tough and costly. However, there's a market for such rocks in flood repairs, mitigation, and landscaping. A client added a primary sorter to separate these rocks before feeding them to the jaw crusher. Over two years, the revenue from the large rock covered the sorter's cost, reduced jaw manganese wear, and improved production rates, enhancing overall profitability.
Implementing good ideas often means facing resistance, challenging existing habits, and securing management support, which can involve significant investments or borrowing. It's a testament to one's courage and conviction in the new approach's merits.
5. They recognize the importance of the work environment
Top industry players ensure a safe work environment that not only complies with regulations but fosters a culture where skilled workers feel secure and valued. They focus on hiring selectively, training, and encouraging continuous improvement. Leaders maintain credibility by practicing what they preach and by being consistent in their actions.
Improving your operation requires effort but can yield significant results. If you see areas for improvement, Contact Us to speak with one of our product specialists.
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What Type of Crusher Is Best for Primary Crushing?
Primary crushers reduce large run-of-mine material, like rocks and ore lumps, into smaller sizes for further processing. This initial crushing stage can include secondary, tertiary, and even quaternary crushing, depending on material and end-product requirements.
Types of Primary Crushers
Primary crushers include:
- Gyratory Crushers
- Jaw Crushers
- Hammermills
- Horizontal Shaft Impact Crushers
- Sizers
- Roll Crushers
- Cone Crushers
- Feeder-Breakers
Gyratory Crushers
Gyratory Crushers are ideal for primary crushing of very hard and abrasive materials. They are suitable for dry to slightly wet materials but not sticky ones. These crushers primarily serve in high tonnage applications in heavy mining and quarries with a reduction ratio of 4:1 to 7:1.
Main features include a tall crushing chamber, a main shaft with head and mantle, and a spider to anchor the shaft bearing. They have an adjustable main shaft system and are available in single or multiple cylinder designs. Material is fed through the top, compressed between the mantle and concaves, and exits when crushed to the desired size.
No pre-screening is needed as the machine can handle all-in feed. Gradation is controlled by adjusting the gap between the mantle and liners.
Jaw Crushers
Jaw Crushers are excellent for primary crushing applications, handling the toughest, hardest, and most abrasive materials, suitable for dry or slightly wet and non-sticky materials.
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These crushers are best for heavy mining, quarried materials, sand, gravel, and recycling. They feature a V-shaped chamber with a moving "pitman" and a stationary steel piece. Crushing occurs mainly in the bottom third of the chamber.
Material is squeezed and then allowed to drop further down the chamber before the next cycle. Output size is adjusted through hydraulic or manual shim adjustments.
Hammermills
Hammermills are versatile primary crushers in aggregate and industrial applications. They are ideal for materials including limestone, gypsum, bauxite, and coal. Using impact, shear, and attrition methods, they produce finer material and are effective in lower abrasive applications.
Types include Standard, Non-Clog, and Centerfeed. Each type suits different materials and applications, from free-flowing friable materials to wet, sticky materials.
Horizontal Shaft Impact Crushers
Horizontal Shaft Impact Crushers are used for primary size reduction of soft to medium hard materials. They manage slightly abrasive, dry, or wet material, providing high reduction ratios and a uniform, highly cubical product.
They feature a spinning rotor with blow bars that fling material against breaker plates. Adjusting RPM controls gradation and throughput.
Sizers
Direct-Drive Crushing Sizers offer primary crushing of soft to medium-hard materials. With two inward rotating rolls, they crush material between teeth and roll bodies, minimizing fines and handling variable feed qualities.
Roll Crushers
Roll Crushers are suitable for primary crushing of soft to medium-hard materials, offering compression-type crushing with control over output gradation by altering the gap between rolls.
Types include Single, Double, Triple, and Quad configurations, each providing different capacities and product sizes.
Cone Crushers
Cone Crushers, typically found in secondary stages, can act as primary crushers for hard, abrasive materials. Material is compressed between a wobbling mantle and concaves.
Output gradation is controlled by the gap setting and machine speed.
Feeder-Breakers
Feeder-Breakers combine feeding and crushing for primary processing of friable materials. Featuring high capacity and a chain and flight drag conveyor, they size run-of-mine material to a beltable product.
Secondary or tertiary stages may be needed to achieve the desired product size.
How To Choose the Right Primary Crusher
Choosing the right primary crusher depends on factors such as material to be crushed, feed size, desired product size, capacity, compressive strength, and moisture content.
Primary Crushers Used in Aggregate Applications
Common types in aggregate applications include Jaws, Gyratories, Impactors, and Cones.
Primary Crushers Used in Mining Applications
Common types in mining include Roll Crushers, Sizers, Feeder-Breakers, Jaws, Cones, and Impactors.
The right primary crusher based on material characteristics and application can enhance operational efficiency.
The company is the world’s best jaw rock crusher supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
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