A JVI customer reached out to upgrade two of their cone crusher stations. In this article we will cover why the customer wanted to upgrade their stations and how JVI was able to retrofit the new cone crusher feeders.
Reasons to Upgrade
The customer is currently utilizing a JVI Cone Crusher Feeder to feed a tertiary cone crusher at one of their other plants. Since installing the feeder, they have experienced significant improvements in their process:
Increased Crusher Service Life
When compared to a standard horizontal discharge pan feeder, the cone crusher feeder facilitated even wear around the entire crusher. This greatly increased the service life of the crusher. The standard pan feeder would bias the material towards one side of the crusher. This bias would cause that side of the crusher to wear out while the opposite side of the crusher still had service life remaining. The JVI feeder is able to promote an even wearing of the concave (bowl liner) and mantle. This is accomplished by the 360-degree peripheral feed created by the feeder’s center hole discharge. The uniform feed ensures there is no bias to one side and promotes even wear across the entire crusher.
Higher Yields of Cubicle Material
Due to the unique feeding action, the material turns over or folds onto itself when introduced to the crusher, enabling a more uniform crush and yield of cubicle rock. Additionally, this 360-degree feed improves efficiency by approximately 30%, eliminating the need to recirculate material back through the crusher a second time, maximizing the overall process.
Higher Turn Down
Another benefit the customer noted was more precise feed rate control. The feeder was able to be turned down to optimize the feed rate to crusher. This ensured that the crusher was not under or overfed.
Custom Cone Crusher Feeders Package
After reviewing the process requirements, JVI proposed both a 425 and 225 ton/hour feeder package:
Retro Fit
Both cone crusher feeders would be designed to fit and work within the available work envelope of the existing stations. Space around the equipment was not a limiting factor. The main requirement was discharging the material from the existing hopper at the required rate directly above the cone crusher. To meets these requirements, the larger feeder required a pan width of 48” and an overall length of 135-5/16” The smaller feeder’s pan width required a width of 40” and have an overall length of 115-13/16” These dimensions would enable to the new feeders to be integrated into the existing stations and have their outlets centered over the cone crusher for optimal performance.
Replaceable Wear Liners
Abrasion resistant liners were included to accommodate the abrasive nature of the material. JVI designed the liners to be bolted and replaceable for easier maintenance and extended service life.
Electromechanical “Unbalanced” Motors
Dual unbalanced motors were utilized as the drive mechanism. The motors were sized based on the weight of each feeder to allow for field optimization through a variable frequency drive. This allows for higher turn down and optimal crusher feed.
Single Mass Design
Single mass design utilizes fewer operating components resulting in high reliability and low maintenance. There are no “tuning” requirements, and the machine can operate through variations in material and head load.
Upon customer review and approval, both feeders were manufactured, delivered and successfully commissioned.