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How to maximize your 5-8 mm and minimize 0-5 mm fraction with less energy
© Metso© Metso
A potential 60% reduction in operational costs in tertiary crushing
2
0
20 000
40 000
60 000
80 000
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120 000
Liner wear cost Electricity cost Total operation cost
© Metso© Metso3
You can increase the profitability of your crusher in two easy ways
Control and adjustment of the feed level height
Choke plate feed arrangement
© Metso© Metso4
Choke plate feed arrangement has a significant effect in re-crushing applications
Choke plate Ø opening500 mm400 mm300 mm
© Metso© Metso
40
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kW &
tph
Choke plate Opening [mm]
A reduced feed opening lowers the energy consumption per crushed ton
5
Capacity
Power Draw
1.13 kWh/t
1.43 kWh/t
0.95 kWh/t
© Metso© Metso
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Capa
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Choke plate opening [mm]0/5 5/8 8/11 11/16 16/22
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The lower the energy used, the less fines produced
© Metso© Metso7
You can increase the profitability of your crusher in two easy ways
Control and adjustment of the feed level height
Choke plate feed arrangement
© Metso© Metso8
0- level
+300 mm level
+600 mm level
Constant, controlled feed level height adjustment can significantly improve the performance of your crusher
© Metso© Metso
406080
100120140160180200220240
0300600
kW &
tph
Feed Material Level [mm]
The lower the height of the feed material level, the lower the energy consumption per crushed ton
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1.12 kWh/t
0.91 kWh/t
0.53 kWh/t
Power Draw
Capacity
© Metso© Metso
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600 300 0
Capa
city
[t/h
]
Feed material level [mm]0/5 5/8 8/11 11/16 16/22
10
The lower the energy used, the less fines produced
© Metso© Metso
A potential 60% reduction in operational costs in tertiary crushing
11
0
20 000
40 000
60 000
80 000
100 000
120 000
600 300 0
Cos
t / 1
yea
r pro
duct
ion
[Eur
]
Feed Level [mm]Liner wear cost Electricity cost Total operation cost
© Metso© Metso
In summary, making profit is not about increasing production – it is about reducing costs
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0%
10%
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Pro
fit
Cos
t, In
com
e, P
rofit
/ 1
year
pro
duct
ion
[kE
ur]
Feed Material Level [mm]Plant costs Income Profit Profit %
© Metso© Metso13
What if you would need to crush a mountain?
Nordberg cone crushers - designed to reduce your operating costs (and mountains)
Less fines More Profit
HP Range GP Range
Questions?
14
© Metso© Metso
FAQ• How the feed level height impacts on end product shape?
- Extremely good question: There is a slight impact on the shape when you run with lower levels, but change we have seen has been only 2%
• What type of level sensor I need?- E.g. ultrasonic sensor or a radar would work
• Can I control the level with IC ?- Yes Metso offers this for cone crushers with IC-automation
• Can I order the choke plate solution for my HPx00?- That will be available later. Metso has a patent pending for the solution.
• Does my mantle nut wear out fast if I keep the level at 0mm?• Why have you earlier advised to keep the feed level high?
- With constantly ongoing research we as Metso also drive to learn new things and develop our machines. If you are producing sand high feed level is still the thing to use, but if you don’t need the fines you have a possibility to adjust your crusher.
• When running my 220kW HP3 at 0mm level, power draw is only 80kW. Should I have bought rather HP100 than high power HP3?
- In that case you would produce the high level of fines with HP100. The general rule with e,g, HP´s is to run the crusher over 40% if the nominal power.
