crusher operating costs: how to optimize and reduce
The approximate running costs for crushing plants of different capacities up to 4,000 tons per day on the basis of an eight-hour crushing day are easy to calculate. The figures must be regarded only as a rough guide to the average costs of modern installations ; they are direct costs and include no overhead charges.
It is assumed that power is charged to the plant at the rate of 0.75d. per kilowatt-hour in the case of the smallest plant, decreasing as the capacity increases to a minimum of 0.5d. per kw.-hr. for the largest. The power consumption of a machine or installation is usually expressed in kw.-hours per ton as being the most convenient method.
In every case the power consumption is in excess of the figure that would be obtained by totalling the power requirement of each individual machine when running at full load for the whole eight hours, the reason being that a crushing plant can very seldom be kept working at full capacity all the time ; if it could, the power consumed would be at least 25% under the figures given. It is time lost when the machines are running at less than full load that brings up the power costs.
The power cost falls as the size of the plant increases up to a capacity of about 2,000 tons per day on account of the fact that large machines are more economical as regards power up to a capacity of about 250 tons per hour ; single machines are made to handle greater tonnages than this, but their power consumption per ton crushed shows no appreciable saving.
The labour cost is the largest item in small and medium plants. This is one reason for the modern tendency towards a larger ratio of reduction in the minimum number of crushing stages, since the simplification of the layout that results reduces the cost of operating andmaintenance labour considerably, besides that of power and supplies. As was explained in the previous paragraph, the mine output, if it does not exceed 2,000 tons per day, is usually crushed in one shift in order to reduce the cost of labour, since two shifts require double the number of men for the same output.
The wear on the liners of the crushing machines accounts for less than half of the cost of supplies. With manganese steel liners the steel consumption can be relied upon never to exceed 0.1 lb. per ton crushed for any of the machines described in this chapter, and as a rule it is considerably less. General wear and tear of the accessory plant and accidental breakage due to the very rough nature of the work that the machines have to perform is responsible for most of the cost of supplies ; lubrication and routine replacement of worn parts other than liners are not costly items.
It will be seen that there is a gradual fall in the total direct cost as the size of the installation increases up to a capacity of about 500 tons per hour. Above that figure the decrease is so small as to be negligible for purposes of rough calculation ; in any event, small economies only can be expected, chiefly in the reduction of the cost of supervision and of general overhead charges.
50 tph quartz rock crusher for sale | hxjq
Quartz rocks are the second most abundant mineral in the continental crust after feldspar. Quartz rocks are very hard and always in the block-shaped. Pure quartz stone is colorless and transparent, but most of the quartz stones appear in different colors because they contain micro pigment ions or transitional elements that reduce their clarity.
Quartz jaw crusher is widely used in the quartz crushing line as the primary crushing equipment. Because it has a simple structure, reliable operation, and easy maintenance, the quartz jaw crusher is widely applied in the industrial apartment such as metallurgy, chemical engineering, building materials, electric power, and transport.
Different vulnerable parts of jaw crusher have different replacement frequency. If the jaw crusher processes the materials with small hardness such as limestone, the replacement is less frequent, but if the jaw crusher processes the materials with high hardness such as quartz, it must have a large impact on the equipment, and the replacement of vulnerable parts is more frequent. Therefore, the replacement frequency of vulnerable parts should depend on its degree of wear.
Quartz cone crusher as the common medium crushing equipment plays an important role in the quartz stone crushing line. It adopted the working principle of laminating crushing which differs from the squeezing crushing. Quartz cone crusher crushes materials by the action of materials, which can better control the crushing and shaping of the finished product.
It has a high performance of wear-resisting and shock-resisting. All the wear-resisting parts of the crusher are made of wear-resisting materials and advanced technology, which can improve the wear-resisting performance and prolong the service life of the machine.
The finished product has a uniform size and good particles. After processing by the quartz cone crusher, the quartz rocks with high performance can satisfy the different needs of customers. Moreover, the crusher is reliable and flexible in operation, which can create more value in the coming future.
The crusher is very environmental because it produces less dust and noise in the production process. In the working site of the quartz cone crusher, the crusher can work stable with less frequency of fault, and reduce the pollution effectively.
It is inevitable that the crusher will wear out in contact with hard stone for a long time, so the selection of wear-resisting materials and the protection of vulnerable parts are very important for crusher. Prolonging the service life of vulnerable parts is equal to prolong the service life of crushing equipment.
Movable cone (mantle) and fixed cone (concave) are the main parts that are material and easy to wear. To prolong the service life of vulnerable parts, several aspects should be managed, such as checking the bolts and nuts, frequently, choose the suitable wear-resisting materials, purchasing the crusher or vulnerable parts from the powerful and famous manufacturer, etc.
There are a lot of manufacturers producing quartz crusher, and the materials of crushers they used are different. Actually, the quality and performance of the equipment produced by large and powerful manufacturers can be guaranteed.
At present, the network is very convenient, the price of each manufacturer are very transparent, thus influencing the other manufacturers in their equipment price, then the price of the whole devices on the market will be reduced.
Although there are so many quartz stone crusher manufacturers, in some of these manufacturers just middlemen, and they don't have any equipment production workshop. They are just nominal and make money by earning profits, then the corresponding prices of these manufacturers' equipment will be high.
In order to improve the sales of quartz stone crusher, some manufacturers will engage in some promotional activities of their equipment. During the promotional activities, the price of their equipment would be much lower than the original price, which also affects the price of equipment to a certain extent.
Last April, Abbas from Pakistan came to us and said he needed a stone crushing line, producing 50 tons per hour. After knowing the detailed requirements of the customer, the engineer of the HXJQ Machinery technology department matched the crushing production line, including the feeder, pe-400 600 jaw crusher, PYZ900 cone crusher, etc.
During the process of making customers' visit, the honest words of Abbas are very moving, the crushing line has a high capacity and creates good economic benefits. The HXJQ engineer designed it reasonably. The after-sale service is trustworthy. When I met any problems in the operation process, they answered me promptly and helped solve the problem. There will be more opportunities for cooperation between us in the future.
HXJQ Machinery as one of the most famous mining machinery manufacturers in China has been the production of reliable quality of crushers and sold the products directly. There are no middlemen earning price difference, so the price is relatively cheaper than others in the industry. If you are interested in our products, please leave a message on the right, we will give you the first time reply.
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crushing equipment purchase price means less than you think
If purchase price was the determining factor in profitability, why does a difference in price exist? Wouldnt the operations that spent the least amount of money on equipment, parts and service own the market? One look around tells you that this isnt the case.If you dig deeper, its the operators who understand the two drivers of crushing profitability that are the most successful. Those drivers are:
Assume: 250 tons per hour production Crushing price of $2.50 per ton 3 crew members on shift, average hourly wage $20 per hour 60 hours per week operation Crushing season 26 weeks or 130 Days Approximately 6-7 months of operation Annual production tonnage of 390,000 ton
You're spending money whether your equipment is crushing or not - your crew is still there, fixing equipment instead of managing quarry production. If they're waiting or working on a piece of broken equipment, they are still getting paid.
While youre spending this money, you arent getting paid. To add insult to injury, you may now have to pay overtime after the breakdown to get back on track and you may even face penalties if youre late.
Based on a 12 hour production day, this translates to a daily cost of downtime of $8,220 if you have no downstream processes the crusher feeds. Do you get better production? Different sell price for your gravel? Plug in your numbers and see what your cost of downtime is.
ProductivityAs we saw in the cost of downtime, the impact of productivity improvements are significant. Lets say you are losing 10% of your potential production due to blinding screens or worn down manganese. Here is the math.
This means that for every day that an operation is not running at peak production it loses out on $750 revenue. Putting off maintenance or not sure if you can afford a screen cloth upgrade? The cost of this spread running at just 10% less production for one week is $3,750.
At $2.50 per ton it takes 2,320 tons per month. In our earlier scenario, to pay for that extra $300,000 for the crusher takes 9.7 tons per hour! This is a very achievable gain. In fact, getting an additional 25 tons per hour is easily attinable when you include liner performance and crushing chamber automation.
Over 15 years if a cone plant delivered an extra 9.7 tons per hour of production would produce an additional 209,520 tons and at a crush price of $2.50 would generate an additional $523,800 in revenue for an incremental profit of $223,800. If you look at an entire crushing system or spread, spending an additional $500,000 or more may be the best decision.
Lets look at spending over four fold the dollars on advanced screen media vs. plain wire screen cloth. The best advanced screen media products double the wear life than even the best woven wire screen cloth and in our experience give you at least 10% increase in production
Doesnt look like much does it? What if we could sell those 16 days of production? If we could, the gain in revenue is $99,000 and with incremental costs of $33,375. How could you spend another $65,625 per year? To top it off, you have 30 less hours of downtime in a year to change screen media, adding another $20,650 in revenue! A total gain of $86,275 annually.
Its time to change the thinking about price being the greatest consideration in purchasing decisions in your crushing operation. Price is insignificant in calculating total cost when you look at both uptime and productivity.
What can you do? Share this thinking with your employees and co-workers. If you want what comes with a more successful operation start to think in terms of uptime and productivity in everything you do that surrounds crushing.
Understanding that purchase price and actual cost are two very different considerations, is one of the Five Characteristics of Successful Crusher Operators and Owners discussed in our downloadable article. Click the button below to learn more.
premium crushers and lump breakers |franklin miller inc
DELUMPER Lump Breakers and Crushers break solids, lumps and agglomerates down to desired size with a once-through, non-churning, crushing action that produces minimal fines. They reduce plant downtime, increase processing speed and improve product consistency. These units are precision manufactured and aligned for smooth operation with low vibration or noise.
Franklin Miller offers a wide variety of crushers and lump breakers with processors to meet almost any application. Our powerful units are designed to handle capacities from 50 lbs an hour to 1000 tons per hour. DELUMPER Crushers can also be customized to meet the exacting requirements of a customer's applications including easy maintenance, custom sizes, and special materials.
DELUMPER Lump Breakers can handle wet, sticky, dry, hard or soft substances. They tear through chemicals, lumps, agglomerates, ore, filter cake, ash, sugar, food, plastics and more. The units are available in various sizes with single, dual or triple-shaft configurations for capacities up to 1000 tons per hour.
DELUMPER Lump Breakers are used in a wide variety of orientations. Our units can handle dry or wet applications in either in-line or gravity configurations. These powerful lump breakers can be customized to meet the requirements of your operation and configuration.
The PIPELINE DELUMPER In-line Processor converts a solids-laden stream into a fully suspended homogeneous flow instantly. It stops settling out, clustering and over pressure. The reduced particles are entrained in the stream, away from the pipe walls. Scale is dislodged from reactors, silos and tanks and is crushed before it can impede the flow.
The PIPELINE DELUMPER improves product quality, blend and consistency. It instantly reduces tough solids to a uniform output size. This unit improves mixing, drying and dissolving operations. Nozzles are kept clear and sensitive media is protected. The result is reduced downtime, a process that is in better control, and with substantial savings to the operation.
DELUMPER Crushers reduce lumps, crush minerals, improve product consistency, facilitate mixing, drying and conveying, and keep process lines running smoothly. These units have extraordinary processing capabilities on a wide range of materials including chemicals, sugar, food, minerals, urea, ammonium nitrate, salts, colors, plastics, pharmaceuticals and more.
DELUMPER L series lump breakers typically employ no screens. Instead, specially designed teeth mounted on a smooth, rotating drum, intermesh with sizing combs, reducing solids to their basic grain size without overgrind, heat rise or fines. Lumps up to the full inlet opening size can be processed. The unit runs at low speed and creates little vibration or noise.
DELUMPER S4 Crushers feature precision operation, easy interior access, clean-in-place capability, and a meticulously polished finish. A convenient side door provides fast and easy access to the interior of the cutting chamber for maintenance. The S4 employs a direct gear drive for smooth and quiet operation as well as low maintenance. The unit features a teflon shaft seal to protect bearings and keep the product in the chamber. The drum can be quickly removed for cleaning or change-out. The drum with teeth and shaft are one piece with all fasteners located outside the cutting chamber.
DELUMPER LP Processors are ruggedly constructed of heavy plate and channel for long, dependable service. These units are precision manufactured and aligned for smooth operation with low vibration or noise. The bodies are constructed with ample mounting flanges for connection to ducts, hoppers, feeds or valves. The DELUMPER LP models are supplied in one-piece bodies, lip-type seals and heavy tapered roller bearings.
DELUMPER Multi-Shaft Crushers models are provided in a number of configurations to fit many application requirements, in standard (LP) and Ultra-Heavy-Duty (LP-HD) versions. These units feature: direct gear drives, shaft seals and heavy-duty bearings. The DELUMPER TWIN-LP lump breaker features multiple high profile LP cutters stacked on heavy parallel shafts. Each tooth is constructed for precise balance, interchangeability and smooth operation.
The teeth are mounted in a staggered pattern around the shaft diameter to assure smooth continuous operation, reduced power consumption and optimal feeding. The rugged extended LP teeth rotate through a heavy bar grating with a low friction design. The teeth are typically supplied with leading edges to crack the feed with a pick-like action and handle solids with reduced shock and power consumption.
Franklin Miller has extensive engineering know-how and manufacturing capabilities to meet your processing needs. We can provide a variety of options and accessories for our wide range of standard DELUMPER lump breakers or we can provide a fully custom engineered solution.
Our equipment can be provided stand-alone, with stand and hopper, with a control system or as part of a complete engineered system, which can include conveyors, feeders, bag dump and unload stations and more. Our test facility can be your resource for determining the best size reduction solution to meet your needs.
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Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line. Dewo Machinery can provide high quality products, as well as customized optimized technical proposal and one station after- sales service.
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Production capacity: 600-700 tons/hour. Equipment configuration of iron ore beneficiation production line: PE1200x1500 deep cavity jaw crusher, two HPC400 hydraulic cone crushers, two VSI5X1145 sand making machines, GZD15006000 vibrating feeder, three YZS2160 vibrating screens, and belt conveyors, electrical control equipment, etc.
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