In the field of iron ore mining and processing, the selection of crushing equipment and process design directly affect production efficiency and operating costs.
1. Equipment selection: matching ore characteristics with production needs
Jaw crusher
As the main primary crushing equipment, jaw crusher is suitable for the coarse crushing stage of high-hardness iron ore (such as magnetite and hematite). It has a simple structure, low maintenance cost, and a crushing ratio of 4-62.
Cone crusher
For the medium and fine crushing stage, the hydraulic cone crusher can handle iron ore with a compressive strength of ≤350MPa and achieve uniform particle size output with automatic overload protection and high energy efficiency.
Mobile crushing station
For example, 100t mobile crushing equipment integrates feeding, crushing and screening functions, which is suitable for dispersed mining sites or temporary mining scenarios, significantly reducing transportation costs.
2. Key points of process optimization
Multi-stage crushing and closed-loop circulation
The three-stage crushing system of "coarse crushing-medium crushing-fine crushing" is adopted, and the closed-loop circulation is formed by combining the screening equipment, which can control the iron ore particle size to ≤12mm and improve the grinding efficiency.
Application of pre-selection technology
Pre-dispensing tailings by X-ray sorting or magnetic separation can reduce the amount of ore entering the crusher and reduce equipment wear. Actual cases have proved that the energy consumption of crushing after pre-selection has dropped by 18%.
Automated control system
Integrated PLC and sensors to monitor parameters such as crushing chamber pressure and motor load in real time to achieve dynamic matching of feeding speed and crushing intensity.
3. Industry technology trends and equipment upgrade directions
Energy-saving and consumption-reducing design
The new crusher reduces unit energy consumption by 20%-30% by optimizing the cavity structure (such as the principle of laminated crushing), which meets the green mine standards.
Intelligent operation and maintenance system
The remote monitoring platform based on the Internet of Things can predict the wear cycle of the liner, plan spare parts replacement in advance, and reduce downtime1.
Environmentally friendly dust removal solution
The combination of dry fog dust suppression and bag dust collector makes the dust concentration in the crushing workshop ≤10mg/m³, meeting the requirements of occupational health and safety.
Summary, coordinated optimization of selection and process
Iron ore crushing and processing need to comprehensively consider ore hardness, production capacity requirements and investment budget. It is recommended to give priority to modular design equipment (such as mobile crushing station) and use it with online particle size analyzer to achieve dynamic control. Through the deep coordination of equipment and process, the overall energy efficiency can be improved by 15%-25%, helping enterprises to achieve the goal of reducing costs and increasing efficiency.
