iron ore crusher

Iron ore crusher is a mechanical equipment that crushes iron ore raw ore step by step, from large pieces of raw iron ore (about 500mm) to millimeter level fine materials. It usually uses iron ore dry beneficiation machine to enrich lean ore, sends enriched iron ore rich ore to ball mill for grinding, and then separates and extracts iron concentrate powder by wet selection. ...

Introduction to Iron Ore

Iron ore is an important raw material for steel production enterprises. Natural ore (iron ore) is gradually selected for iron through processes such as crushing, grinding, magnetic separation, flotation, and reselection. It is a mineral aggregate containing iron elements or iron compounds that can be economically utilized.

Introduction to Iron Ore Crusher
Iron ore crusher is a mechanical equipment that crushes iron ore raw ore step by step, from large pieces of raw iron ore (about 500mm) to millimeter level fine materials. It usually uses iron ore dry beneficiation machine to enrich lean ore, sends enriched iron ore rich ore to ball mill for grinding, and then separates and extracts iron concentrate powder by wet selection.
The commonly used iron ore crushers mostly refer to jaw crushers, commonly known as jaw crushers or tiger mouth crushers. A crusher consisting of two jaw plates, a moving jaw and a stationary jaw, that simulates the movement of animals' two jaws to complete material crushing operations. Jaw crushers are divided into fine crushing and coarse crushing, and are widely used for crushing various ores and bulk materials in industries such as mining and smelting, building materials, highways, railways, water conservancy, and chemical engineering. The maximum compressive strength of the crushed material is 320Mpa.
In iron ore production lines, in addition to jaw crushers, commonly used iron ore crushers also include cone crushers, hammer crushers, etc. depending on the material and the fineness of the crushingimpact crusherEfficient fine crusherRoll CrusherWait.

Picture of iron ore crusher

Structure of iron ore crusher
The iron ore crusher is our flagship product of Hongtong Machinery. This iron ore crusher has various advantages such as high production capacity, low energy consumption, low failure rate, long service life, and good crushing effect. It is the best choice for you to choose an iron ore crusher.
Iron ore crusher（Jaw crusher）The structure mainly consists of a frame, eccentric shaft, large pulley, flywheel, movable jaw, side guard plate, elbow plate, elbow plate rear seat, gap adjusting screw, reset spring, fixed jaw plate and movable jaw plate, among which the elbow plate also plays a safety role.

Main components and functions of iron ore crusher
The main components of the iron ore crusher are the frame, jaw plate, side guard plate, and transmission parts, which play an important role in the production of iron ore crushers. At the same time, these main components are also vulnerable parts of the iron ore crusher, which require regular maintenance and upkeep, as well as regular replacement. Only in this way can the iron ore crusher always maintain its best working condition to serve you.
1. Rack
The rack is a four wall rigid frame with upper and lower openings, used to support eccentric shafts and withstand the reaction force of crushed materials. It requires sufficient strength and rigidity, and is generally cast as a whole with cast steel. High quality cast iron can also be used instead of cast steel for small machines. The frame of a large machine needs to be cast in sections and firmly connected into a whole with bolts, and the casting process is complex. The frame of a homemade small iron ore crusher can also be welded with thick steel plates, but the rigidity is poor.
2. Jaw plate and side guard plate
Both fixed jaw and movable jaw are composed of jaw bed and jaw plate. The jaw plate is the working part, fixed on the jaw bed with bolts and wedges. The fixed jaw bed is the front wall of the frame, while the movable jaw bed is suspended on the periphery and needs sufficient strength and rigidity to withstand the crushing reaction force. Therefore, most of them are cast steel or iron parts.
3. Transmission components
The eccentric shaft is the main shaft of the crusher, which is subjected to a huge bending torque and is made of high carbon steel. The eccentric part requires precision machining, heat treatment, and Babbitt alloy casting for the bearing lining. One end of the eccentric shaft is equipped with a pulley, and the other end is equipped with a flywheel.

Technical parameters of iron ore crusher

Specification Model	feed inlet size (mm）	Maximum entry Particle size (mm)	Discharge port adjustment The entire scope (mm)	processing power (t/h)	偏心轴转速 (r/min)	Motor power (kw)	Total weight (t)	Overall dimensions (Length x Width x Height) (mm)
PE-150×250	150×250	125	10-40	1-3	250	5.5	0.8	720×660×850
PE-200×300	200×300	180	15-50	2-6	260	7.5	1.2	910×750×990
PE-200×350	200×350	180	18-70	3-10	260	11	1.5	1000×870×990
PE-250×400	250×400	210	20-60	5-20	300	15	2.8	1300×1090×1270
PE-400×600	400×600	340	40-100	16-60	275	30	7	1730×1730×1630
PE-500×750	500×750	425	50-100	40-110	275	55	12	1980×2080×1870
PE-600×750	600×750	500	150-200	80-240	275	55	15.8	2070×2000×1920
PE-600×900	600×900	500	65-160	50-180	250	55	17	2190×2206×2300
PE-750×1060	750×1060	630	80-140	110-320	250	110	29	2660×2430×2800
PE-800×1060	800×1060	640	130-190	130-330	250	110	29.8	2710×2430×2800
PE-830×1060	830×1060	650	160-220	150-336	250	110	30.7	2740×2430×2800
PE-870×1060	870×1060	660	200-260	190-336	250	110	31.5	2810×2430×2800
PE-900×1060	900×1060	685	230-290	230-390	250	110	33	2870×2420×2940
PE-900×1200	900×1200	750	95-165	220-450	200	110	52	3380×2870×3330
PE-1000×1200	1000×1200	850	195-265	315-500	200	110	55	3480×2876×3330
PE-1200×1500	1200×1500	1020	150-350	400-800	180	160	100.9	4200×3300×3500
PE-1500×1800	1500×1800	1200	220-350	500-1000	180	280	122	5160×3660×4248
PE-1800×2100	1800×2100	1500	300-400	600-1200	160	400	150.6	6210×4013×4716
PEX-150×750	150×750	120	18-48	8-25	320	15	3.8	1200×1530×1060
PEX-250×750	250×750	210	25-60	13-35	330	30	5.5	1380×1750×1540
PEX-250×1000	250×1000	210	25-60	16-52	330	30	7	1560×1950×1390
PEX-250×1200	250×1200	210	25-60	20-61	330	37	9.7	2140×1660×1500
PEX-300×1300	300×1300	250	20-90	16-105	300	55	15.6	2720×1950×1600

Note: The equipment model parameters are constantly being improved. If you cannot find the required model in the parameter table, you can contact us directly. Our technicians will configure the equipment that best suits your production needs and site requirements according to your requirements.

Working principle of iron ore crusher
The iron ore crusher, as the first process in the crushing production line - coarse crushing, plays a significant role. Many large pieces of iron ore must be crushed by an iron ore crusher before entering the second crushing process for intermediate and fine crushing operations. The reason for choosing an iron ore crusher (jaw crusher) as the head crusher is that the jaw plate of the jaw crusher is relatively strong and can withstand the impact of iron ore of various hardness, thus completing the rough crushing operation.
When the iron ore crusher is in operation, the movable jaw plate performs periodic reciprocating motion on the fixed jaw plate, sometimes approaching and sometimes leaving. When approaching, the material is crushed by compression, splitting, and impact between the two jaw plates; When leaving, the crushed material is discharged from the discharge port by gravity.
In the process of breaking large stones into small ones, the first crusher is usually the "main" crusher. The longest and strongest crusher in history (iron ore crusher). When feeding the iron ore crusher, the material is poured into the crushing chamber containing jaw teeth from the top inlet. The jaw teeth exert tremendous force to push the material towards the chamber wall, crushing it into smaller stones. The support for jaw tooth movement is an eccentric shaft that runs through the fuselage structure. Eccentric motion is usually generated by flywheels fixed at both ends of the shaft. Flywheels and eccentric support bearings often use spherical roller bearings, which must withstand enormous impact loads, abrasive wastewater, and high temperatures.

Advantages of iron ore crusher:

1. The iron ore crusher effectively solves the problem of high operation rate and no maintenance time caused by low output of the original limestone crusher.
2. The iron ore crusher can complete the crushing of large limestone blocks, with a maximum crushing particle size of 1000 * 1200mm, effectively solving the problem of "tight supply of limestone on one side and the inability to use a large amount of large limestone blocks stored on the other".
3. The mixing uniformity of the two materials is good, and the dosage of desulfurization limestone is significantly increased. The dosage can reach 60%, effectively reducing the cost of raw materials.
4. Electricity consumption has decreased. Reducing electricity consumption by 1-2 kWh/t per ton of limestone can save 100000 yuan in electricity costs annually.
5. The small particle size of waste, only 2-15mm, effectively solves the problem of large limestone particle size, frequent blockage and even affecting the output of the grinding machine.

Instructions for using iron ore crusher

Our Hongtong Machinery Factory in Gongyi City provides customers with an instruction manual for each iron ore crusher sold. The instructions for using an iron ore crusher are the essence summarized by our Hongtong Machinery Factory based on more than 30 years of practical production experience. They can teach customers how to operate the iron ore crusher correctly and how to maintain and care for iron ore. We hope that customers will study them seriously.
Instructions for using iron ore crusher
（1） Preparation work
1. Careful inspection should be conducted to ensure that the lubrication of the bearings is good and that there is sufficient grease at the elbow joint inside the bearings.
2. All fasteners should be carefully checked for complete tightness.
3. Whether the protective device is in good condition and any unsafe phenomena should be immediately eliminated.
4. Check if there are any ores or other debris in the crushing chamber, and eliminate them immediately if there are.
（2） Start up
1. After inspection and verification, it can only be started if the iron ore crusher and transmission parts are in normal condition.
2. This iron ore crusher can only be started under no-load conditions.
3. After starting, if any abnormal situation is found, the vehicle should be stopped immediately and the cause should be identified and hidden dangers eliminated before starting again.
（3） Maintenance and use
1. The iron ore crusher can only be fed after normal operation.
2. The material to be crushed should be evenly added into the crushing chamber, and side feeding should be avoided to prevent sudden load changes or unilateral increases.
3. Under normal working conditions, the temperature rise of the bearing should not exceed 35 ℃, and the maximum temperature should not exceed 70 ℃. Otherwise, the vehicle should be stopped immediately, and the cause should be identified and eliminated.
（4） Lubrication
1. Regular attention to timely lubrication of the friction surface can ensure the normal operation and prolong the service life of the iron ore crusher.
2. The lubricating grease used in this iron ore crusher should be determined according to the usage location, temperature, and other conditions. Generally, calcium based, sodium based, or calcium sodium based lubricating grease can be used.
3. The lubricating grease added to the bearing seat is 50-70% of its volume and must be replaced every three months; When changing the oil, clean gasoline or kerosene must be used to clean the dirt inside the bearings and bearing seats.
4. Before starting the machine, lubricating grease must be added to the contact area between the elbow plate and the elbow pad.

Correct operation method of iron ore crusher

Proper operation of iron ore crushers can effectively reduce their failure rate and maximize their service life, creating greater economic benefits for customers. So, please ensure that every operator strictly follows the correct operation method of the iron ore crusher during their work period to avoid safety accidents.
1. No load test run
(1) The iron ore crusher shall operate continuously for 2 hours, and the temperature rise of the bearings shall not exceed 30 ℃.
(2) All fasteners should be firm and free of looseness.
(3) The flywheel and pulley operate smoothly.
(4) All friction components are free from scratches, debris, and grinding, and there are no abnormal noises.
(5) The adjustment device of the discharge port should be able to ensure the adjustment range of the discharge port.
2. On load test drive
(1) The iron ore crusher shall not have periodic or significant impact or sound.
(2) The maximum feeding particle size should comply with the design specifications.
(3) After continuous operation for 8 hours, the temperature rise of the bearing shall not exceed 30 ℃.
3. Preparation work for iron ore crusher
(1) Carefully check whether the lubrication of the bearings is good and whether there is sufficient lubricating grease at the connection of the thrust plate.
(2) Carefully inspect all fasteners to ensure they are securely fastened.
(3) Carefully check if the drive belt is in good condition. If any damage is found, it should be replaced in a timely manner. When there is oil stains on the drive belt or pulley, a cloth should be used to wipe off the oil stains.
(4) Check if the protective device is in good condition, and promptly eliminate any unsafe phenomena.
(5) Check if there are any ores or debris in the crushing chamber. If there are ores or debris, they must be cleaned thoroughly to ensure that the crusher chamber starts.

Maintenance and daily repair of iron ore crusher

Maintenance of iron ore crusher
1. Regularly shut down and inspect the iron ore crusher. Any stone crushing equipment should pay attention to regularly turning off the iron ore crusher and checking the internal wear of the iron ore crusher, such as the wear degree of the central feeding pipe, cone cap, impeller upper and lower channel lining plates, circumferential guard plates, and wear-resistant blocks. The severely worn components should be replaced in a timely manner and repaired. At the same time, pay attention to the weight, model, and size of the replacement components, and make sure to replace them according to the original component parameters.
2. Regularly inspect the transmission belt of the iron ore crusher. The conveyor belt of the iron ore crusher is indispensable in the stone production line, and the driving force of the iron ore crusher is all thanks to the conveyor belt. Regularly adjust the tightness of the conveyor belt to ensure even force distribution. When driving with dual motors, the triangular tape on both sides should be grouped and selected to ensure that the length of each group is as consistent as possible. If you find that the wear of the drive belt is too severe, please replace it in a timely manner.
3. Lubrication of mechanical components. The iron ore crusher adopts special grade or 3-lithium-based grease for vehicle use, and an appropriate amount of grease is added every 400 hours of operation; Worked for 2000 hours, opened the spindle assembly to clean the bearings; Replace the bearings after 7200 hours of operation.
In addition, to ensure the normal operation of the iron ore crusher, planned maintenance must be carried out, including daily maintenance checks, minor repairs, medium repairs, and major repairs, in addition to operating the iron ore crusher correctly.
Maintenance of iron ore crusher
1. The main content of minor repairs includes inspecting and repairing the adjustment device of the iron ore crusher, adjusting or replacing the gap between the high-speed discharge port, and adjusting or replacing worn lining plates. Inspect the transmission system, lubrication system, and replace lubricating oil. The cycle of minor repairs is about 1-3 months.
2. In addition to carrying out minor repairs, medium maintenance also includes replacing thrust plates, lining plates, inspecting and repairing bearing shells, etc. The maintenance cycle is generally around 1-2 years.
3. In addition to carrying out all the work of intermediate repairs, major repairs also include replacing or turning eccentric shafts and moving jaw shafts, casting Babbitt alloy on the upper part of the connecting rod head, and replacing or repairing various worn parts. The overhaul cycle of iron ore crushers is generally around 5 years.

Common faults and solutions of iron ore crushers

Iron ore crushers often encounter various malfunctions in daily production, which are normal phenomena. Many customers are at a loss when encountering these malfunctions and often worry about them. Our Hongtong Machinery technicians have summarized the following common faults and solutions for iron ore crushers based on their years of experience and customer feedback, hoping to help everyone.
Iron ore crushers often experience high torque or vibration during operation, which can cause transmission system failures. Common causes include wear on the shaft head and hub due to clearance between the belt pulley and the shaft head, and wear on the bearing position due to eccentric shaft stress.
After the above problems occur, the traditional maintenance method is mainly to enlarge the wheel hub, repair it by welding or brushing, and then machine repair it. However, both methods have certain drawbacks: the thermal stress generated by high temperature welding cannot be completely eliminated, which can easily cause material damage and lead to component bending or fracture; However, electric brush plating is limited by the thickness of the coating and is prone to peeling off. Both methods use metal to repair the metal and cannot change the "hard to hard" fit relationship. Under the combined action of various forces, it will still cause further wear.
The above repair methods are no longer common in Western countries. Developed countries such as Europe and America often use polymer composite materials for repairing the above problems. The most mature application is a certain country's technology, which has super strong adhesion, excellent compressive strength and other comprehensive properties, and can be repaired on-site without disassembly or machining. The use of polymer materials for repair is not affected by welding thermal stress, and the repair thickness is not limited. At the same time, the metal material of the product does not have the flexibility to absorb the impact and vibration of the equipment, avoiding the possibility of further wear and greatly extending the service life of equipment components, saving a lot of downtime for enterprises and creating huge economic value.
Reasons and solutions for severe jumping of iron ore crusher frame
When severe jumping of the frame is found during the operation of the iron ore crusher, the machine should be stopped first to check several aspects
1. Is the anchor bolt loose or broken
2. Is the position of the flying groove wheel off track
3. Is the foundation of the host firmly fixed, and are there any vibration isolation measures in place
There are several solutions:
If the anchor bolt is loose, use a wrench to tighten the bolt. If the anchor bolt breaks, a new bolt needs to be replaced.
The solution to the deviation of the flywheel position is to remove the cover plate of the flywheel, loosen the tightening bolts of the flywheel, adjust the position of the flywheel, and then tighten the tensioning bolts of the flywheel.
If the jaw crusher shakes severely due to the instability of the host, the foundation should be reinforced and sleepers or rubber strips should be added between the machine and the ground.

Production process of iron ore crusher

In the process of iron ore crushing, several steps are generally used, including feeding machine, first crushing, second crushing, screening, fine crushing, and dry selection. For economic reasons, the finer the particle size of the ore entering the dry selection machine, the higher the proportion of iron ore that is dry selected. Some small beneficiation plants directly carry out dry beneficiation operations on finely crushed iron ore, resulting in extremely serious waste of natural resources.
Therefore, choosing the most economical production method and maximizing the dry beneficiation rate of iron ore is a topic that iron ore beneficiation units must face and study. At present, a large number of individual mineral processing units in China use traditional hammering, which is the production mode with the lowest investment cost. This not only has low production efficiency, but also causes great waste of natural resources.
1. Head broken
Jaw crushers are generally used for head breakage in iron ore production operations, while large production units (especially large mines abroad) use gyratory crushers. Jaw crusher is the most traditional and stable coarse crushing equipment, with the widest range of applications. In 2013, the manufacturing process and technological level of jaw crushers were already very mature. As long as products from legitimate manufacturers are used, they can meet the design and production requirements.
2. Two broken
In the production process of iron ore crushing, there are generally two types of secondary crushers: either fine jaw crushers or cone crushers.
Thin jaw crusher is generally used for smaller iron ore selection sites, with low equipment value, simple structure, and easy maintenance. However, the discharge port of the slender jaw can only be adjusted to a minimum of 25mm, so its crushing particle size is generally below 40mm.
The structure of the cone crusher is relatively complex, and the equipment value is high. However, its production is large, the crushing particle size is fine, and the service life of wear-resistant parts is longer. Therefore, cone crushers are widely used in larger iron ore selection sites.
In terms of production efficiency and cost of iron ore, the use of cone crushers can effectively reduce production costs. Because cone crushers can provide smaller product particle sizes, from an overall process perspective, using laminating equipment to complete the main crushing task of iron ore is the most economical production method.
3. Fine sieving
The screening equipment generally uses a circular vibrating screen to screen the materials that have undergone secondary crushing. Generally, materials with a size of 10mm or smaller can be sieved and dry sorted. Materials with a size of 10-40mm can be sieved and enter the fine crusher for fine crushing. Materials with a size of 40mm or more can be returned to the secondary crusher for material recycling and crushing. Of course, the particle size range of screening can be adjusted according to actual conditions in order to achieve the most economical operating mode.
There are many types of fine crushing equipment, generally divided into hammer breaking (vertical, horizontal)fine crusherRoll crushers, short cone crushers, and vertical impact super fine crushers developed in 2013. These fine crushing devices have different crushing principles and are suitable for different environments.
hammer crusherIt is the most traditional fine crushing equipment, with a very low value for simple hammering. It uses a forged integral hammer head and is widely used in small mineral processing plants. Its characteristics are cheap equipment and low investment costs; The disadvantage is that the production capacity is very small, the hammer head wears out quickly, and the particle size is not fine enough.