Blocking crushers, also known as clogged or choked crushers, occur when the feed material obstructs the crushing chamber, preventing proper operation. This can lead to reduced efficiency, mechanical stress, and even equipment damage. Below are key aspects to understand and address blocking in crushers:
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Common Causes of Blocking Crushers:
1. Oversized Feed Material
– Exceeding the crusher’s designed feed size limits can cause jamming.
– *Solution:* Use pre-screening (e.g., grizzly screens) to remove oversized particles.
2. Wet or Sticky Material
– Clay, mud, or moist ore can adhere to chamber walls or block discharge points.
– *Solution:* Pre-dry material, use water sprays, or select crushers designed for sticky feeds (e.g., impact crushers with self-cleaning features).
3. Improper Feed Rate
– Overfeeding can overwhelm the crusher, while inconsistent feeding causes uneven processing.
– *Solution:* Optimize feed rate with controlled feeders (e.g., vibratory or apron feeders).
4. Worn or Damaged Components
– Worn liners, broken teeth, or dull blades reduce crushing efficiency and promote blockages.
– *Solution:* Regular maintenance and timely replacement of wear parts.
5. Incorrect Crusher Selection
– Using a jaw crusher for highly abrasive material or an impact crusher for very hard rock may lead to blockages.
– *Solution:* Match the crusher type (jaw, cone, impact) to the material properties.
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Types of Crushers Prone to Blocking:
– Jaw Crushers: Blockage often occurs at the discharge point if fines are not removed.
– Cone Crushers: Choking can happen if the crushing chamber is overloaded.
– Impact Crushers: Sticky materials may cling to rotors or aprons.
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Prevention and Solutions:
1. Pre-Screening
Install scalping screens to remove fines or oversized material before crushing.
2. Automated Monitoring
Use sensors (e.g., power draw, pressure) to detect abnormal conditions and trigger alarms.
3. Regular Maintenance
Inspect liners, bearings, and discharge openings; clear debris buildup.
4. Adjust Discharge Setting
Ensure the crusher’s