Hydraulic Cone Crusher
Providing High-Quality Hydraulic Cone Crushers
Hydraulic Cone (HC) series crushers efficiently combine cavity design and crushing speed, which not only increases production capacity and widen the range of application suitability but also assures reliable quality. From limestone to taconite, from metallic ores crushing to manufactured sand, HC crushers provide high size reduction ratio in quaternary, tertiary, and secondary applications.
Hydraulic Cone Crusher Operating Principle
AF cone crushers adopt the layered materials selection. The crushing cavity is filled with feeding material. Since the materials bear all-around extrusion, shearing and kneading in the crushing cavity, materials can be broken by themselves.
This crushing method makes the wall of the crushing cavity avoid direct contact and effectively prevent liners from friction, avoiding material pollution from metal pollutants. Meanwhile, it makes the machine reduce the consumption of wear parts and prolong the service life of wear parts. Its reduction ratio is twice as larger as other similar equipment.
AF CC- and CC-S series of cone crushers have a wide field of use as they can easily be matched to changes in production through the proper selection of crushing chamber and eccentric throw. Our cone crushers are ideal for secondary and tertiary crushing and their compact and easy-to-service design makes them a perfect choice for mobile installations.
Our crushers provide automatic overload protection and can be equipped with our automatic setting system, ASRi. This system optimizes cone crusher efficiency and automatically adapts the crusher to variations in feed conditions. By continuously measuring and compensating for crusher liner wear, ASRi allows you to fully utilize crusher liners and schedule liner replacements to coincide with planned maintenance stops.
ASRi also assists in keeping your crusher choke fed. This maximizes rock-on-rock crushing, which helps optimize the quality of your final product.
Machine Cutaway View
Hydraulic Cone Crusher Features and Benefits
High Performance, Lowest Total Cost
The hydraulically adjusted CC and CC-S cone crushers manufactured by AF Minerals Equipment are characterized by robust design and high performance.
In combination with the CLP crushing chambers, high-motor powers give these crushers capacities, which in most cases are comparable with those of other larger crushers.
The CLP advantages are:
CLP crushing chamber. CLP stands for Constant Liner Performance. The almost vertical profile of the feed opening area means that the shape of the chamber remains virtually unchanged throughout the wearing life.
Our cone crushers have a wide field of use. Several standard crushing chambers are available for each model. The crushers can easily be matched to changes in production through the proper selection of crushing chamber and eccentric throw.
AF cone crushers are an excellent choice as secondary crushers in combination with a jaw or primary gyratory crusher or in the third or fourth crushing stage. Thanks to their built-in versatility, these crushers will enable you to cope with most production requirements in a changing future.
Hydraulic Cone Crusher Full-Control System
Full Control of the Process
The hydraulic system provides safety and setting adjustment functions and incorporates a heavy-duty hydraulic cylinder, which supports the main shaft and adjusts its position.
The hydraulic system provides automatic overload protection to permit the passage of tramp iron and other uncrushable material. The system then automatically returns the main shaft smoothly to its original position.
When the cone crusher is equipped with our automatic setting system, the actual crushing load inside the crusher is continuously monitored. This makes it possible to optimize crusher utilization, allowing you to squeeze the ultimate performance from your machine at all times.
Easy to Maintain and Quality Service
Easy to Handle and Maintain
Much attention has been paid to making our crushers as easy to operate and maintain as possible. All service and inspection are carried out from above, which makes the work easier and the maintenance costs lower.
Robust sealing to the inner crusher mechanics provides more effective protection against dust and other unwanted particles, reducing maintenance and increasing the life of the crusher.
The automatic setting regulation system not only optimizes production, but it also keeps track of liner wear. This makes it easy to plan liner changes and minimize interruptions in production.
In addition to the high capacity, AF CC and CC-S crushers are compact, which makes them very easy to move and install.
Building strong customer relationships is highly prioritized in our daily work to help you keep your AF crushing system in operation, improve your uptime and productivity, lower your costs, and provide you with the best possible total economy.
AF has vast experience and teams spanning the globe in order to provide you with total support.
AF has a highly efficient worldwide service and distribution network to make sure all essential parts and consumables are available to you according to your needs.
AF offers intensive training courses tailored to fit your needs in order to help achieve optimum equipment performance.
AF offers efficient, cost-effective repair and rebuilding services when it becomes necessary, more economical or environmentally beneficial to repair, overhaul, or rebuild the equipment.
Whatever your needs are, wherever you are, and whatever the time is, AF is here to support you.
Dimensions, Product Curves, and Technical Data
The product curve and the percentage of the crusher product that is smaller than the closed side setting (square hole, mm) are dependent on the crushability (Wi) of the material, the size distribution of the feed, and other factors.
Three standard crushing chambers are available:
Several standard crushing chambers are available:
Capacity, MTPH performance figures are approximate and give an indication of what the crusher can produce. They apply to open circuit crushing of dry materials with a bulk density of 1600kg/m3. It is assumed that material much finer than the crusher’s closed side setting (CSS) is removed from the feed.
Consult us regarding the application of the crusher since the chosen eccentric throw, degree of reduction, the materials’ crushability (Wi), the size analysis of the feed, the design of any re-crushing circuit, and the moisture content in the feed all affect the performance of the crusher.
Main Components and Basic Concepts
The AF cone crusher is a compressive crusher where feed material is crushed between a fixed concave and a movable mantle. Bigger rock particles are crushed against the mantle and concave. This is called single-layer crushing. When smaller rock particles are crushed between other rock particles, it is called multilayer crushing. Multilayer crushing plays a significant role in the AF cavity. This improves the end product shape and reduces wear in wear parts.
Feed Opening (OSS)
The feed opening defines the maximum feed size to the crusher. In AF cone crushers, the closed side feed opening is measured from the top of the mantle when the mantle is at the closed side setting position. Wear parts application guide— AF series cone crusher, AF cone crusher, and basic concepts.
The maximum feed size in AF cone crushers is the same as closed side feed openings. Maximum feed sizes are also stated in cavity configuration tables later in the guide.
Closed Side Setting (CSS)
The closed side setting defines the reduction ratio in AF cone crushers and has a significant bearing on product gradation, capacity, and power draw. The closed side setting is measured from the bottom of the mantle to the bottom of the concave at their closes coincidence during the gyrating cycle.
The nip angle is the angle between the mantle and the concave. Too large nip angle reduces the capacity and increases the wear due to feed materials bouncing up.
The reduction ratio means the reduction factor between the feed and a product. This ratio is usually taken from the 80% point of the feed and product curve. A typical reduction ratio for the AF secondary crusher is 3-5 and for the AF fine crusher, 1.5-3.
How to Operate a Hydraulic Cone Crusher
Good Feed Level and Distribution
In order to get optimum capacity and the maximum lifetime of wear parts, consider the following points:
The crusher should be choke fed so that the crushing chamber is full all the time. This is important, especially in fine crushing. Choke feeding maximizes the amount of multilayer crushing and improves wear shape and crushing efficiency.
Choke feed level for the AF secondary crusher is at the level of the mantle fixing nut.
Choke feed level for the AF fine crusher is max one meter above the top bearing arrangement.
- The feed must be distributed evenly 360 degrees across the crushing chamber. Uneven feed distribution may cause unbalanced crushing forces and uneven wearing in the AF cone cave.
- The feed should not be segregated (for example, finer material on the other side of the cavity).
- The flow of the feed should be stable and continuous (however, AF cone crusher can be used in pulse fed applications as the head spin is minimized).
Circulation is needed when producing high-quality products.
- Oversize feed material decreases the capacity and can cause unnecessary loads to the crusher.
- Too small feed size for the cavity increases wearing at the bottom part of liners and may cause poor utilization rate of wear parts.
- Fines (0-4) should be screened away before the crusher as they may cause packing (AF secondary is not sensitive to fines).
- Feed gradation should be stable (no gaps in feed).
Too big feed material
Too small feed material
Note: Feed material characteristics such as gradation, bulk density, moisture, clay content, and crushability have a significant impact on the crusher capacity.
It should be close to:
- Setting Increases – Product Size Increases
- Setting Increases – Capacity Increases
- Setting Increases – Power Draw Increases
- Stroke Increases – Capacity Increases
- Stroke Increases – Power Draw Increases
- Based on feed size
- Based on the required end product size, which gives the required setting range
- Check the crushing ratio
A distorted wear profile may decrease capacity, increase wearing, and increase crushing forces.
Example of bad wearing: cupping has occurred.
Example of normal wearing: obtained with correct feed arrangements, feed gradation, and parameters for the cavity.
Liners must be changed before they are worn through in order to prevent damage to the frame or head. Liners should be changed no later than when the A dimension is 10-15mm depending on the crusher model. Production aspects may sometimes favor changing of wear parts before they are fully utilized. Hourly capacity or product quality may decrease towards the end of liner lifetime, and it may be economical to change the liner before the end of its lifetime.
A distorted wear profile typically causes a reduction in capacity. Other symptoms of distorted wear profiles are high power and pressure and short lifetime of wear parts. A distorted wear profile may lead to liners having to be replaced before they are fully worn.