1. Core strategy of cost reduction and efficiency improvement in crushing link
The cost-effectiveness advantage of multi-stage crushing combination process
Although the initial investment of jaw crusher + cone crusher combination is 15% higher than that of single-stage hammer crusher, it can reduce the loss of wear-resistant parts by 30%, and significantly optimize the long-term operating cost. Taking the 3 million tons/year iron ore project in Hebei, China as an example, a high-pressure roller mill (HFKG-180 model) and a two-stage closed-circuit crushing combination are used, and the particle size entering the mill is stably controlled below -8mm, which reduces the power consumption of the ball mill by 1.8kWh/ton, and saves more than 2 million yuan in electricity bills annually.
Equipment selection recommendation: HPT800 cone crusher (crushing ratio 6.5:1) with PLC automatic adjustment of the discharge port, the product qualification rate is increased to 92%, which is particularly suitable for medium and high hardness iron ore.
Pre-selection and waste disposal technology reduces the crushing load
After coarse crushing, the CTDG-1510 dry magnetic separator can discard 18%-25% of waste rock, directly reducing the subsequent crushing and grinding processing volume. A Yunnan beneficiation plant uses this technology to reduce the energy consumption of the crushing system by 22% and extend the equipment life by 40%.
2. Collaborative optimization of crushing equipment and the entire process
Three-dimensional layout reduces hidden costs
The "crushing-screening-dry selection" three-in-one workshop design can shorten the belt transportation length by 40% and reduce the construction of transfer stations (Shandong case saves 1.27 million yuan in electricity bills per year). It is recommended to use BIM technology to simulate the material flow direction, realize the vertical height difference connection between the crushing system and the grinding system, and use gravity potential energy to reduce secondary lifting energy consumption.
Return on investment of intelligent control system
Although the intelligent control system increases the budget by about 800,000, it can reduce labor costs by 15% and energy consumption by 8% by adjusting the crusher discharge port in real time and optimizing the feeding speed.
3. Equipment upgrade opportunities in environmental compliance
New requirements for crushing particle size in tailings reduction
The tailings dry discharge system (water content <18%) needs to be matched with a finer crushing particle size. It is recommended to use an impact crusher (PF-1820) to achieve 80% of -15mm particle size to meet the production needs of building aggregates.
4. Investment risk avoidance suggestions
Second-hand equipment trap: After a mining company in Shandong purchased a second-hand spiral classifier, the maintenance cost exceeded the new equipment by 20%. It is recommended that customers give priority to brand-new equipment equipped with an intelligent monitoring system.
Process adaptability verification: Emphasize the importance of laboratory mineral embedding particle size testing to avoid doubling the ball mill electricity bill due to misjudgment of the ore hardness coefficient.
At present, iron ore beneficiation is shifting from "scale expansion" to "fine operation". The crushing equipment of the investment company can be reduced by:
- High-pressure roller mill technology to reduce the particle size of the mill
- Intelligent control system to achieve energy efficiency management
- Modular design to adapt to different scales of beneficiation plants
Become a key fulcrum for customer investment optimization. The iron ore project in Akto County, Xinjiang, China shows that the optimized crushing system can reduce the processing cost of a ton of ore by 10%-20%.
If you have any questions about iron ore crushing and beneficiation, please consult our engineers online.
