Investigating the chamber filling effect on the jaw crusher, cone crusher and HPGR performance

Comminution equipment, which includes crushing and grinding machinery, is a significant contributor to the operational costs of mineral processing plants. Choke feeding is reported to enhance the crushing process. The research examined the effects of varying chamber fill levels on the performance of jaw crushers, cone crushers, and High Pressure Grinding Rolls (HPGR) in an industrial setting to optimise the crushing process and improve the overall productivity. Analytical techniques like image analysis, sieve analysis, and the Bond ball mill work index (BBWI) were employed. Comprehensive plant trials provided samples and data, comparing the crusher chamber at 50% (half-full) and full level. In the Steel-Sirjan Iron Ore Complex (SSIOC), choked conditions led to a 9.3% increase in crushing plant throughput compared to half-full conditions. By increasing the operational pressure and hopper level of the HPGR, the product BBWI was reduced from 16 ± 0.20 kWh/t to 14.9 ± 0.25 kWh/t under super-choked conditions. This reduction is attributed to the generation of micro-cracks in particles during super-choked operation. In a parallel study at the Sarcheshmeh Copper Complex (SCC), a 62% enhancement in crushing capacity was observed when the crusher operated in a super-choked state, compared to a half-full state.