Ugarov Stary Oskol Institute of Technology (Branch), National University of Science and Technology – MISIS, Stary Oskol, Russia:

P. F. Boyko, Associate Professor, Candidate of Engineering Sciences

Petropavlovsk – Ferrous Metallurgy, Moscow, Russia:
E. M. Titievsky, Chief Mechanical Engineer, Candidate of Engineering Sciences, efimtitievskiy@mail.ru

Moscow State Technological University – Stankin, Moscow, Russia:
V. A. Timiryazev, Professor, Doctor of Engineering Sciences

The article describes application conditions and justifies criticality of crushers as the key member in production circuit of a mining and processing plant. Ore crushing in the mining and processing flow chart is one of the basic stages of iron production. Experience of crushers shows that considerable downtime is conditioned by accidents due to insufficient design reliability. Downtime of a coarse grinding machine within a shift means shutdown of equipment along the entire process chain and results in under-supply of integrated iron-and-steel works by more than 200 thousand cubic meters of ore, which makes 8.5% of ore supply across Russia. The operations characterized by the largest amount of work and labor intake are replacement of liner of crusher bowl and cone as well as recovery of accuracy of skid base of eccentric shaft. The features of operation, repair and reconditioning of cone crushers, the error-free performance of which governs the smooth and high-output operation of the whole mining and processing plant, are described. The problems arising in the course of operation are discussed and analyzed, their causes are defined, and recommendations on elimination are made. For the transition from the repair scheduling to a more advanced and economically efficient method of repair planning based on the actual condition of equipment, the authors review the methods of ultrasonic, vibration and endoscopic control for calculating average in-use life of liners and optimal repair intervals. When in operation, liner of a crusher is under complex stress state. The liner takes and transfers forces to 100–190 t. The share of liner in repair-and-operating costs makes 90.5% and 80% in terms of medium- and fine-crushing plants, respectively. The authors discuss approaches to enhancing endurance of liners based on the reasoned use of new steel grades and systematic control over chemical composition and mechanical properties of steels. The use of lifters with in-built hydraulic drives, pneumatic nut setters and load-lifting magnetic grips will eliminate heavy manual work from repair operations and will improve their productivity and quality, which also expands useful life of crushers. With a view to cutting down the duration and to improving the quality of repair, the configuration of equipment for mechanization of repair operations and reconditioning of large-dimension parts and units on the spot is selected. For the repair of units and blocks of machines and to reduce the risk of repair interrupt due to unforeseen complications, the authors propose the calculation procedures for technical and economic efficiency, working assets and reserve stock of units and parts of crushers.

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