Unraveling the Mysteries of Screening and Crushing Equipment: Your Comprehensive Guide

In the world of material handling, screening and crushing equipment play pivotal roles. Whether it's in mining, construction, or recycling, these machines are the workhorses that transform raw materials into valuable products. In this blog post, we'll take an in - depth look at both screening and crushing equipment, covering everything from their basic functions to the latest technological advancements.

Screening Equipment: The Precision Separators

Definition and Function

Screening equipment is an essential part of the mechanical screening process. Its primary function is to separate one material from another. Acting as the second step in the material - handling process, it takes raw materials from crushers or quarries and refines them into even finer grades, bringing us closer to the final, market - ready product. For example, in a mining operation, it can separate valuable minerals from the surrounding rock.

Technical Specifications

Let's take a closer look at some popular models of screening equipment and their technical parameters:

These numbers give us a clear picture of the different capabilities of each model, from the amount of material they can handle per hour to the size of the screen and conveyor belt.

Working Principle

Screening equipment, whether it's a full - circuit or single - screening device, can be installed horizontally or on an incline. It typically consists of an engine that generates vibrations, screens that cause particle separation, and a catching area. Once the material is fed into the machine, it moves over the screens and is separated through vibration. The separation process can be quick for some materials, while for others, it may be a longer and more complex process, involving multiple passes or different separation points within the machine.

Maintenance and Troubleshooting

Maintenance

Screen Cleaning: Regularly clean the screens to prevent material buildup. Use a soft - bristle brush or a high - pressure water jet (for wet - resistant screens) to remove any stuck - on particles.

Vibration Component Lubrication: Lubricate the vibration - generating components, such as the motor bearings and vibrating shafts, every 200 - 300 operating hours. Use a high - quality lubricant recommended by the manufacturer.

Overall Equipment Inspection: Conduct a comprehensive inspection of the equipment at least once a week. Check for loose bolts, worn - out belts, and any signs of structural damage.

Troubleshooting

Screen Blockage: If the screen is blocked, it could be due to oversized particles or a high - moisture material clogging the mesh. First, stop the machine and remove the power source. Then, use a wire brush or a special screen - cleaning tool to clear the blockages. If the problem persists, adjust the feed rate or consider using a pre - screening device.

Abnormal Vibration: Abnormal vibration may be caused by unbalanced weights on the vibrating motor, loose screen attachments, or worn - out shock absorbers. Check the vibrating motor for any loose parts or damaged weights. Tighten all screen - mounting bolts and replace any worn - out shock absorbers.

Applications

Screening equipment is widely used across various industries. In the mining industry, it helps separate valuable ores from waste rock. In aggregate processing, it ensures that the produced aggregates are of the right size for construction purposes. Recycling plants use it to separate recyclable materials from non - recyclables, such as separating glass and plastic from general waste.

Industry Trends and Technological Developments

Intelligentization: Future screening equipment is likely to feature intelligent control systems that can automatically adjust the screen vibration frequency according to the characteristics of the incoming material. This will improve the efficiency and accuracy of the screening process.

Energy - Saving and Environmental Protection: The development of low - energy - consumption vibration motors and innovative designs to reduce dust emissions will be a major trend. For example, using enclosed screening chambers with built - in dust - collection systems.

New Materials: New materials are being developed for screen manufacturing. These materials, such as high - strength synthetic meshes and wear - resistant alloys, can significantly improve the durability and screening efficiency of the equipment.

Safety and Training

Safety

Pre - startup Checks: Before starting the screening equipment, check that all guards are in place, the electrical connections are secure, and there are no loose parts.

Operation Precautions: During operation, do not reach into the machine while it is running. Keep the work area clear of debris and ensure proper ventilation.

Post - shutdown Maintenance Safety: After shutting down the equipment, wait for all moving parts to come to a complete stop before performing any maintenance. Disconnect the power source and lock it out to prevent accidental startup.

Training

Theoretical Knowledge Training: Provide operators with training on the basic principles of screening equipment, including how it works, the different types of screens, and the importance of proper operation.

Practical Training: Conduct hands - on training sessions where operators can practice starting and stopping the equipment, adjusting the settings, and troubleshooting common problems.

Vertex Bergbaumaschinen offers professional solutions for screening equipment. Their team can help you select the right equipment based on your production goals, especially for the mining and mineral processing industries. They also provide installation, construction, and after - sales service.

Crushing Equipment: The Powerhouses of Size Reduction

Definition and Function

Crushing equipment is designed to reduce the size of materials into much smaller pieces. It's an integral part of the material - handling system or plant. Rock crushers, for instance, use a significant amount of force to impact and break materials. In a rock quarry, large boulders are fed into crushers to be transformed into smaller stones for construction use.

Working Principle

Most crushers are equipped with chambers that have heavy, durable plates or jaws. When the raw material enters the crusher, these plates or jaws come together to apply pressure, reducing the size of the material. Some large - scale operations use multiple crushers. First, a heavy - duty crusher like a jaw crusher is used to break down large pieces of material into more manageable sizes. Then, the reduced material is fed into smaller crushers for further processing. After that, the material is transported by a conveyor belt to a screening machine.

Maintenance and Troubleshooting

Maintenance

Predicting Wear - part Replacement Cycles: For parts like jaw plates, hammers, and liners, the replacement cycle can be predicted based on the amount of material processed, the hardness of the material, and the operating time. Generally, for a jaw crusher processing hard rock, the jaw plates may need to be replaced every 3 - 6 months.

Regular Maintenance of Moving Parts: Regularly check and lubricate the transmission components, such as the gears, bearings, and belts. Clean the lubrication points and replace the lubricant every 1 - 2 months.

Troubleshooting

Sudden Decrease in Production: This could be due to a blocked feed inlet, worn - out crushing parts, or a malfunctioning motor. Check the feed inlet for any obstructions and clear them. Inspect the crushing parts for wear and replace them if necessary. Also, check the motor for any electrical issues.

Abnormal Noise and Vibration: Abnormal noise and vibration may be caused by misaligned parts, loose bolts, or worn - out bearings. Check all the connections and tighten any loose bolts. Replace the bearings if they are worn out.

Applications

Crushing equipment is widely used in industries such as mining, rock quarries, mineral processing, and recycling. In the mining industry, it is used to break down large - scale ores into smaller pieces for further processing. Recycling plants use crushers to break down glass bottles and other waste materials into recyclable raw materials.

Industry Trends and Technological Developments

New Crushing Principles: New crushing principles are being explored to increase the crushing ratio and improve product quality. For example, some crushers are now using a combination of impact and shear forces to achieve better results.

Automation and Remote Monitoring: Advanced automation control systems are being developed to enable remote monitoring and control of crushers. Operators can monitor the equipment's performance, adjust settings, and receive real - time alerts about any potential problems.

Compact and Mobile Design: There is a growing demand for crushers with a smaller footprint and higher mobility. This allows for easier transportation and deployment in different production sites.

Safety and Training

Safety

Preventing Material Splashing: Operators should wear appropriate personal protective equipment, such as safety glasses and helmets, to prevent injury from splashing materials.

Avoiding Overload: Do not overload the crusher. Follow the recommended feed rate and material size limits to prevent damage to the equipment and ensure safe operation.

Training

Training Course Setup: Design training courses that cover safety knowledge, operation skills, and maintenance essentials. Include modules on emergency response in case of equipment failures.

Training Assessment: Establish a training assessment standard to ensure that operators are proficient in operating the equipment. This can include written tests, practical demonstrations, and on - the - job evaluations.

Vertex Bergbaumaschinen, with over 30 years of experience in the material - handling industry, supplies and installs a variety of crushers, including cone crushers, jaw crushers, and more. They offer comprehensive services, from consulting and planning to designing full - circuit systems and providing after - sales maintenance.

In conclusion, understanding screening and crushing equipment is crucial for anyone involved in the material - handling industry. Whether you're looking to upgrade your existing equipment, start a new project, or simply expand your knowledge, the information provided here should serve as a valuable resource.