How to improve jaw crusher performance and productivity

Avoid bridging

Continuous bridging in the feeding area of jaw crushers is a common problem.

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What is it?

Bridging means stones blocking the flow from entering or moving down in the crushing chamber. It can be caused by just one stone that is larger than the feed opening, or then many average-sized stones of crossing against each other and blocking the crusher's feed.

Why it is a problem?

Bridging can cause a significant loss of production that oftentimes goes unnoticed. It is relevant to keep an eye on bridging in the feeding area of a primary crusher as it can take several minutes to resolve the issue (big rock being removed, fragmented or directed to the chamber). If it occurs say ten times in a day, it quickly leads to one hour of lost production.

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If that happens, for instance, in one of our crusher models, C130 with 352 short ton per hour (stph) working capacity and assuming a USD 12 /short ton, the daily loss can easily add up to four thousand dollars.

How to prevent bridging?

Bridging can be avoided by implementing a tight control of the blasting grid to avoid generating oversize material, training the truck loader operator to separate the oversize material at the pit and the primary crushing plant operator visualizing the flow of material to the crusher and controlling the stones' speed and direction by varying feeder speed and using the hydraulic hammer installed in the area.

1. Size of the Crushing Chamber: The size of the crushing chamber is one of the most important factors affecting the efficiency of a jaw crusher. The larger the chamber, the more material it can process at one time, and the faster it can crush material. However, a larger chamber also requires more energy to operate and can lead to increased wear and tear on the machine.
2. Width of the Discharge Opening: The width of the discharge opening also plays a significant role in the efficiency of a jaw crusher. A wider opening allows more material to be discharged from the crusher at a faster rate, which can improve efficiency. However, if the opening is too wide, it can cause the material to be crushed unevenly, which can lead to poor efficiency and increased wear and tear on the machine.
3. Horsepower of the Motor: The horsepower of the motor driving the jaw crusher is another important factor in its efficiency. A higher horsepower motor can process material faster and more efficiently, which can lead to increased productivity and throughput.
4. Crushing Capacity: The crushing capacity of the machine is also an important factor in its efficiency. A jaw crusher with a higher capacity can process more material at one time, which can improve efficiency and reduce the need for multiple crushing cycles.

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