Optimizing Jaw Crusher Discharge and Belt Conveyor Selection

In mineral processing and bulk material handling, the proper configuration of the jaw crusher discharge opening and the selection of belt conveyors are critical to ensuring efficient throughput, equipment longevity, and operational safety. This article outlines key considerations and best practices for setting the jaw crusher discharge opening and selecting belt conveyors, particularly in projects similar to the Guomao project.

Jaw Crusher Discharge Opening Setting

The combination of raw material bins, feeders, and jaw crushers is typically fixed in design. When setting the jaw crusher discharge opening, it is essential to balance the required throughput with the feed size and characteristics of the secondary crushing stage.

• Throughput Considerations: The discharge opening must be sized to allow the designed capacity to pass through without causing material buildup or crusher overload.
• Secondary Crusher Feed: The discharge opening should be adjusted to produce a particle size distribution suitable for the secondary crusher, avoiding oversize material that could cause blockages or damage downstream equipment.
• Optimization: Selecting a reasonable discharge opening size ensures smooth material flow, reduces wear on crusher components, and improves overall plant efficiency.

Belt Conveyor Selection

Belt conveyors are the backbone of material transport in beneficiation plants. Their selection must consider several critical factors to ensure reliable and efficient operation.

1. Capacity

• The conveyor belt width must be selected based on the required throughput.
• Special attention is needed for materials with unusual bulk densities, as this affects the volumetric loading capacity.
• For example, in the Guomao project, B6X series belt conveyors are suitable for capacities below 500 tons per hour. For higher capacities, either custom non-standard designs or upgrading to B7X series conveyors is recommended.

2. Maximum Feed Size

• The maximum feed size (Dmax) is a key parameter influencing conveyor design.
• The recommended maximum lump size for the conveyor feed is calculated as: (Dmax*2.5+200mm)
• This ensures the belt and conveyor structure can handle the largest material without damage or blockage.

Belt Conveyor Design and Operational Guidelines

1. Conveyor Inclination Angle:

• For material sizes between 0–80 mm, the maximum recommended conveyor incline is 17°.
• For material sizes exceeding 80 mm, the incline should not exceed 16°.
• When conveying washed sand or similar materials, the incline should be limited to 14° to prevent material rollback.

2. Material Size Restrictions:

• Conveyed material should not exceed 350 mm in size.
• Large lumps must not impact the conveyor’s receiving device vertically; appropriate buffering systems such as buffer beds should be installed to absorb impact and protect the belt.

3. Standardization:

• Using conveyors of the same belt width and similar lengths simplifies maintenance and spare parts management.
• It is advisable to keep conveyor lengths as uniform as possible to facilitate future adjustments and reduce inventory complexity.

4. Operating Temperature Range:

• Conveyors should be designed for operation within -20°C to +40°C.
• For extreme climates, special belts resistant to cold or heat should be selected to maintain performance and durability.

5. Layout Flexibility:

• The principle of “prefer longer conveyors over shorter ones” is recommended to allow operational flexibility and future plant expansions.
• In spatially constrained areas, curved or angled conveyors can be designed to optimize plant layout without sacrificing performance.

Proper setting of the jaw crusher discharge opening and careful selection of belt conveyors are essential to optimize material flow, reduce equipment wear, and ensure reliable operation in iron ore beneficiation and other bulk material handling applications. Following the outlined guidelines helps in achieving stable throughput, minimizing downtime, and extending equipment life, thereby contributing to the overall efficiency and profitability of the processing plant.