Crushers are key to mining operations, and parallel shaft reducers are key components of crushers. Ever since mechanical and explosive technology allowed the removal of large rock chunks, mining outfits have been looking for ways to crush ore. Rocks must be broken into similarly sized particles for two main reasons: 1) To ready materials for market, and 2) to prepare ore for beneficiation, the separation of valuable materials and gangue (valueless rubble). As an example in the first category, engineers require uniform aggregate for the construction of roads, foundations, and pipe bedding. Therefore, gravel mines must use crushers and mills for ore reduction. The second category of crushing is required for the extraction of multiple industrial and metallic minerals, from gold to galena.
Typically, beneficiation requires several stages of crushing, which may also be referred to as liberation or particle size reduction. Ore is sequentially reduced in size with each crusher or mill. Types of crushers include:
• Jaw Crushers offer a reduction ratio ranging from 3:1 to 5:1; they are used in extracting sand, gravel, and heavy mining. Within jaw crushers, the mobile swing jaw works like a nutcracker, breaking ore against the fixed jaw. Gravity draws smaller chunks of ore downward through the crushing chamber.
• Gyratory Crushers provide a reduction ratio from 4:1 to 7:1; they are utilized in heavy mining and breaking up quarried materials. Like jaw crushers, they use gravity to pull crushed ore down through a narrow sizing gap. However, rather than the back-and-forth movement of the swing jaw, gyratory crushers use an eccentric shaft, which rotates to crush ore between inner and outer cones.
• Vertical Shaft Impactors are able to reduce ore at a 6:1 to 8:1 ratios. They use high-speed rotary motors to throw rock against surrounding anvils. This approach takes advantage of the fact that rocks naturally have small fissures. When the velocity of the motor throws rocks against the anvil, the fissures break the ore into cubical, uniform particles.
Each crusher requires a specialized gearbox to refine the speed of input rotation. For crushing operations, parallel shaft reducers are optimal. A Falk parallel shaft reducer is strong enough to provide steady service in high-torque environments. In addition to high-torque output, crushers require unparalleled performance in tight spaces. Parallel shaft reducers are perfect for compact spaces like a mine shaft. Finally, crushing rock is one of the dirtiest assignments possible for gearboxes. Mining firms tend to prefer parallel shaft reducers, as they seal out dirt to prevent equipment wear, tear, and malfunction.
Here are a few additional benefits of parallel shaft reducers for crushers:
—Easy to maintain. Large inspection covers and smooth flat surfaces make parallel shaft reducers easier to clean than other gearboxes.
—Protection against dirt and grease. An outer cover assembly prevents contaminants from entering the parallel shaft reducer. This design feature extends gearbox life.
—Repair in-place. Thanks to a split design, the gear drive is easy to access for repairs. No need to disassemble or drain lubrication—just repair on the line, and keep going. Less disassembling means less downtime and lower maintenance costs.
Contact us today to learn about which Falk parallel shaft reducer is right for your crusher. If your parallel shaft reducer requires repair, you can trust us to fix your gearbox quickly. We are one of three authorized Falk Renew repair providers in the United States, and we operate 24 hours a day, 365 days a year to keep mining operations running smoothly.
[Photo from Bert Kaufmann via CC License 2.0]
Posted under Machinery Maintenance, Products/Services on Thursday, February 26th, 2015