The aim of this project was to identify and reduce the production constraints on site, increasing the overall efficiency of the plant. The project focused on the primary impact crusher and was split into two trial phases. Firstly, optimising the clearance between the rotor and the impact aprons, secondly adjusting the composition of the blow bars to prolong use.
Method – Phase 1
The settings for the impact aprons would be critical before embarking on the blow bar trials. Figure 9 shows the main adjustable components of the horizontal impact crusher.
Figure 9. Diagram of horizontal impact crusher
Results – Phase 1
The clearances for the impact aprons were derived from research and the impact crusher manufacturer recommendations, with the results shown in figure 10
Figure 10. Particle size distribution results for the different clearance settings on the impact crusher
From the evidence gathered in this trial, a 40mm/20mm clearance setting produced the most desired products.
Method – Phase 2
Differing blow bar compositions were trialled to establish the best performance. It should be noted that the blow bars are changed weekly due to the nature of the material being crushed. Three differing blow bar compositions were selected for the trial. Firstly, the Original Equipment Manufacturer (OEM) high durability blow bars, secondly, high chromium blow bars and finally recycled blow bars created from re-forging pre-used blow bars.
Results – Phase 2
Figure 11. the performance of the three different types of blow bars
The trials proved that the OEM blow bars were most durable, resulting in the lowest overall operating cost. This was due to the potential sales revenue loss associated with the frequency and time changing the recycled blow bars. Concluding that the OEM blow bars are to be used during periods of high demand and the recycled blow bars during periods of lower demand.
Since the completion of the project further trials have been conducted with the recycle blow bars by addition of further chromium when they are being re-forged. The initial results are proving to be promising.
Ben Campbell TMIQ comments
“The degree course really helped me develop independent thinking, especially through the "Work Based Project" module. This module was great for applying what I learned in real-world settings, pushing me to be creative and self-reliant. The course also provided in-depth knowledge of the mineral products industry and business management, giving me a well-rounded understanding of both specific and broad concepts. Overall, it broadened my perspective on the industry and the business world, boosting my confidence to take on projects and solve problems effectively. I'm looking forward to adding more experience to my knowledge in the years to come.”
Simon Smith FIQ, Operations Director, Longwater Gravel
“The BSc (Hons) in Mineral Products Management has allowed Ben and his fellow students to show that they are ‘the very best’. Achieving the qualification requires enthusiasm, commitment, and a lot of hard work, all key attributes for those who will have a role in inspiring, motivating and leading a successful and sustainable minerals industry.”
Celebrating 10 successful years of the Honours Degree in Mineral Products Management
Throughout April, IQ and the University of Derby shared case studies of innovative projects driving change in the mineral products industry, led by recent graduates of the BSc (Hons) in Mineral Products Management:
These cutting-edge projects highlight the next generation of industry leaders, applying their skills to deliver practical, sustainable, and financially beneficial solutions.
For further details on any of the projects or the honours programme covered within this article please contact j.austin@derby.ac.uk