Increase your material output: A guide to tons per hour in crushers
When we talk about how much work a heavy machine such as a crusher can do, we often use the term 'tons per hour' (TPH). Knowing all about tons per hour is really important for your business as it can affect productivity and profit of your operations. Let's take a closer look at what 'tons per hour' means and why it's a big deal for crusher operators and owners.
Introduction: Tons Per Hour - The Lifeblood of Industrial Efficiency
In industries ranging from mining and construction to aggregate recycling, the concept of tons per hour (TPH) is more than just a simple measure of the amount of material a machine like a crusher is producing. TPH acts as a cornerstone for evaluating equipment efficiency and overall process optimization. Tons per hour of a machine is an ever changing number that is influenced by many different factors in the production pipeline.
So, what are tons per hour and how do they change in response to a range of different factors including the hardness of a material, the size of the rock you add in and the size of the material you want out.
What are Tons per Hour?
As the name suggests, tons per hour signifies the amount of material (in tons) processed by industrial machinery within a single hour. It is a quantifiable measure that serves as a performance benchmark for the equipment, processes, and production capacity.
Crushers, be they jaw crushers, impact crushers, or cone crushers, are responsible for breaking down the raw materials. From concrete to stone, the TPH that these crushers can produce will change dramatically depending on a number of factors including how hard the stone is you want to crush.
Factors Affecting Tons per Hour
Before diving into the factors that affect TPH, it's crucial to grasp the types of crushers at play and their roles within the operation. From jaw crushers for heavy-duty primary crushing, to cone crushers for fine-tuning the finer details, each crusher type brings its strengths to the production line.
Primary crushers like jaw and gyratory units set the stage by tackling hard rocks and boulders. Secondary crushers, including cone crushers and hammer mills, further reduce material size before passing it on to tertiary units for the final sizing. The difference, for instance, between a cone crusher's mantle and a gyratory crusher's gyrating head, dictates the nature of the crush and ultimately the output.
How Small You Want To Crush Material
Machinery Partner explored how tons per hour of a jaw crusher differed depeding on the size of the crusher opening and how small you want to crush your material. The data shows that the Tons per Hour (TPH) consistently increase with the output size across various jaw box sizes, indicating higher throughput for larger output sizes. Conversely, crushing to smaller output sizes lowers the TPH, reflecting the increased effort and time required to achieve finer material granularity. Larger jaw box sizes, such as 20 X 30, exhibit significantly higher TPH values, demonstrating their capacity for greater material handling compared to smaller jaw box sizes like 10 X 16 and 10 X 19. This trend is particularly pronounced at larger output sizes, suggesting that larger jaw box sizes are optimized for higher efficiency and throughput. Overall, the data highlights that for higher throughput needs, larger jaw box sizes are more effective, while achieving smaller output sizes generally reduces throughput.
Equipment Efficiency
The intrinsic design and quality of machinery bear heavily on TPH output. Rotational speed, crusher geometry, and power ratings are some of the primary factors that directly influence equipment efficiency. The crusher’s configuration significantly impacts its productivity. Adjusting the gap at which the two jaw plates are set to - known as the closed-side setting (CSS) on a jaw crusher setting will alter the hourly throughput. With a smaller gap, the machine will be working hard to break the larger pieces into smaller ones - taking more time before they can pass out though the jaw box. This will slow down your output from say 60 TPH with the jaw open to 5 TPH with the jaw closed as tight as possible.
Feed Material Characteristics
The raw material being fed into the crusher largely determines the plant's efficiency. Different materials behave differently under stress. Materials like the crushed concrete - often used in landscaping or foundational work - have unique crushing requirements compared to virgin aggregates. In addition to material hardness, factors such as moisture content and size distribution also come into play. All these intricacies have a significant impact on how effectively a crusher can perform its intended function, making it imperative to consider these details when optimizing crushing operations.
Another critical factor that affects crusher performance is the Mohs hardness of the material. The Mohs hardness scale measures the mineral hardness of a substance on a scale from 1 to 10, with 1 being the softest (talc) and 10 being the hardest (diamond). Harder materials require more energy to break down, resulting in lower tons per hour (TPH) capacity. Therefore, it is crucial to take into account the Mohs hardness of the material being crushed to accurately estimate the throughput and adjust the operational parameters accordingly. By understanding the relationship between material hardness and TPH, operators can optimize their crushing operations for maximum efficiency.
| Common Rocks | Hardness |
|---|---|
| Diamond | Hardest |
| Granite | Very Hard |
| Basalt & Quartz | Hard |
| Limestone | Medium Strength |
| Sandstone & Concrete | Soft |
| Caliche | Soft |
| Soft Slate | Very Soft |
When it comes to crushing materials with different hardness levels, such as granite (Mohs hardness of 7) and concrete (Mohs hardness of 5), there are notable differences in the process. Granite, being a harder material, requires more energy to break down compared to concrete. This means that crushing granite may result in a lower tons per hour (TPH) capacity compared to crushing concrete with the same machine using the same settings. Differences in the TPH output of these two machines could be as different as 10 TPH with granite and 50 TPH with concrete! Operators need to consider this variation in hardness to accurately estimate the throughput and adjust the operational parameters accordingly. By understanding the relationship between material hardness and TPH, operators can optimize their crushing operations for maximum efficiency, whether they are processing harder materials like granite or softer materials like concrete.
Operating Conditions
The environment in which the equipment operates, such as temperature, humidity, and altitude, can affect the machinery's performance, ultimately influencing the TPH value. For maximum output, a crusher requires consistent feed flow throughout its run-time. However, several factors can disrupt this balance: bridging, surging due to uneven loading into the hopper or conveyor belt feeding rate. Additionally, the operating speed (RPM) directly affects the crusher's output. A higher RPM results in finer crushing, while a slower speed translates to coarser material.
Maintenance and Upkeep
Regular maintenance is critical for any high-performance machinery, including crushers. Regular inspections help identify and address potential problems before they escalate into costly breakdowns or unplanned downtime. Furthermore, replacing worn parts on the jaw box, toggle fuse, or other components inside an impactor is crucial to maintain the desired throughput capacity (TPH). Excessive wear on these critical components can lead to a decrease in TPH, impacting the overall efficiency and productivity of the crushing process. Therefore, proactive maintenance practices and timely replacements are essential to ensure optimal performance and achieve the desired production levels. Check out our heavy machinery maintenence tips here.
Tips for Maximizing Tons per Hour
Proper Equipment Sizing and Selection
When it comes to optimizing TPH (tones per hour), one critical factor is selecting the appropriate type and size of equipment based on the materials to be processed and the desired throughput. By carefully considering these factors, you can ensure that the equipment chosen is tailored to meet the specific requirements of your operations, ultimately leading to improved efficiency and productivity.
Regular Maintenance and Inspections
Investing in a robust maintenance schedule and conducting frequent inspections can prevent downtime and ensure that equipment operates at its TPH potential consistently.
Operator Training and Skill Development
Skilled operators who understand the equipment and the production process can make real-time adjustments to improve TPH performance based on changing material conditions or environmental factors.
Conclusion: TPH — More Than Just a Number
In the end, a crusher's performance can be summed up by how effectively its operation parameters are managed. Knowledge of your machinery's characteristics, coupled with a keen eye on material selection and maintenance schedules, will lead to improved tons per hour output and contribute to a thriving operation.
For plant operators looking to enhance their equipment or require expert advice, companies like Machinery Partner offer comprehensive solutions tailored to the crushing industry's nuanced needs.
Remember, whether you're breaking new ground or recycling old concrete, the success of your operation hinges on the fine-tuning of your crushers. Keep pushing the boundaries of performance, and the results will follow.
Want to learn more about optimizing your crusher's output or need to find the right equipment for your operation? Visit Machinery Partner for expert advice and a wide range of crushing equipment designed to meet your needs.
