What Formulas Are Used to Determine a Crusher's Hourly Output?

Determining a crusher's hourly output involves considering several factors and using specific formulas related to mechanical and operational aspects. Here are some aspects and formulas used to determine a crusher's output:

1. Crusher Throughput Capacity:

   • The capacity of a crusher is given by the formula: $$Q=\frac{w\times s\times f\times n}{k}$$ where:
     • ( Q ) is the capacity (in tons per hour),
     • ( w ) is the width of the discharge opening (typically in meters),
     • ( s ) is the stroke length (in meters),
     • ( f ) is the frequency of the crushing cycle (number of cycles per minute),
     • ( n ) is the bulk density of the material (in tons per cubic meter),
     • ( k ) is a constant that varies depending on the type of crusher and material.

2. Crushing Efficiency:

   • Efficiency can be estimated from the power consumption and the size reduction ratio, given by: $$\text{Efficiency}=\left(\frac{\text{Output Size}}{\text{Input Size}}\right)\times 100\mathrm{\%}$$

3. Material Hardness and Size:

   • The characteristics of the material being processed (such as hardness and moisture content) can influence throughput.
   • Hard materials might lower the crusher capacity, whereas excessive moisture can affect the throughput rate by causing blockages or reduced feed rates.

4. Adjustment Factors:

   • Downtime due to maintenance or equipment adjustments,
   • The operational settings such as closed side settings (CSS),
   • Wear and tear which might reduce overall efficiency and throughput.

5. Empirical Equations:

   • Empirical data and manufacturer guidelines provide charts and tables that give expected production rates for different settings and feed characteristics.

6. Power Consumption:

   • The energy consumed by the operation can be used to estimate output: $$\text{Power Consumption}=\frac{\text{Capacity}\times \text{Material Work Index}}{\text{Total Crusher Efficiency}}$$

By analyzing these aspects, you can objectively determine a crusher's potential production output per hour. Practically, field testing and adjustments based on onsite conditions provide the most accurate capacity figures.