Weir Minerals’ range of Trio® cone crushers cater to every application
Written by Dr. Ekkhart Matthies - Global Applications Director and Global Product Manager, Crushers.
The first cone crushers were invented at the beginning of the 19th century and, thanks to their durable and simple design, they quickly became the preferred choice as a secondary or tertiary position machine. The basic principle of these early live-shaft cone crushers was to have the head and main shaft as a single component. In the TC Series live-shaft machines, the countershaft takes the motor power and turns the eccentric to produce the crushing action. However, because of these machines’ component geometry, there is a limit to increases in stroke and speed. These limitations drove the development of the TP Series fixed-shaft machines.
With its moveable head and stationary pedestal, the fixed-shaft style machine was widely celebrated as a faster running cone crusher. While this style cone doesn’t necessarily guarantee operators more production, it does ensure more hits – on the head and the bowl, as well as interparticle crushing – per pass. These extra hits usually result in an overall better particle shape.
As a result, many manufacturers decided to stop producing their live-shaft crusher, despite the fact that it excels in various applications and creates less fine material. Weir Minerals decided otherwise; no two operations are the same and, therefore, it has continued to manufacture both its Trio® TP fixed-shaft and TC live-shaft range of cone crushers. There is, in other words, a cone crusher for every application. In an application like pebble crushing, which requires an extremely high level of force in order to crush what’s essentially the hardest rock, the Trio® TC machine is really the only viable option.
However, in most applications, determining whether the Trio® TC or Trio® TP machine is the preferred option is best determined through a consultation process with Weir Minerals’ team of comminution experts. Ultimately, the application will dictate which machine is the best choice as each crusher has its place in the flow sheet; however, it is one consideration among many. And, whereas competitors don’t have the flexibility to offer customers both live-shaft and fixed-shaft options, Weir Minerals does, allowing it to provide a more tailored solution.
The Trio® TC Series design – with its aforementioned stroke and speed limitations – has been engineered for maximum output without compromising reliability. The Trio® TP Series – with its fixed main shaft – allows the head to move independent of the shaft, which, in turn, allows a faster input speed, higher pivot point and increased stroke. These features allow additional power input, which equates to an increase in production compared with similarly sized live-shaft machines.
The Trio® TC machine excels in applications where the end goal is size reduction or the system has a potential for low or intermittent feed rates. It is also a direct replacement for legacy machines, so installation into an existing site is quick and easy.
As with any high performance machine, the Trio® TP range of crushers requires a bit more care with regard to the infeed in order to get the benefits of its design. The Trio® TP machine will give the customer maximum product on a single pass with great particle shape due to the crushers’ ability to crush at the liner face, as well as between particles themselves.
Furthermore, the compact design of the Trio® TP Series is beneficial in reducing feed height and weight in mobile or semi-mobile applications.
Feed material to all cones should be screened for optimal performance, but the Trio® TP crushers perform at their best with a screened and well graded feed material. Fines percentage in the feed should be kept to less than 10% passing the CSS for proper operation; any exceptions should be discussed with your local Weir comminution expert. Maintaining the proper chamber density will reduce the potential for bowl float or overload. In some applications, this may equate to a lower overall reduction ratio compared to the Trio® TC Series, which can accept a higher level of fines material; some limits still apply, nonetheless. Typically, the reduction ratio (F80/P80) should be about 4:1 in the Trio® TP Series, whereas the Trio® TC Series can be as high as 6:1.
Driven by the need for upgrades and an increase in service requirements, some competitors have started upgrading the coiled spring tramp release system with a hydraulic one. These upgrades can be achieved more effectively by replacing the whole machine. A new installation brings all the benefits of an unused machine without the performance and reliability challenges of a machine that’s been operating for decades.
Contact a Weir Minerals’ comminution specialist today to find out which Trio® cone crusher is the best fit for your operation.