Anti-clogging measures for crushers processing high-moisture sticky iron ore

High-moisture iron ore (typically >8% free moisture) with clay content can cause severe clogging in crushers, leading to unplanned downtime and reduced throughput. Implementing effective anti-clogging measures for crushers processing high-moisture sticky iron ore is essential for operations in tropical regions or during rainy seasons. OCP Machinery, with 40+ years of experience, has developed a suite of solutions including: (1) steep-angled cavity designs that reduce material hang-up, (2) hydraulic cavity clearing systems, (3) heated liners or anti-stick coatings, and (4) vibrating grizzly feeders with self-cleaning bars. The most effective anti-clogging measures for crushers processing high-moisture sticky iron ore start at the feeder: OCP’s vibrating feeders use elliptical motion and rubber-lined decks to prevent clay buildup. For severe cases, we install a pre-screening deck that bypasses fine wet material around the crusher.

In actual operation, sticky ore tends to compact in the crusher’s crushing zone, especially in cone crushers with parallel chambers. OCP’s solution includes a hydraulic “cavity flush” system that momentarily opens the CSS to release packed material. For a Brazilian iron ore mine processing 1,200 t/h of ore with 11% moisture, OCP implemented anti-clogging measures for crushers processing high-moisture sticky iron ore that included a custom jaw crusher with a 25° steep cavity (vs standard 18-20°), plus a self-cleaning feeder with punch plate openings. Clogging incidents dropped from 12 per week to 1 per month. OCP’s custom capability extends to adding ultrasonic sensors that detect material buildup and automatically activate clearing hammers. Our direct factory pricing includes these anti-clogging features as standard options at no extra cost for many models. Environmentally, OCP uses water sprays only at the feed point to reduce dust without adding more moisture, and we offer enclosed crusher housings to contain spills.

OCP’s 40 years of experience has resulted in a proprietary “Sticky Ore Package” that guarantees 95% uptime even with 15% moisture ore. For a customer in Indonesia processing lateritic iron ore, OCP’s anti-clogging measures for crushers processing high-moisture sticky iron ore increased throughput from 80 t/h to 145 t/h. We also provide retrofitting of existing crushers with anti-clogging devices. To stop clogging in your iron ore crusher, contact OCP today. Describe your moisture content and clay type, and our engineers will recommend the most effective anti-clogging measures for crushers processing high-moisture sticky iron ore for your specific setup. Click the online chat button for 24/7 support and a free site assessment. Request a video demonstration of our anti-clogging technology and a direct factory quotation.

(The technical parameters and pricing information mentioned in this article are subject to change as products are upgraded and are for reference only. Please contact customer service on the website for the latest equipment details.)