How to Reduce Recirculating Load in Crushing Circuit
For mining operations in Kazakhstan and Mongolia, high recirculating loads in a crushing circuit waste energy, increase liner wear, and reduce plant capacity. Knowing how to reduce recirculating load in crushing circuit helps you improve throughput and lower operating costs. Recirculating load is the material that returns to the crusher after screening, typically expressed as a percentage of fresh feed. Below we explain practical methods to optimize your circuit and how OCP Mechanical Company supports efficient crushing.
Measure and Monitor Your Current Load
The first step in how to reduce recirculating load in crushing circuit is to measure what you have. Recirculating load can be calculated by taking sieve analyses of crusher feed, crusher discharge, and screen oversize. A typical target for secondary crushing is 150‑250% recirculating load; anything above 300% indicates inefficiency.
OCP recommends installing belt scales and sampling points at key locations. Note: Product data are constantly updated; for the latest automation options, please contact our online customer service.
Many copper and gold mines in the Karaganda region and the Gobi Desert have reduced recirculating loads from 350% down to 200% simply by measuring and adjusting screen aperture sizes.
Optimize Screen Efficiency
The most effective way for how to reduce recirculating load in crushing circuit is to improve screen performance. A poorly performing screen sends too much material back to the crusher. Here are practical fixes:
Increase screen area – If your screen is overloaded, add a second screen or replace with a larger unit (e.g., from 1,800 x 5,000 mm to 2,000 x 6,000 mm). This alone can cut recirculating load by 30‑50%.
Use the correct screen media – For wet or sticky ore, use polyurethane panels instead of woven wire to reduce blinding. For dry, abrasive ore, use high‑open‑area wire mesh.
Adjust screen slope – A steeper slope increases throughput but reduces efficiency. For a 250 tph circuit, a slope of 18‑22 degrees is a practical balance.
Check amplitude and frequency – Insufficient vibration causes material to build up. Aim for 5‑7 mm amplitude at 850‑950 rpm.
OCP’s Type S vibrating screen offers adjustable stroke and modular screen panels. Many operators in East Kazakhstan have reduced recirculating loads by 40% after switching to polyurethane panels on their final screen.
To master how to reduce recirculating load in crushing circuit, we recommend:
Conducting a daily screen efficiency test (measuring undersize in oversize).
Keeping a spare set of screen panels to replace worn ones immediately.
Installing water sprays on the screen feed to reduce dust and blinding.
Adjust Crusher Settings and Feed
Another key to how to reduce recirculating load in crushing circuit is optimizing the crusher itself:
Increase CSS (closed side setting) – A wider CSS produces coarser crusher discharge, which means more material passes the screen on the first pass, reducing recirculation. For a cone crusher, increasing CSS from 12 mm to 16 mm can cut recirculating load by 20‑30%.
Maintain choke‑fed conditions – A fully loaded crusher produces a more consistent product with fewer elongated particles that tend to be retained on screens.
Match crusher cavity to feed size – Using a short head cavity when feed is coarse causes packing and high recirculation. Use standard cavity for feed >40 mm.
OCP’s Type C cone crusher allows remote CSS adjustment, making it easy to fine‑tune while the plant is running. Many Mongolian gold operations have reduced recirculating load from 280% to 180% by widening CSS by 3‑4 mm and adding a pre‑screen before the crusher.
As a direct‑selling manufacturer, OCP provides factory pricing on crushers and screens, with no middleman markup. We ship to Aktau or Ulaanbaatar ports within 25‑30 days.
Why OCP Is Your Partner for Efficient Crushing
Understanding how to reduce recirculating load in crushing circuit is a combination of proper measurement, screen optimization, and crusher tuning. OCP Mechanical Company has over 40 years of history in crushing and screening equipment. We offer:
Free pre‑sale circuit audit to identify recirculation bottlenecks.
A customized recommendation for screen media and crusher settings.
24/7 online technical support for remote tuning.
Our equipment has been successfully deployed in hard rock mines across Central Asia. Customers often highlight the robust construction, easy adjustability, and economical price.
For a no‑obligation consultation and personalized advice on how to reduce recirculating load in crushing circuit for your plant, simply click the live chat icon on this page. Our online customer service team is available 24 hours a day, 7 days a week, to answer your technical questions, provide free recommendations, and help you improve your crushing efficiency.
