Crushing Efficiency: How to Calculate the Cost of Running a Crusher

Crushing or grinding a material is much higher costlier than its initial purchase and running expenses. With rising energy costs, the importance of evaluating and improving crushing efficiency has become paramount for industries looking to reduce their operational costs. In this article, we will explore how to calculate the cost of running a crusher efficiently.

To begin with, it is essential to understand the concept of crushing efficiency. Crushing efficiency refers to the ratio of the amount of material crushed to the energy consumed in the process. In other words, it measures how effectively the crusher utilizes the energy input to break down the material into smaller fragments. A higher crushing efficiency indicates that more material is being crushed for a given amount of energy input, resulting in lower operational costs.

The first step in calculating the cost of running a crusher is to determine the energy consumption. This can be done by analyzing the crusher's motor power and throughput capacity. For instance, a jaw crusher with a motor power of 30 kW and a throughput capacity of 100 tph can consume approximately 26.4 kWh of energy per hour.

To calculate the power consumption of the crusher, we can multiply the motor power by the running hours per day and the energy tariff per kilowatt-hour. Assuming the crusher operates for 8 hours per day and the energy tariff is $0.10 per kilowatt-hour, the daily energy consumption would be:

Daily energy consumption = 30 kW x 8 hours/day x $0.10/kWh = $24 per day

The second step is to determine the material throughput. This can be done by analyzing the crusher's feed size, product size, and production rate. For instance, if a crusher has a feed size of 200 mm, a product size of 20 mm, and a production rate of 50 tph, we can calculate the material throughput as follows:

Material throughput = (Production rate / 100) x (Product size / Feed size) x 100

Material throughput = (50 tph / 100) x (20 mm / 200 mm) x 100 = 5 tph

Finally, to calculate the cost of running the crusher, we need to consider the production cost per ton of crushed material. This includes expenses such as labor, wear parts, maintenance, electricity, and other overhead costs. The production cost per ton can be obtained by dividing the production cost by the material throughput. Assuming a production cost of $10 per ton, the cost of running the crusher per day can be calculated as follows:

Crusher running cost per day = Production cost per ton / Material throughput

Crusher running cost per day = $10 per ton / 5 tph = $2 per tph

Therefore, if the crusher operates at a throughput of 5 tph, the running cost per day would be $2 x 5 tph = $10 per day.

In conclusion, maximizing crushing efficiency is crucial for industries looking to reduce operational costs. By calculating the cost of running a crusher, companies can identify areas for improvement and implement strategies to enhance efficiency. This involves evaluating the energy consumption, material throughput, and production costs to arrive at an accurate estimation. By employing these calculations, businesses can optimize their crushing operations, reduce costs, and ultimately increase their profitability.

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