Best Crusher for Lead-Zinc Ore Processing

• Understanding Lead-Zinc Ore Characteristics

  Lead zinc ore is special. It is distinct from limestone. It is heavier. The density is high. Usually 3.5 to 4.0 g/cm3. This is heavy. It puts stress on machines. The rock is also abrasive. It acts like sandpaper. It wears down steel parts fast. You must know this.

  Also the moisture varies. Sometimes it is dry. Sometimes it is wet. Wet ore is sticky. Sticky ore blocks machines. We call this plugging. You need a big opening. You need power. The Bond Work Index is high. It is usually 12-14 kWh/t. This means it needs energy. Lots of energy to break.

• Primary Stage: The Jaw Crusher Choice

  First step is big crushing. We call this primary. The best machine is Jaw Crusher. Why is it best? Because it has a big mouth. It takes big rocks. Rocks up to 1000mm. It crushes them down. It makes them 150mm. This is a good size. The ratio is good.

  How it works is simple. One plate is fixed. One plate moves. The moving plate swings. It squeezes the rock. The rock breaks. It falls down. The gap at bottom controls size. This gap is CSS. Closed Side Setting. You can change this gap.

  For lead zinc you need PE series. Or maybe PEW series. These are strong. They use high manganese steel. This steel gets harder when hit. We call it work hardening. It lasts longer. This saves money on parts. It is smart choice.

• Technical Focus: Key Parameters for Jaw Crusher

  You must look at the toggle plate. It protects the machine. If iron gets in it breaks. This saves the expensive parts. Why? Because iron cannot break. It stops the machine. The toggle plate acts like a fuse. It snaps.

  Also look at the nip angle. This is the angle between plates. It must be right. Usually 18 to 22 degrees. If too big rock pops out. We call this regurgitation. It is dangerous. If too small it crushes slow. Proper angle grips the rock. It breaks it fast. Efficiency goes up.

  Key Data Points:

  – CSS Range: 10mm – 300mm

  – Reduction Ratio: 4:1 to 6:1

  – Motor Power: Matches the hardness

• Secondary Stage: The Hydraulic Cone Crusher

  After jaw crusher rock is smaller. But not small enough. You need second stage. We use Cone Crusher here. Why cone? It makes good shape. It makes cubes. Cubes are better for grinding. Ball mill likes cubes. It grinds faster.

  The hydraulic cone is best. It uses oil pressure. The oil pushes the shaft. It keeps the setting tight. If hard rock comes oil lets it pass. This is safety release. It is automatic. No need to stop machine. This saves time. Time is money.

  We recommend HPT or HST series. They are modern. They have high speed. High speed means more hits. The rock gets hit more. It breaks finer. This is lamination crushing principle. Rock breaks rock. It reduces wear on steel liner. Smart design.

Here is a data table. It shows difference. It helps you compare.

• Case Study 1: High Altitude Project in Peru

  We had a client in Peru. His name is Mr Carlos. His mine is high up. 4200 meters altitude. Air is thin there. Motors get hot easy. He mines lead zinc. The rock is very hard. He tried other machines. They failed. They overheated.

  He came to ZENITH. We gave him solution. We used PE900x1200 Jaw Crusher. We used big motor. We added cooling. For secondary we used HPT300 Cone. It is multi cylinder. It is strong.

  The Result:

  The plant runs smooth. It produces 300 tons per hour. The shape is good. The ball mill works less. He saves electricity. He is happy. He says “ZENITH machine is beast”. It runs 20 hours a day. No problem.

• Case Study 2: Wet Ore in Southeast Asia

  Another client in Indonesia. It rains a lot there. The ore is wet. It is sticky. Old machine got blocked. Mud filled the chamber. Production stopped. Workers had to clean it. It was dangerous.

  We changed the design. We used ZENITH European Jaw Crusher. It has deep cavity. We adjusted the throw. We made speed faster. The material moves quick. It does not stick. We also used water spray. It washes mud away.

  The Result:

  No more blocking. Output went up 40%. The profit went up. The maintenance time went down. Workers are safer. The client bought second line. This proves quality.

• Why Does Liner Wear Happen so Fast?

  This is a big pain point. Users ask this often. Lead zinc has silica. Silica is hard. It scratches steel. It cuts like knife. Standard steel is soft. It wears out in weeks. You change parts often. You stop production.

  The Solution:

  Use Mn18Cr2 steel. This is high manganese. It has chrome too. Chrome is hard. Manganese is tough. Together they fight wear. They last 1.5 times longer. Also check the feed. Feed must be center. If feed is side wear is uneven. Center feed uses all metal. It is efficient.

• How to Lower Energy Cost?

  Energy is expensive. Crushers use big motors. 200kw. 400kw. It costs much money. Bosses worry about bills. High amp spikes are bad. They hurt the grid.

  The Solution:

  Match the motor right. Don’t use too big. Don’t use too small. Use soft starter. It starts motor slow. No big spike. Also keep chamber full. A full chamber is better. It crushes rock on rock. This is free crushing. We call it “choke feed”. Try to keep it full. Efficiency jumps up.

• Why is the Output Size Too Big?

  Sometimes stones come out big. They are flakes. Flat stones. These are bad. Ball mill hates them. They float inside. They don’t grind.

  The Solution:

  Check the CSS. It might be too big. Close it tight. Also check the liner profile. If liner is worn gap changes. You must calibrate often. Measure the gap. Adjust the hydraulic. ZENITH crushers have auto adjust. You push button. It sets gap. Very easy. No tools needed.

• Installation and Maintenance Tips

  Installation is the base. If base is bad machine shakes. Shaking breaks bolts. You must use concrete. Make it level. Use a spirit level. Check it twice. Tighten anchor bolts. Use a torque wrench. Do not guess.

  For maintenance make a schedule. Check oil every day. Oil is blood of machine. If oil is dirty bearing dies. Change filter often. Listen to the sound. Good machine hums. Bad machine knocks. If it knocks stop it. Check inside. Safety first.

  Spare parts are vital. Keep them in stock. Keep toggle plate. Keep liners. Don’t wait for break. Order early. Shipping takes time. Downtime is lost money. Be smart. Plan ahead.

Here is another data chart. It shows power use.

• Investment and Returns

  Buying cheap is tempting. But cheap is expensive later. Cheap machine breaks. Repairs cost money. Lost time costs more. Good machine costs more now. But it runs long. It runs 10 years. It runs 20 years. The value is high.

  Think about ROI. Return on Investment. If machine runs every day you make money. If machine stops you bleed money. ZENITH machines run. They are reliable. The resale value is also good. People want used ZENITH. It holds value.

• Common Questions (FAQ)

  Q1: Can I crush wet ore?

  A: Yes you can. But be careful. Use jaw crusher. Do not use impact crusher. Impact crusher gets clogged. Jaw is better. Keep output open.

  Q2: How often to grease bearings?

  A: Depends on work hours. Usually every 8 hours. Add a little. Do not overfill. Too much grease causes heat. Heat kills bearing. Just right amount.

  Q3: Is dust a problem?

  A: Yes dust is bad. It hurts lungs. It hurts machine. Use water spray. Or use dust collector. Bag filter is good. Keep air clean. Workers will be happy.

• Conclusion and Suggestion

  To finish up. Lead zinc needs strong tools. Do not use soft stone crusher. It will fail. Use heavy duty. Use Jaw and Cone combo. This is standard. It works.

  Check your ore grade. Check your budget. Talk to experts. We at ZENITH help you. We design flow chart. We give layout. We train workers. We are partners. Not just sellers. Good luck with your mine.

Mining is a journey, It is tough but rewarding. With right gear you win. The earth gives treasure. We help you take it. Efficiently and safely. Trust the science. Trust the data. Make the right choice today.