Surge Storage Capacity in Crushing Circuit
We have commented Oil the influence of surge storage upon plant operation several times in the preceding discussions. The provision of adequate surge storage at the right places in the flow line is of sufficient importance to warrant a little further consideration.
It is desirable, in the crushing plant, as it is in any production process, to achieve a smooth and uninterrupted flow through the plant so that the reduction crushers and sizing screens will be operating at all times under uniform load conditions, and at full capacity. It is not always possible to feed the plant in this manner; a smooth flow of feed to the primary crusher is the exception, rather than the rule; therefore, if we are to smooth out the flow in the plant itself we must have elasticity in our flow line, and the logical way to obtain it is to provide surge storage ahead of each crushing stage.
We can, of course, get around this by providing enough crushing capacity to absorb the peaks, but this method is expensive; also it throws a variable load on the screens; and screens do not perform at maximum efficiency under such a load.
While the case for an ample surge storage is clear cut enough, the question of just what constitutes an adequate storage is not always an easy one to answer. It is difficult to visualize beforehand just how smoothly a projected scheme of quarry or pit operation is going to function, and impossible to forecast accidental delays in loading, transportation, and feeding. About all we can do is to rough out our plan of operation, and allow a comfortable margin for contingencies. For example, if it is calculated that one trainload of rock will be delivered to the plant each one-half hour, on the average, and our primary crusher has been chosen with a view to getting this train through in ten minutes, then we must, obviously, either provide stage crushing capacity to match the high capacity of the primary or, if we want to get the most work out of our investment dollar, set up a surge capacity in the plant to absorb the peak load and feed it through the plant steadily over the entire 30-minute cycle. That is the essence of the problem: to keep as many as possible of the plant units running under uniform load and at full capacity.
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