The importance of hopper - intermediate feeder in stone crushing and screening line

In the field of mining and mineral processing, optimizing product performance and quality is always the top goal. One of the important factors that helps ensure optimal operating performance of the production line crushing and screening is the intermediate hopper - feeder. This device not only helps increase the stability of the line but also overcomes the inherent disadvantages of each type of crusher, especially cone crusher.

1. Concept of intermediate hopper – feeder

The intermediate hopper – feeder (also known as the intermediate hopper, material extraction tunnel) is an integrated device between a hopper and a vibrating feeder. The hopper capacity can vary according to usage needs, from a few dozen m³ to thousands of m³. This device is designed to:

• Collect and stock up on raw materials from previous stages.
• Continuous and stable feeding to the crushers in the next stage, ensuring smooth operation of the entire line.

Intermediate funnels are often integrated with feeder vibrating plate feeder or vibrating plate feeder, controlled by inverter to optimize material withdrawal speed. This is an indispensable part of modern stone crushing lines.

2. Why is the intermediate feed hopper important to a cone crusher?

2.1. Overcoming the disadvantages of cone crusher

Cone crusher is a popular equipment in Stone crushing line thanks to its high efficiency, long life, and ability to process rocks with high hardness. However, the biggest disadvantage of the cone crusher is the flatness of the product (uneven rock particles, lack of aesthetics and difficult to apply in high-demand construction projects).

The intermediate funnel helps overcome this disadvantage by:

• Provide stable, continuous, and uniform material supply to cone crusher.
• Optimize the grinding process, minimize flattening, help improve the quality of finished stone.
• Minimize material consumption (crushing cone, crushing jaw) by maintaining stable load on the machine.

2.2. Increase the operating efficiency of the production line

The intermediate funnel acts as a “buffer” between grinding stages, allowing for more flexible system operation:

• Load balancing between stages: When the crusher in the previous stage stops working (due to maintenance or failure), the intermediate hopper can still supply material to the next stage, preventing the line from being completely interrupted.
• Increased continuity: Especially important when connecting between a jaw crusher (primary) and a cone crusher (secondary), or between a cone crusher and VSI crusher (third). This ensures stable output, reducing machine downtime.

3. Advantages and disadvantages of intermediate hopper - feeder

Advantage

1. Stable and continuous feeding
   • The intermediate hopper ensures that the downstream crusher always operates at peak efficiency, which is especially important for cone crushers. When the cone crusher is fed stably, it will:
     • Reduces product flatness.
     • Reduce material consumption.
     • Maintain consistent output stone quality.
2. Increase flexibility of the chain
   • Enables stages in the chain to operate independently when needed.
   • Allows maintenance or repair of part of the line without interrupting the entire system.
3. Section save operating costs long term
   • Maintains mill performance at peak levels, thereby reducing material consumption and maintenance costs.

Disadvantages

1. Increased initial investment costs
   • Installing an intermediate hopper requires significant equipment costs, inverter control systems, and floor space. However, in the long run, this investment is highly cost-effective.
2. Increase installation area
   • Intermediate hoppers are often large in size, especially hoppers with a capacity of hundreds of m³, requiring large installation space.

4. Application of intermediate hopper - feeder in crushing and screening line

Intermediate feed hoppers can be used in many positions in the Stone crushing and screening line, depending on the specific requirements of the project:

4.1. Connection between primary and secondary stages

• Often used to connect jaw crusher (or primary crushing station) with cone crusher.
• In case of large raw material storage, the intermediate hopper can be replaced by an intermediate material dump.

4.2. Connection between secondary and tertiary stages

• Ensure continuous supply of materials to VSI crusher or impact crusher for production artificial sand.
• Helps control the size of input rock, avoiding overloading the crusher at the next stage.

4.3. Before each cone crusher or VSI

• Installing an intermediate hopper before a cone crusher or VSI is an effective solution to:
  • Maintains optimum grinding performance.
  • Reduces flatness and improves grain quality.

5. Factors to consider when designing and installing intermediate funnels

To maximize the effectiveness of the intermediate funnel, the following factors need to be noted:

1. Hopper capacity
   • Choose the capacity suitable for the production line capacity. If the hopper is too small, it cannot ensure continuous material supply. If the hopper is too large, it will waste investment costs and installation space.
2. Feeder type
   • Vibrating feeders or vibrating plates are popular choices, combined with frequency converters for flexible feeding speed adjustment.
3. Manufacturing materials
   • The hopper should be made from wear-resistant steel to ensure durability in harsh working environments.
4. Installation location
   • The hopper should be located in a location that ensures easy access for inspection, maintenance and operation.

6. Conclusion

The intermediate hopper is not only an auxiliary device but also an "important link" in stone crushing and screening lines. With the ability to improve product quality, optimize operating efficiency and increase line flexibility, intermediate hoppers are increasingly widely used in mining and mineral processing plants.

Enterprises in the field of stone mining, artificial sand production or construction materials should consider investing in intermediate hoppers and feeders to ensure long-term business efficiency, minimize operating costs, and meet strict market requirements.

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