Tracked Cone Crusher for Sale

What Exactly is a Tracked Cone Crusher? Coarse or Fine Work in a Mobile Crushing Plant?

A Tracked Cone Crusher is a Cone Crusher – a compression-type crusher that breaks rock between a gyrating mantle and a stationary concave (bowl liner) – mounted on a tracked chassis with integrated power, feeding, and conveying systems. In a mobile crushing and screening plant, it primarily handles secondary, tertiary, or even quaternary (fine) crushing tasks, excelling at processing hard, abrasive materials and producing well-shaped aggregates.

Compared to Tracked Jaws or Impacts, What “Tough Stuff” Does a Tracked Cone Crusher Handle?

Tracked Cone Crushers are specifically designed to tackle hard, abrasive, and tough materials that would quickly wear out an impact crusher or be beyond the optimal reduction range of a primary jaw crusher in secondary/tertiary stages. 

Crusher Type	Primary Application & Material Strength	Product Shape	Key Advantage for “Tough Stuff”
Tracked Jaw Crusher	Primary Crushing, all rock types, large feed sizes	Angular	Handles oversized, hard feed
Tracked Impact Crusher	Secondary/tertiary, medium-soft to medium-hard, C&D waste, shaping	Excellent (cubical)	Superior shaping, but high wear on very hard/abrasive rock
Tracked Cone Crusher	Secondary/tertiary/quaternary, hard to very hard, abrasive materials	Good to Excellent (cubical)	Efficiently crushes hard/abrasive rock with manageable wear

A Tracked Cone Crusher is your go-to when dealing with materials like granite, basalt, gabbro, hard river stone, and abrasive ores. It excels where impact crushers would suffer excessive wear costs and where jaw crushers have reached their limit in terms of product size reduction.

What are the Real Benefits of “Tracked Mobility” for a Cone Crusher? Especially in Which Conditions?

Tracked mobility offers significant benefits: rapid setup and relocation, reduced civil engineering costs, ability to follow the quarry face, and easier integration into multi-stage mobile crushing trains. This is especially valuable in:

• Multi-stage crushing circuits: Allowing flexible plant layouts.

• Contract crushing operations: Moving between sites frequently.

• Quarries with advancing faces: Minimizing haulage distances.

• Remote or temporary sites: Where fixed plant installation is impractical.
• Reduced Setup Time: No need for extensive concrete foundations. Drive it in, level it, connect, and start crushing.
• Lower Site Preparation Costs: Minimal civil works compared to stationary plants.
• Operational Flexibility: Easily reposition the crusher to optimize material flow or adapt to changing quarry plans. For instance, as the quarry face moves, the Tracked Cone Crusher can move with it, reducing the need for long hauls by trucks or conveyors.
• Improved Safety: Remote control operation for tracking and some functions reduces operator exposure to hazardous areas.

How Large a Rock Can a Tracked Cone Crusher “Eat”? How to Match Its Feed Opening to My Jaw Crusher’s Output?

Tracked Cone Crushers typically accept feed sizes ranging from approximately 40mm up to 250mm (or more for larger models), depending on the specific crusher size and chamber configuration (coarse, medium, fine). To match your jaw crusher’s output, ensure the P80 (80% passing size) of the jaw crusher product is comfortably smaller than the cone crusher’s maximum recommended feed size for the selected chamber.

• Maximum Feed Size: This is dictated by the “gape” or feed opening of the cone crusher. It’s crucial not to overfeed a cone crusher with oversized material, as this can lead to bridging (material blocking the feed opening), excessive stress on components, and poor crushing performance.
• Matching with Primary Crusher:
  • The output from your Jaw Crusher (primary stage) becomes the feed for your Tracked Cone Crusher (secondary stage).
  • Rule of Thumb: The cone crusher’s maximum feed size should generally be at least 1.2 to 1.5 times the P80 size from the jaw crusher.
  • Consider a Scalping Screen: Often, a screen (sometimes integrated as a pre-screen on the tracked cone is placed between the jaw and cone to remove fines that are already to spec, or undersized material that doesn’t need to go through the cone. This improves efficiency and reduces wear.

How Fine Can It Crush Hard Rock? Product Shape? Can It Make Manufactured Sand?

Tracked Cone Crushers can crush hard rock down to very fine sizes, typically producing products from 5mm to 50mm, depending on the CSS (Closed Side Setting) and chamber type. They are renowned for producing good to excellent cubical product shape, especially when choke-fed. Yes, certain cone crusher models, particularly those with fine or extra-fine chambers and optimized settings, can produce manufactured sand (0-5mm).

• Fineness of Crushing: Achieved by adjusting the CSS – the narrowest gap between the mantle and concave at the discharge point. Smaller CSS = finer product.
• Product Shape (Cubicity):
  • Choke Feeding : Keeping the crushing chamber full (“choke-fed”) promotes interparticle crushing (rock-on-rock), which significantly improves cubicity and minimizes liner wear. This is a critical operating principle for cone crushers.
  • Proper Chamber Selection : The right chamber for the feed material and desired product is crucial.
• Manufactured Sand Production:
  • Modern high-speed cone crushers with specialized fine or “sand” chambers can effectively produce high-quality manufactured sand.
  • Often combined with a VSI (Vertical Shaft Impactor) or a dedicated Sand Making Machine in a tertiary or quaternary stage for optimal sand shaping if very high cubicity is required.

The Dreaded Liner Wear (Concave & Mantle): How Long Does a Set Last? How to Extend Life?

Liner (concave/mantle) wear is a significant operating cost. Lifespan varies dramatically – from a few hundred to several thousand hours – depending on rock abrasiveness, hardness, feed conditions, CSS, and operating practices. To extend life: maintain choke feed, use correct CSS, select appropriate liner material/profile , ensure proper lubrication , and remove fines before feeding.

Factors Influencing Wear:

• Material Abrasiveness (SiO2 content): The higher the silica content, the faster the wear.

• Material Hardness & Toughness.

• Feed Size and Gradation: Consistent, properly sized feed reduces localized wear.

• Operating Practices: Choke feeding is paramount. Non-choke feeding leads to point impact and accelerated wear.

• Liner Material and Profile : High manganese steel is common, but its grade and heat treatment matter. The profile (shape) of the liners must match the application.

• CSS Setting : Too tight a CSS for a given chamber can increase wear.

Extending Liner Life:

• Maximize Choke Feed: Use level sensors and automated feed control.

• Pre-Screening : Remove fines and soil; they are abrasive and don’t need to go through the cone.

• Correct CSS Adjustment: Regularly monitor and adjust CSS as liners wear. Some advanced units have automatic CSS adjustment.

• Tramp Iron Removal: Prevent uncrushables from entering.

• Regular Inspection: Monitor wear patterns and rotate/flip liners if design allows (less common with cones than impactors).

• Proper Lubrication : Ensures smooth operation and prevents heat buildup that can affect liner seating and integrity.

Different Chamber Types (Coarse/Medium/Fine): Impact on Throughput & Liner Wear? How to Choose?

Chamber types (e.g., Extra Coarse, Coarse, Medium, Fine, Extra Fine) are designed for specific feed sizes and product requirements. Coarser chambers accept larger feed and have higher throughput for a given CSS but produce coarser products. Finer chambers accept smaller feed, produce finer products, but typically have lower throughput for a very tight CSS and may experience higher wear rates if not fed correctly. Choosing depends on your feed material size, desired product size, and overall plant balance.

Chamber Type	Typical Feed Size	Typical Product Size	Throughput Potential (for given CSS)	Wear Characteristics
Coarse	Larger	Coarser	Higher	Generally good if choke-fed
Medium	Medium	Medium	Moderate	Balanced wear if operated correctly
Fine	Smaller	Finer	Lower (especially at tight CSS)	Can be higher if not choke-fed or if CSS is too tight

Uneven Feed or Tramp Iron: Will the Cone Crusher “Strike” or Get Damaged? Protection Measures?

uneven feed can lead to poor performance and accelerated, uneven liner wear. Tramp iron (uncrushable metal objects) can cause significant damage. Modern Tracked Cone Crushers have sophisticated protection systems: hydraulic overload protection (allowing the bowl to lift and pass tramp iron) and hydraulic clearing of a choked or stalled crusher.

• Uneven Feed Issues:
  • Difficulty maintaining choke feed.
  • Increased point loading on liners.
  • Poor product shape.
  • Potential for off-center loading and stress on bearings/shaft.
  • Solution: Good Vibrating Feeder control, proper surge pile management, and level sensors in the feed hopper.
• Tramp Iron Protection :
  • Hydraulic Overload Release: If an uncrushable object enters, a hydraulic system allows the upper frame/bowl to lift temporarily, increasing the CSS to let the object pass. The system then automatically returns to the set CSS.
  • Hydraulic Clearing: If the crusher stalls due to a blockage, hydraulics can be used to open the CSS wide or even lift the upper frame to clear the chamber.
  • First Line of Defense: Despite these systems, upstream magnetic separators (Magnetic Separator) and vigilant operators are crucial to prevent tramp iron from reaching the cone crusher. Frequent activation of the overload system still puts stress on the machine.

Actual Hourly Throughput (Tons/Hour) of a Tracked Cone Crusher? What Factors Influence It?

Actual throughput varies widely based on crusher size, chamber type, CSS, material hardness, abrasiveness, moisture content, feed gradation, and operational efficiency (e.g., choke feeding). It can range from under 100 tph for smaller units to over 500 tph for large ones. Manufacturer ratings are typically for optimal conditions and specific materials.

• Key Influencing Factors:
  • Crusher Size (Head Diameter): Larger crushers generally have higher capacity.
  • CSS (Closed Side Setting): Tighter CSS = lower throughput (but finer product).
  • Chamber Type: Coarser chambers usually have higher throughput for a given CSS.
  • Material Characteristics:
    • Hardness & Compressive Strength: Harder rock reduces throughput.
    • Abrasiveness: Doesn’t directly reduce throughput much but increases wear costs.
    • Moisture & Clay Content : High moisture/clay can cause packing and reduce flow, especially in fine crushing chambers. Pre-screening is vital here.
    • Bulk Density.
    • Feed Gradation: Well-graded feed without excessive fines or oversized material optimizes capacity.
  • Operational Efficiency: Consistent choke feed, minimal downtime.
  • Power Availability: Crusher must have adequate motor power.

How to Perfectly Pair a Tracked Cone Crusher with a Mobile Screening Plant for Spec Product?

Perfect pairing involves matching the cone crusher’s output capacity and product size distribution with the Tracked Mobile Screening Plant‘s screening area, screen media, and throughput capabilities. Often, a closed-circuit system is used where oversized material from the screen is recirculated back to the cone crusher for further reduction. This ensures maximum production of spec-compliant material.

• Closed-Circuit Operation:
  1. Material from the cone crusher feeds the mobile screen.
  2. The screen separates material into different sized products.
  3. Oversized material (larger than the desired top size) is conveyed back to the cone crusher’s feed hopper.
     This maximizes yield and improves product shape due to multiple passes.
• Key Considerations for Pairing:
  • Capacity Matching: The screen must handle the cone’s output. If the screen is undersized, it becomes a bottleneck.
  • Screen Media Selection: Aperture sizes and types of screen media (e.g., wire mesh, polyurethane) must match the desired products and material characteristics.
  • Conveyor Capacities: Ensure transfer conveyors can handle the material flow.
  • Plant Layout: Minimize transfer distances and drops.
  • Automation: Integrated control systems can optimize flow between the crusher and screen.

Buying a Tracked Cone Crusher: Beyond Price, What Technical Parameters & Configurations are “King”?

It is generally considered that operating and maintaining a mobile cone crusher is more complex and demandiBeyond price, “king” factors include: crusher design and size (head diameter, power), chamber/liner options , CSS adjustment mechanism (hydraulic, automation), lubrication and hydraulic system quality , tramp iron protection system , pre-screen effectiveness , intelligent controls and telematics , chassis durability , and crucially, manufacturer support and parts availability.ng than for a mobile jaw or impact crusher. This is mainly because its structure is more precise, featuring more sophisticated hydraulic systems, lubrication systems, and automation controls.

Key Parameter/Configuration	Why It’s “King”	Your Benefit from a Good Choice
Crusher Size & Power	Determines base throughput potential and ability to handle tough rock.	Meets production targets, avoids underpowering.
Chamber/Liner Selection	Critical for product quality, throughput, and wear life. Variety of options for different applications.	Optimized performance, better product shape, lower wear costs.
CSS Adjustment	Hydraulic adjustment is standard. Automated CSS control maintains product consistency and optimizes performance as liners wear.	Easy and precise product size control, consistent output, optimized liner usage.
Lubrication System	The “lifeblood” of a cone crusher. Needs robust filtration, cooling, and monitoring.	Prevents catastrophic failures (bearings, bushings), extends component life, reduces downtime.
Tramp Iron Protection	Essential for protecting against uncrushable objects. Effectiveness of release and reset.	Prevents major damage, reduces downtime and costly repairs.
Pre-Screen Unit	Removes fines/soil before crushing. Size and efficiency matter.	Increases cone capacity, reduces liner wear, improves product quality (less contamination).
Intelligent Controls	PLC-based systems for load sensing, automated adjustments, diagnostics, telematics.	Optimized performance, proactive maintenance, higher uptime, better operational insights.
Chassis & Track System	Durability to withstand crushing forces and travel stresses. Ease of maintenance for tracks.	Long machine life, reliable mobility, lower undercarriage maintenance costs.
Environmental Adapt.	Suitability for extreme cold/heat, high altitude. Proper cooling, heating options.	Reliable operation in diverse climates, prevents environment-related failures.
Manufacturer Support & Parts	Availability of technical support, training, and genuine spare parts. Service network.	Minimizes downtime, ensures correct maintenance, protects investment.