Secondaries/PCA Technicals Prep Questions and Answers | Latest Version | 2025/2026 | Correct & Verified

Secondaries/PCA Technicals Prep Questions and Answers | Latest Version | 2025/2026 | Correct & Verified What is the main role of a Process Control Assistant (PCA)? To monitor and support stable plant operations What does “secondary crushing” mean in mineral processing? Crushing material after primary crushing to reduce size further Why is secondary crushing important? To prepare material for milling or further processing What type of equipment is commonly used for secondary crushing? Cone crushers What is the main feed to a secondary crusher? Crushed material from the primary crusher Why must feed size be controlled in secondary crushing? To prevent blockages and equipment damage What happens if oversized rocks enter the secondary crusher? 2 Increased wear, blockages, or crusher failure What is a choke-fed crusher? A crusher kept full to improve efficiency Why is choke feeding preferred in cone crushers? It improves particle shape and crusher performance What is circulating load in crushing circuits? Material recycled back for further crushing Why is screen efficiency important in secondary circuits? It controls product size and crusher load What does a vibrating screen do? Separates material by size What is the purpose of a grizzly screen? To remove fines before crushing What does “P80” mean in size analysis? Size at which 80% of material passes 3 Why is consistent feed rate important? To maintain stable plant operation What instrument measures crusher power draw? Amp or kilowatt meter What does a sudden increase in power draw indicate? Possible blockage or high crusher load Why is liner wear monitored? To maintain product size and efficiency What happens when crusher liners are worn? Reduced crushing efficiency What is CSS in a cone crusher? Closed Side Setting Why is CSS adjustment important? It controls product size 4 What safety rule applies before entering crusher areas? Lock-out and tag-out procedures What is a major safety hazard around secondary crushers? Moving parts and falling rocks Why should spillage be controlled around crushers? To prevent slips and equipment damage What is the role of lubrication systems in crushers? To reduce wear and overheating What happens if lubrication fails? Equipment damage or seizure Why are conveyor belts used after secondary crushing? To transport crushed material What does belt tracking mean? Keeping the belt centered Why is belt misalignment dangerous?