crushing equipments
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WELCOME TO
TRAINING PROGRAMME ON
‘MATERIAL HANDLING’ DURING
17TH – 18TH DECEMBER, 2013 AT
SAIL / CET , RANCHION
BY B.K.BISOYI
MANAGER (MECH.)SAIL/CET, RANCHI
THE TECHNOLOGY OF CRUSHING
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Crushing is the reduction of large rocks into smaller rocks by
Impact
Attrition
Shear
Compression
THE TECHNOLOGY OF CRUSHING
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When a material is compressed/sheared/attrition, it will break from the weakest zone.
Weakest zones
What is a Crusher ?
A crusher is a machine designed to reduce large rocks into smaller rocks by compression/attrition/shear/impact.
CLASSIFICATION OF CRUSHERS(BASED ON TYPE OF CRUSHING)
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COMPRESSIVE CRUSHERS IMPACT CRUSHERS (Compress the material until it breaks) (Principle of quick impact to crush the material)
JAW CRUSHERS IMPACTORS
CONE CRUSHERS HAMMER MILLS
GYRATORY CRUSHERS
ROLLER CRUSHERS
CRUSHERS
CLASSIFICATION OF CRUSHERS (BASED ON SIZE OF CRUSHING)
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TERTIARY/ FINE CRUSHERS
CRUSHERS
QUATERNARY / FINE
CRUSHERS
JAW CRUSHERS
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Mainly used as primary crushers
Produce materials that can be transported by belt conveyors to the next crushing stage.
Capacity: Upto 1600 tphPrinciple of operation:
The crushing process takes place between a fixed jaw and a moving jaw
Intermittent process
Hydraulic setting adjustment
Liner platesManganese steel, Ni-cr alloyed CI
JAW CRUSHER IS A RELIABLE, ROBUST EQUIPMENT AND IS QUITE POPULAR IN PRIMARY CRUSHING APPLICATIONS.
BETTER RETURN ON INVESTMENT.
CONE CRUSHERS
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Principle of operation:The material is crushed in a crushing cavity between an external fixed element(bowl liner) and internal moving element (mantle) mounted on the oscillating shaft assembly.
An eccentric shaft rotated by a gear and pinion produces the oscillating movement of the main shaft.
The fragmentation of materials results from the continuous compression that takes place between the mantle liners and bowl liners in the chamber.
Mainly used as intermediate or fine crushing to obtain a product with good uniform shape
Capacity: Upto 1200 tph
BOWL WITH LINER
MANTLE WITH LINER
CSSOSS
CONE CRUSHERS Contd…
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Adjustment of OSS/CSS:
The settings can be adjusted by
Rotating the bowl against the threads so that the vertical position of the outer wear part is changed.
•Time consuming but uniform wear & tear of liners
By lifting and lowering the main shaft
•Adjustment can be done continuously under load.
Principle of operation:
The eccentricity causes the cone head to oscillate between OSS and CSS discharge opening.
The eccentricity is one of the major factors which determine the capacity of the cone crushers.
Higher capacity in secondary crushing with
low operating cost
TERTIARY CONE CRUSHER OF M/s HEC FOR MIOM – VARIOUS COMPONENTS UNDER MFG.
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MAIN FRAME
PINION
RING GEAR
DRIVE SHAFT
Capacity 500 tphFeed Size: (+)30 to (-)75 mmOutput: 30 mm
TERTIARY CONE CRUSHERS OF M/s HEC FOR MIOM – VARIOUS COMPONENTS UNDER MFG.
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ECCENTRIC SHAFT HOUSING
ADJUSTMENT RING ASSEMBLY
GEAR ASSEMBLY
CONE CONE
MAIN SHAFT
GYRATORY CRUSHERS
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Efficient primary crushing in mining application.
Crushing chamber designed to accept feed materials of relatively larger size.
Capacity: 100 tph-9000tph
Principle of operation:
Same as cone crusher.
Provides much larger feed area than a jaw crusher
Taller, heavier with massive foundation
Adjustment of closed side settings(CSS):
Equipped with a hydraulic setting adjustment, which adjust CSS and thus have better productivity.
ROLLER CRUSHERS
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Purpose:Mainly for crushing easily fractured materials such as soft limestone, chalk and clay.
Reduction ratio - 3:1 to 5:1
Principle of operation:The roller crushers consists of two rollers. One of the roller shafts is adjustable while the other has a fixed position and is provided with a flywheel.
The gap between the two rollers can be varied depending upon the degree of crushing required.
Rollers have scrapers to remove any material sticking to the surface.
IMPACT CRUSHERS
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Purpose Generation of fine materials e.g. Sand.Liberate hard minerals from waste materialsHigh reduction ratio and cube shaped product.Capacity: Upto 1800tph
Principle of operationThe feed material is crushed in the quick rotational movement of hammers/bars fixed to the rotor .
The particles produced are then further crushed inside the crusher as they collide against crusher parts and against each other, producing a finer, better-shaped product.
HAMMERS/ BARS
HIGHER CAPACITY, CUBICAL PRODUCT & GENERATION OF
FINES IS NOT A PROBLEM
NOT RECOMMENDED FOR CRUSHING TOO FINES MATERIALS
VERTICAL SHAFT IMPACT CRUSHER
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Vertical shaft impactor
The vertical shaft impactor is like a “stone pump” which operates like a centrifugal pump.
The material is fed through the center of the rotor, where it is accelerated to high speed before being discharged through the openings in the rotor periphery.
The material is crushed as it hits on the outer body and also due to the rock-on-rock action.
Used for generation of fines e.g. Sand, gravel etc. VERTICAL SHAFT
IMPACTOR
HAMMER MILLS
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PurposeTo grind and pulverise materials that are not too hard or abrasive.
Principle of operation:
Similar to impactors
The hammer mill rotor has many pivoted hammers attached to it and the discharge opening consists of a grate through which the material has to pass, thus contributing to the reduction process.
The rotor speed and the grate spacing can be optimised to suit different applications.
FACTORS AFFECTING THE SELECTION OF CRUSHERS
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Purpose of crushing (Primary / Secondary / Tertiary / Quaternary)
Location (Fixed /Mobile)
Type of material (Hard /Soft/Medium)
Abrasiveness (Abrasive/Non Abrasive)
Feed size of materials (Larger/Smaller/Medium)
Capacity of crusher (Higher /Medium / Lower)
Reduction ratio (Higher /Medium / Lower)
Product Size (Fines /Coarse)
Operation & Maintenance aspects
Other Economic aspects
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Crusher type
Typical Process Stage
Feed Size upto (mm)
Typical maximum
End Product size (mm)
Reduction Ratio
Typical Capacity
(tph)
Amount of Fines
Produced
Hardness of material
Abrasiveness
Moisture content Application
Jaw crushers
Primary 1400 200-300 3:1 to 5:1 Upto 1600 Low Soft to very hard
HighDry to slightly wet, not sticky
Heavy mining
Gyratory crushers
Primary 1500 200-300 4:1 to 7:1 > 1200 LowSoft to
very hardHigh
Dry to slightly wet, not sticky
Heavy mining
Cone crushers
Secondary 450 60-80 3:1 to 5:1 Upto 1200 Low
Medium hard to
very hard
Low /High
Dry or wet, not sticky
Mining, Quarried
materials, Sand & gravel
Tertiary / Quaternary
300 0-30 3:1 to 5:1 Upto 1000 Low / Medium
Horizontal shaft
impactors
Primary / secondary
1300 200-300 10:1 to 25:1
Upto 1800 Medium / High Soft to
medium hard
LowDry or wet, not
sticky
Quarried materials, sand
& gravel, recycling
Vertical shaft
impactors
Tertiary 40 0-30 6:1 to 8:1 Upto 600 HighMedium hard to
very hardLow
Dry or wet, not sticky
Sand & gravel, recycling
Roller Crusher
Primary Fines Fines 3:1 to 5:1 Upto 500 HighSoft Low Dry or wet
crushing of easily fractured
materials
SELECTION OF CRUSHERS
COMPARISION OF TYPES OF CRUSHERS
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Characteristics Jaw crusher Gyratory crusher Cone Crusher
Type Primary Crushing Primary CrushingSecondary / Tertiary /
QuaternaryCapacity Lesser
(≤ 1600 tph)
Higher
(1000-9000 tph)
Medium
(≤ 1200 tph)
Work Intermittently Continuously Continuously
Reduction Ratio 3:1 to 5:1 4:1 to 7:13:1 to 5:1
Weight of Equipment Medium Heavy Medium
Crushing Surface Jaw Platescrushing surface flares in
from top to bottomcrushing surface flares in
from bottom to top
Feed OpeningLarger /Medium feed
openingLarger feed opening Smaller feed opening
Principle of operation
Compression Gyration Gyration
Operating Cost Medium High Economical
Relative merits/demerits
Chances of passage of material without
crushing
No chance of passage of material without crushing
No chance of passage of material without crushing
CRUSHER – SPECIFIC POWER CONSUMPTION (TYPICAL)
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Type of crusher Specific Power Consumption (kWhr/t)
Gyratory Crusher 0.1 to 0.2
Jaw Crusher 0.4 to 0.6
Cone Crusher 0.4 to 0.6
Impactor Crusher 1 to 1.2
CRUSHER - SPECIFICATION
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Sl. No. Description Specification
1 TYPE OF CRUSHER JAW / GYRATORY /CONE
2 Quantity (No.) 1
3 Rated Capacity (tph) 1000
4 Design Capacity (tph) 1300
5 ROM Dimensions(mm x mm x mm)
1200x1000x1000
6 Material to be handled Direct Ore and Beneficiable ore
7 Crusher Feed F100 (mm) 1000
8 Crusher Feed F80 (mm) 600
9 Crusher Product P100 (mm) 288
10 Crusher Product P80 (mm) 134
11 Bulk Density (t/m3) 2.2
12 Crushing Work Index (kWh/t) 11
CRUSHER - PERFORMANCE
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The performance of a crusher depends upon the right choice & correct operation of associated equipments such as feeders, conveyors, screens, drives, silos etc.
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