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KMC Global companies have the advantages of shared engineering, industry experience, manufacturing capacity, and complimentary pricing structures. This accelerates development of material handling and processing systems that deliver unmatched performance and efficiencies to customers.

Triple/S Dynamics CDM Systems Kalamazoo FabricatingHapman O’Vibra EnvirodynePrab STC

The operating stages in mineral processing have remained the same for thousands of years.

Crushing and screening is the first controlledsize-reduction stage in the processing of industrial minerals.

More often than not, size reduction of the raw material is done in stages and the

material is crushed several times

JAW CRUSHER GYRATORY CRUSHER CONE CRUSHER IMPACT CRUSHER

Typical 3-Stage Crushing Primary/Secondary/Tertiary

Primary Circuit:This is the first crusher in the circuit. It is designed to reduce the largest particle size received at the highest capacity.

Secondary Circuit:This is the second stage crusher which typically has a primary function of reducing the material for the next stage of crushing.

Tertiary Circuit:This is the third stage in crushing. Because gradations are finer at this stage, the crusher must be more accurate to settings and screens must be capable of finer screening.

Screens are used at each step to separate the undersized material fromthe oversized material

Size reduction below 5-20 mm moves into a different category of size reduction referred

to as the grinding stage. Grinding is the pulverizing or powdering of a mineral.

Quaternary Circuit:This is the 4th stage of crushing. At this stage, the type of crushers

used in the previous three stages give way to grinding mills. Examples of this type of mill includes air-swept roller mills,

hammer-mills, and various types of ball mills

Crushing of the material over and over can result in too many fines for

certain types of grinding mills.

Roller mills are

considered the

industry standard

for mineral processing

• Soft to medium hard minerals (typically 5 or less on Mohs scale)

• Typical feed size range of ¼” minus to 1” minus

• Typical product range of 325 mesh to 100 mesh

WAYS TO INCREASE ROLLER MILL CAPACITY

•Improve air classification efficiency (vertical blade over whizzer)

•Improve feed control system (keep mill under a constant load)

•Reduce number of rolls in mill (only an option if you have even number of rolls)

•Increase air flow (if out of fan rpm’s, tipping fan blades may be an option)

•Reduce amount of fines in roller mill feed

The MAX3 ScreenerMAXimum Capacity/MAXimum Efficiency/MAXimum Performance

How to cost-effectively reduce the amount of fines in your feed?

APPLICATION

•Grinding Mill – Air-swept Roller Mill•Material – Soft Mineral•Product Spec – 97% minus 200 mesh•Current Capacity – 20 TPH

Existing Problem

•Needed 25% more production from mill•Already have vertical blade high efficiency classifier•Already have adequate feed controller•Fan is already sized correctly•Mill is a 5 roll (odd number of rolls)

SOLUTION

•Remove existing 20 percent of minus 200 mesh from feed

•Install a MAX3 Fine Mesh Screener ahead of roller mill

•Increase material flow in circuit from 20 to 26 TPH

•MAX3 screens out 4 TPH of finished product before it goes to roller mill

•Roller mill production is increased (minus fines) from 20 to 22 TPH

•Net result - Increased circuit production by 6 TPH (30 percent)

Economic Viability

8,760 Operating hours in a year

80% run time –7,008 hours a year

19.2 operating hours per day

Production Increase of 6 tons per hour

Simple ROI = Amount of Financial Gain Total Investment Amount

ROI Analysis – Total cost vs. benefit analysis

Direct Costs

Direct – One Time Expenses Costs

1) Testing (travel/expenses) 2) Engineering (40 hrs. @ $125/hr)3) Procurement (8 hrs. @ $50/hr.)4) Equipment - MAX3 Screener5) Additional Equipment needed 6) Shipping (all equipment)7) Installation Cost (all equipment incl. modifications)8) Start-Up Assistance (travel/expenses)

TOTAL COST

$1,200.00$5,000.00 $400.00

$40,000.00 $17,000.00 $5,800.00

$59,500.00$1,500.00

$130,400.00

Increased Capacity Increased Revenue6 Tons Per Hour $1,800.00 Per Hour115.2 Tons Per Day $34,560.00 Per Day3,504 Tons Per Month $1,051,200.00 Per Month42,048 Tons Per Year $12,614,400.00 Per Year

PRODUCT VALUE- $300/TON

$130,400.00 (Equipment Cost)$34,560.00 (Revenue Increase Per Day)$130,400.00 / $34,560.00 = 3.77 days

Hypothetical APPLICATION

•Grinding Mill – Air-swept Roller Mill•Material – Soft Mineral•Product Spec – 90% minus 100 mesh•Current Capacity – 30 TPH

Existing Problem

•Need more production from mill•Already have vertical blade high efficiency classifier•Already have adequate feed controller•Fan is already maxed out•Mill is a 5 roll (odd number of rolls)

Hypothetical ROI Analysis

Projected Costs

Direct – One Time Expenses Costs

1) Testing (travel/expenses) 2) Engineering (40 hrs. @ $125/hr)3) Procurement (8 hrs. @ $50/hr.)4) Equipment – MAX35) Additional Equipment needed 6) Shipping (all equipment)7) Insallation Costs (all equipment incl. modifications) 8) Start-Up Assistance (travel/expenses)

TOTAL COST

$1,200.00$5,000.00 $400.00

$55,000.00 $17,000.00

$5,800.00 $59,500.00

$1,500.00

$145,400.00

Increased Capacity Increased Revenue3 Tons Per Hour $240.00 Per Hour57.6 Tons Per Day $4,608.00 Per Day1,752 Tons Per Month $140,160.00 Per Month21,024 Tons Per Year $1,681,920.00 Per Year

PRODUCT VALUE- $80/TON

$145,400.00 (Equipment Cost)$4,608.00 (Revenue Increase Per Day)$145,400.00 / $4,608.00 = 31.55 days

Efficient fine size reduction which is often aided through efficient size separation is one of the most effective investments to reduce cost per ton and increase revenue.

Thank you for attending our presentation.