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CRUSHING
by Jerome C . Motz
Primary Crushers
B a s i c a l l y , . f o r primary c r u s h i n g t h e r e a r e only t h r e e d i s t i n c t
t y p e s of c r u s h i n g equipment. These a r e t h e Jaw c r u s h e r s , Gyratory
c r u s h e r s and Impact c r u s h e r s , and t h e y each have t h e i r own d i s t i n c -
t i v e operating characteristics.
. .
The v e l 2 c i t y i s f i x e d by t h e p e r i p h e r a l spqed .of t h e 'rota=; there-
f o r e , p a r t i c l e s of a i n a t e r i a l with 'a common impact v a l u e - . w i l l break
according t o t h e i r i n i t i a l mass. A l a r g e p i e c e . w i l 1 r e c e i v e a
severe impact and w i l l break more r e a d i l y than a small one. h he .
l a t t e r receives only a l i g f i t impact and w i l l tend t o pass..through. .
with minimal f u r t h e r breakage. I f two m i t e r i a l s of d i f f e r e n t i&
p a c t value a r e fed t o a machine, even though they may be p a r t i c l e s .
of t h e same mass, one w i l l be reduced more than the o t h e r .
. CRUSHING 205
Capacities listed are average based on dry, free crushing rock at 100 Ibs.
per cubic foot. Tonnage will vary depending on size of feed, rate of
feed, operating conditions, breaking characteristics of the rock, type and
condition of crushing members (jaws),speed of crusher, and horsepower
available. Listed capacities may vary 525%.
Crusher cannot be operated economically where ratings are not specified.
MINERAL PROCESSING PLANT DESIGN
Table 2
JAWCRUSHERS GRADATION
OPEN CIRCUIT
Percent of Each Size i n the Produn of a Crusher
EXAMPLE: Jaw crusher fat 1X" with 15% reirculation - find 1%" at top and follow
down verticle column.
+1 112" -15% 718" to 314 .7% 318" t o 5 / 1 6 -4%
1 112 t o 1 114" -9% 314" to 518" -7% 5 / 1 6 t o 114" -5%
1 114" to 1" -11% 518" to 112" .8% 114" t o 4M -4%
1" t o 718" .6% 112" to 318" -6% 4M t o EM -6%
-8M -10%
TOTAL 10096
CRUSHING
Table 3B - pg. 2
. .
10 15 20 30 40 50 ,60 70 80 90 95 100
Percent Pasinng Screen
The abok prcduct gradations which represent lqusre screen opon~nglin inches yield the approia-
mate screen analymr and should bs used in conjunction with table-"A".
MINERAL PROCESSING PLANT DESIGN
Table 3B - pg. 3
PRIMARY CRUSHER PRODUCT
Table "B" - Percent Passing
The above product gradatmm whch reprsenf sq~are~szrben w n n n p r 10 tncher veld the approxi.
mate screen analyses and should W used an conjvnct~onwith,table " A .
' CRUSHING
Table 4 .
DY NAPACTORS Impact Crusher CAPACITY
DY NAPACTOR CAPACITY
. ,:
I n previous Gyratory machines t h e crushing process comprises. ;
Crushing Stages
Primary Crusher
P r e f e r r e d Reduction R a t i o - - 6 o r 8:l
MINERAL PROCESSING PLANT DESIGN
-
:
.. CRUSHING.,'.
I n s e l e c t i n g t h e c r u s h i n g c a v i t y , c a r e i s t a k e n t o o b t a i n a de-
s i g n t h a t w i l l p e r m i t t h e t o p s i z e of t h e f e e d t o e n t e r t h e c r u s h e r
i n s u f f i c i e n t volume throughout t h e e n t i r e wear l i f e of t h e l i n e r s .
S i n c e t h e most e f f i c i e n t c r u s h i n g a c t i o n t a k e s p l a c e when t h e f e e d
i s reduced i n a s e r i e s of f o u r o r f i v e b l o w s ' a s i t p a s s e s through
t h e c a v i t y , i t becomes i m p o r t a n t t o s e l e c t a d e s i g n t h a t w i l l e f f e c t
some r e d u c t i o n i n t h e upper p o r t i o n of t h e c a v i t y a s ' w e l l a s t h e
lower o r p a r a l l e l s i z i n g zone. I n o t h e r words, t o o l a r g e an opening
f o r t h e f e e d w i l l p r e v e n t c r u s h i n g i n t h e upper zones and can de-
v e l o p e x c e s s i v e power draw. S i n c e t h e c r u s h e r f e e d r a t e i s . b e s t
governed b y , t h e power -. d.r a w , an i n c o r r e c t ' c a v i t y can r e d u c e t h e
c r u s h e r c a p a c i t y and, on o c c a s i o n , . c r e a t e unnecessary maintenance.
On t h e o t h e r hand, ' i f t h e c a v i t y w i l l o n l y a c c e p t t h e . f e e d when t h e
l i n e r s a r e new, bhi' a s - t h e l i n e r s wear t h e f e e d opening c l o s e s o f f
r e d u c i n g t h e f e e d r a t e , a more e f f i c i e n t , c a v i t y i s r e q u i r e d . S i n c e
no two o r e s o r c r u s h i n g applications~'are.exactly t h e , s a m e , a l a r g e
number of c a v i t y d e s i g n s , h a v e become a v a * l a b l e through t h e y e a r s .
T h e r e f o r e , t h e optimum i n c a v i t y , d e s i g n . i s one which p e r m i t s c l o s e -
to-th.e-rated power draw throughout. t h e e n t i r e wear l i f e and , r e s u l t s
i n . a s s c r a p l o s s of-.between'.25 and 40 p e r c e n t , depending on c r u s h e r
t y p e and s i z e . ' .
'
.
, .. .
With t h e p r o p e r c a v i t y d e s i g n , maximum e f f i c i e n c y w i l l be o b t a i n e d
i f t h e f e e d i s e v e n l y d i s t r i b u t e d around t h e e n t i r e c r u s h i n g c a v i t y .
Normally, t h e wide f e e d s i z e range r e q u i r e d i n t h e Standard o r sec-
ondary c r u s h i n g s t a g e i s such t h a t t h e c r u s h i n g c a v i t y i s r e q u i r e d
t o have a r e c e i v i n g . o p e n i n g c o n s i d e r a b l y l a r g e r t h a n t h e a v e r a g e
p o r t i o n of t h e f e e d . For b e s t r e s u l t s , t h e f e e d should b e r e g u l a t e d
based on t h e c r u s h e r motor k i l o w a t t draw. When h a n d l i n g t h e h a r d e r
m a t e r i a l s , i t i s l i k e l y t h a t t h e c r u s h i n g c a v i t y i n t h e Standard
Cone c r u s h e r w i l l n o t b e e n t i r e l y f i l l e d up o r "choked". Depending
on t h e s i z e and t y p e of secondary c r u s h e r , normal k i l o w a t t . f l u c -
t u a t i o n s d u r i n g c r u s h i n g may approach:50 t o 70 k i l o w a t t , depehd,ing on
t h e f e e d a n a l y s i s ' and method of f e e d c o n t r o l . However, maximum
c a p a c i t y w i l l b e o b t a i n e d under t h e s e c o n d i t i o n s when c a v i t y d e s i g n
and proper f e e d d i s t r i b u t i o n methods a r e observed.
. . . . .
MINERAL PROCESSING PLANT DESIGN
I800
LTPH
7'SH. HD.
SYMONS M N E
:C S. SETTING
4- RE0
I LTPH 1163
LTPH /' 163
LTPH
1 1
1
/ SURGE PILE 1 . ' . / ?T5P"H
1 1 6 4 0 LTPH
*
8 0 % PASSING $TO h ? l U
The normal 1 0 t o 30 k i l o w a t t f l u c t u a t i o n s i n t h e t e r t i a r y p o s i t i o n
a r e much l e s s than those observed i n the secondary due t o b e t t e r
c o n t r o l of feed c o n s i s t and c o n t r o l .
SCREEN' ANALYSES
"CLOSED CIRCUIT"
These average table values will vary with the method of feeding, selection
of crusher cavity. the weight, cleanliness & moisture contents of the
material and its fracture pattern. Accurate values should be established
by actual testing.
Table 8A
CONE CRUSHER CAPACITY CHARTS
Cane crusher capacity charts ere developed f o r use as a n application t o o l t o p r o p e r l y u t i l i z e t h e
machine's capabilities when operated i n closed c i r c u i t . S y m o n r cone crurherr have 3 separate end
d i s t i n c t capacities (see diagrams o n f o l l o w i n g page). T h e difference betwean there is t h e p o i n t i n
t h e c i r c u i t at w h i c h t h e measure i r t a k e n i n either open c i r c u i t or closed c i r c u i t Operation. The
crusher is one c o m p o n e n t o f t h e circuit. As such, i t i performance is i n p a r t dependent o n t h e
proper selection and operation o f feeden. conveyorr, rcreenr, r u p p o r t i n g structure, elestrlc m o t o n .
drive components and I u r g e bins. Where used, a t t e n t i o n t o t h e f o l l o w i n g factors w i l l enhance
crusher capacity and performance.
1. Proper relaction o f crushing chamber f o r material t o be crushed.
2. A feed grading containing p r o p e r d i s t r i b u t i o n o f t h e particle sizes.
3. C o n t r o l l e d feed rate.
4. Proper faad d i s t r i b u t i o n 360' a r o u n d t h e crushing chamber.
5. Dlschsrpe conveyor sized t o carry m a x i m u m crusher capacity.
6. Properly sized scalping a n d closed c i r c u i t screens.
7. A u t o m a t i o n controls.
8. Adequate crurher discharge area.
T h e f o l l o w i n g factors w i l l detract f r o m crurher capacity and i e r f o r m a n c a .
1. S t i c k y material i n crurher feed.
2. Fin- In crurher feed (smaller t h a n crusher u n i n g ; exceeding 1 0 % o f crurher capecity.
3. Excessive feed moisture.
4. Feed segregation ~n crusher cavity.
5. i m p r o p e r feed d i s t r i b u t i o n around circumference of crushing cavity.
6 . Lack o f feed c o n t r o l .
7. lnefficcent use of recommended connected h o n e p o w e r .
8. I n s u f f i c i e n t conveyor capacltv.
9. I n s u f f i c i e n t scalper and ciared circuit rcreen capacities.
10. Insufficient crurher discharge area.
11.Extremely hard o r tough material.
12.Operation o f crusher at less t h a n recommended f u l l load c o u n t e r r h a f t speed.
T h e capacitier r h o w n i n t h e tables are bared o n results obtained f r o m thousands o f inrtallatlonr
worldwide, crushing the broadest range o f ores, rocks and minerals t o determine e f f e c t o f tndi-
vidual conditions. Consult R e x n o r d Process Machinery Oivlrbon.
Table 8D I -.
SHORT HEAD CAPACITIES
Gyradisc@ ( Q u a r t e r n a r y ) S t a g e ( R e f e r t o F i g . 4)
The G y r a d i s c i s a p p l i e d a s a f o u r t h o r f i n a l s t a g e c r u s h e r . The
~ y r a d i s cn o r m a l l y h a n d l e s f e e d of l e s s t h a n 50 MM ( 1 t o 112 I n . ) .
Feed and p r o d u c t s i z e r a n g e s f o r t h e ~ i r a d i s ca r e a s f o l l o w s :
Feed S i z e -- 75 MM ( 3 I n . ) Maximum
G y r a d i s c c r u s h e r s a r e s p e c i a l i z e d r e d u c t i o n machines. They a r e
d e s i g n e d t o e c o n o m i c a l l y produce l a r g e q u a n t i t i e s o f . c u b i c a 1 p r o d u c t
from s t o n e , g r a v e l , o r e s , and n o n m e t a l l i c m i n e r a l s . The f e e d f o r
G y r a d i s c c r u s h e r s u s u a l l y h a s a t o p s i z e n o t l a r g e r t h a n 75 MM
( 3 I n . ) f o r t h e l a r g e r u n i t s and 30 MM (1-114 I n . ) f o r t h e s m a l l e r
s i z e crushers.
G y r a d i s c c r u s h e r s d i f f e r from c o n v e n t i o n a l cone-type c r u s h e r s
b e c a u s e t h e comminution of m a t e r i a l i s a c h i e v e d by a r e d u c t i o n ,
p r o c e s s c a l l e d I n t e r - P a r t i c l e Comminution. T h i s p r i n c i p l e of r e -
d u c t i o n u t i l i z e s a combination of impact and a t t r i t i o n of a m u l t i -
l a y e r e d mass of p a r t i c l e s .
Through p r o p e r a p p l i c a t i o n of t h e G y r a d i s c c r u s h e r , m i l l f e e d s of
100 p e r c e n t p a s s i n g 3 , 4 , and 6 mesh a r e a t t a i n a b l e . The c r u s h i n g
a c t i o n of t h e G y r a d i s c c r u s h e r r e s u l t s i n c i r c u l a t i n g l o a d s of l e s s
t h a n 50 p e r c e n t of t h e new f e e d r a t e when c l o s e d c i r c u l a t i n g on
3 mesh, t o 150 p e r c e n t when c l o s i n g t h e c i r c u i t on 6 mesh.
R e f e r t o T a b l e s 9 t h r o u g h . : l l f o r c a p a c i t i e s and p r o d u c t a n a l y s e s
f o r Gyradisc c r u s h e r s .
@ ~ ~ r a d i si sc a r e g i s t e r e d t r a d e m a r k of Rexnord, I n c .
FEED PLATFORM
EXTENSION CAP
SHAFT RXTKNSION
ADJUSTMRNT HAM
UPPER I.1NER WK
. .
FLINGER HOUSING
COUNTERSHAFT BOX SEAL
. . .
. . . . ..
,
>
. ,
CRUSHING
DOUBLE DECK
"GP" SCREEN
2 REQUIRED
90
DOUBLE DECK TPH
"GP" SCREEN 3 MESH
I REQUIRED
540 TPH
360 TPH 3 MESH
3 MESH MESH TO MILL BINS
Figure 5
MINERAL PROCESSING PLANT DESIGN
Table 9
Capacity table based on closed circuit operation
, ,
Table 10
Table 11
OPINING INCH
CRUSHING 233
he t r e n d i n d e s i g n of f i n e c r u s h i n g p l a n t s i s i n t h e d i r e c t i o n of
t h e h o r i z o n t a l arrangement w i t h a l l c r u s h e r s on a s i n g l e f l o o r .
Conveyors from t h e c o a r s e o r e b i n o r s t o c k p i l e f e e d s c a l p i n g s c r e e n s
a r e u s u a l l y double decked. When t h e f e e d t o t h e f i n e c r u s h i n g p l a n t
c o n t a i n s l e s s t h a n 1 5 p e r c e n t p a s s i n g 1 9 MM ( 3 1 4 I n . ) and l e s s t h a n
t h r e e p e r c e n t m o i s t u r e , t h e s c a l p i n g s c r e e n s ahead of t h e secondary
c r u s h e r s can b e e l i m i n a t e d w i t h o u t a d v e r s e e f f e c t s t o t h e c r u s h e r .
STOCKPILE -8"
MINING SCREEN
u
100 TPH
- -43" 670 TPH
--43" +
FLOWSHEET FOR
Figure 8 SECONDARY AND TERTIARY
CRUSHING
NORDBERG PRIMARY
1402 TPH 9 4 5 TPH
1
BIN
5 REO'D
8x20 no.
u
. 8 x 2 0 DD.
NORDBERG HEAVY
DUTY"GP"SCREEN
5 REO'D
-- -
--,.
SURGE PILE NORDBFRG HVY.
1482 TPH .
.
'
3 REO'D TOTAL 2070 TPH
--
2 .
3 STAGE CRUSHING FLOWSHEET
Figum9
FOR SINGLE STAGE BALL MILLING
MINERAL PROCESS'ING PLANT DESIGN