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Chapter I 1

CRUSHING

by Jerome C . Motz

Product Manager, Crusher Department


P r o c e s s Machinery D i v i s i o n , Rexnord I n c .
Milwaukee, Wisconsin

Primary Crushers

The t y p e s , s i z e s and number of c r u s h e r s employed i n a complete


r e d u c t i o n system w i l l v a r y w i t h such f a c t o r s a s t h e volume of o r e
t o be processed, t h e s i z e of t h e mine-run lump m a t e r i a l , t h e hard-
n e s s of t h e o r e b e a r i n g r o c k and t h e s i z e and dimension r e q u i r e d
f o r t h e f i n a l product.

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.

Jaw c r u s h e r s o p e r a t e b y ' s q u e e z i n g t h e rock between t h e f i x e d and


t h e movable s i d e s of a t a p e r e d c a v i t y . V a r i a t i o n s of p i t c h and
swing have been t r i e d , b u t most Blake-type machines have a c r u s h i n g
'
a n g l e of about 27' between swing and s t a t i o n a r y jaws.
. .
The p r i n c i p l e of which Gyratory c r u s h e r s work i s v e r y simple.
I f a Cone i s mounted on t h e upper end of a v e r t i c a l s h a f t and t h e
top of t h e s h a f t is h e l d . s t a t i o n a r y w h i l e t h e lower end i s r o t a t e d
e c c e n t r i c a l l y , t h e Cone w i l l a l s o swing e c c e n t r i c a l l y . I f t h e
Cone i s enclosed i n a s u i t a b l e housing, i t w i l l swing toward and
away from t h e housing w a l l s - a s i t r o t a t e s . I f t h e done and t h e
housing w a l l s a r e s u f f i c i e n t l y s t r o n g and heavy, a n y t h i n g caught
between them w i l l b e crushed.
MINERAL PROCESSING PLANT DESIGN

Besides t h e increased e f f i c i e n c y developed by t h e continuous


crushing a c t i o n and curved crushing f a c e s , Gyratory-type crushers
have o t h e r advantages:

1. The l a r g e s t u n r e s t r i c t e d feed opening a v a i l a b l e i n


comparison t o o t h e r crusher 'types.

2. A high range of s i z e s and c a p a c i t i e s where r a t e s of


between 600 and 6,000 tons p e r hour a r e required
' \

3. Generally, no f $ed] c o h t r p l 'is'.n&cdgsary. Direct dump


trucks of 150 t o 200 tons capacity a r e now being used
i n the larger installations.
. .

Impact crushers accomplish m a t e r i a l breaking and reduction p r i -


marily through impact a c t i o n of t h e m a t e r i a l with f i x e d o r f r e e -
swinging hammers revolving about a c e n t r a l r o t o r .

Product gradation i s a function of r o t o r speed and f r i a b i l i t y


of t h e material. An, increase i n r o t o r speed o r m a t e r i a l f r i a b i l i t y
l e a d s t o an increase i n t h e proportion of f i n e s i n the. pr0duc.t;.
conversely, a decrease i n r o t o r speed o r m a t e r i a l f r i a b i l i. t y. w i l l .
decrease t h e proportion o f . f i n e s %n t h e product.

The p r i n c i p l e of impact crushing i s t h e t o t a l use o f ' r o t o r energy


i n t h e reduction of t h e m a t e r i a l . K i n e t i c energy i s - i m p a r t e d t o
a p a r t i c l e of t h e m a t e r i a l , and t h i s energy i s used c h i e f l y t o .,
break down t h e bonding of t h e p a r t i c l e s t r u c t u r e . The p a r t i c l e .
breaks along its planes of weakness producing a cubical n a t u r a l
grain-shaped product a s t h e r e s u l t . The end product is f r e e from
weak zones. The impact f a c t o r is equal t o t h e p a r t i c l e k i n e t i c
energy and v a r i e s as:

E = & when E = Energy, v2 = speed SquHred, 'and M = Mass Weight


2 - 1 .

. .
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

B e n e f i t s i n using primary Impact-type c r u s h e r s , as' compared t o


compression c r u s h e r s , a r e lower i n s t a l l e d c a p i t a l c o s t s p e r t o n of
c a p a c i t y , much g r e a t e r c a p a c i t y weight f o r weight of comparable
Jaw and Gyratory c r u s h e r s t h u s reducing i n s t a l l a t i o n c o s t and
r a i s i n g t h e f e a s i b i l i t y f o r mobile u n i t s , production of more cubical
product and g e n e r a l l y , a f i n e r product gradation. This may reduce
t h e need f o r secondary crushing u n i t s .

Due t o t h e r e l a t i v e l y high maintenance c o s t s generated through


welding of hammers and t h e i n t e r n a l s of t h e Impact u n i t when crush-
i n g moderately a b r a s i v e rock t y p e s , thorough t e s t i n g and e v a l u a t i o n
of t h e f e e d m a t e r i a l is recommended by t h e manufacturer. Refer
t o Tables 1 through 5 f o r c a p a c i t i e s and product a n a l y s e s f o r
primary-type crushers.
Table 1

JAW CRUSHERS CAPACITY


JAW CRUSHER CAPACITY
. . TPH

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

' PRODUCT ANALYSIS


T h ~ schan gwes an anrags analw~so l stone nushed by an overhead eccentr~cjaw crusher I t
does not nmply any gumantee of product suang. snnae all stone warm from area to area and local
conditions are nwer constant.

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

PRIMARY CRUSHER PRODUCT


TABLE " 6 - PERCENT PASSING
10.15 m 30 +,so 60 m BO 90 96 iw
. -

. .

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

1" 2" . 3" 4"


. .
SETTING
CRUSHING,. 213

SECONDARY, TERTIARY AND FOURTH STAGE CRUSHING


., ..- ..
Cone. Crushers
..
The Cone c r u s h e r i s used a s a secondary, . t e r t i a r y a n d ' f o u r t h s t a g e
crusher i n h a r d . r o c k a p p l i c a t i o n s . The Cone crusher.was i n v e n t e d . :
by M r . 'Edgar B. Symons i n t h e mid-1920's a f t e r spending considerable
time i n t h e development of secondary crushing machinery. The Cone
crusher proved t o be remarkable.due t o i t s r a d i c a l d e p a r t u r e s from
t h e normal p r i n c i p l e s , o f a Gyratory crusher operation. L..' ' 7

. ,:
I n previous Gyratory machines t h e crushing process comprises. ;

reduction by pressure between two confining f a c e s and.a subsequent


f r e e i n g movement during which t h e m a t e r i a l s e t t l e s by g r a v i t y un-
t i l it .i ..s caught and subjected t o f u r t h e r pressure and again re-
leased. I n t h e normal Gyratory.the crushing s t r o k e o r t r a v e l of
t h e head has u s u a l l y an important bearing on t h e s i z e of t h e f i n -
ished product, although t h i s f a c t o r is s u b j e c t t o modification when
a p a r a l l e l s i z i n g zone is adopted. . .
The movement of t h e head i n t h e Cone crusher is s i m i l a r t o t h a t
i n t h e ordinary Gyratory with t h e exception t h a t , towards t h e
bottom of t h e Cone, i t t r a v e l s through a much g r e a t e r d i s t a n c e and
g y r a t e s much f a s t e r . This l a r g e s t r o k e , combined w i t h t h e f l a t
angle of t h e Cone, causes t h e s t o n e t o follow a zigzag path through
t h e crusher. The rock e n t e r i n g a t t h e t o p drops upon t h e head and
is then e l e v a t e d and crushed a g a i n s t t h e bowl l i n e r . As t h e head
recedes i n its g y r a t i o n , f a s t e r than t h e e f f e c t of g r a v i t y on t h e .
crushed p a r t i c l e s , t h e crushed rock drops v e r t i c a l l y down towards
t h e head t o . b e met on t h e next g y r a t i o n by t h e upcoming f a c e , and
again i s crushed a g a i n s t t h e bowl l i n e r .

The long movement changes t h e crushing s t r o k e from p r e s s u r e t o


impact, and t h e increased clearance on t h e f r e e i n g s t r o k e allows
t h e s t o n e t o f a l l away v e r t i c a l l y a f t e r each impact. The wide.gap
a t t h e end of t h e opening movement a l s o permits t h e s t o n e t o move
f r e e l y f o r t h e g r e a t e r p a r t of t h e time occupied i n passing through
t h e crushing zone. The periods of confinement a r e t h e r e f o r e l i m i t e d .

The angle between t h e f a c e s of t h e bowl l i n e r and 'the mantle de-


c r e a s e s gradually, and t h e s e f a c e s a r e p a r a l l e l near t h e o u t l e t f o r
a s u f f i c i e n t d i s t a n c e t o ensure t h a t t h e head must make one o r two
g y r a t i o n s before t h e m a t e r i a l can pass through t h e s i z i n g zone, which
again means t h a t i t is t h e opening on t h e closed s i d e o f t h e crush-
ing head which r e g u l a t e s one dimension of t h e product s i z e . A s i n
t h e slow-speed Gyratory crusher, t h e volume t r a n s p o r t e d through
each v e r t i c a l p o s i t i o n i n t h e Cone crusher c a v i t y is d i r e c t l y re-
l a t e d t o t h e l e n g t h o f t h e crushing s t r o k e , sometimes c a l l e d eccen-
t r i c throw, b u t more a c c u r a t e l y defined a s head displacement.
MINERAL PROCESSING PLANT DESIGN

The machine d e p a r t s from t h e u s u a l design i n t h a t t h e r e i s no


upper bearing f o r t h e Gyratory s h a f t and no s p i d e r t o bridge over
t h e feed opening. The head is supported i n a p a r t - s p h e r i c a l s e a t -
i n g and t h e t a p e r i n g main s h a f t is actuated by an e c c e n t r i c . The
absence of the s p i d e r ensures a more even d i s t r i b u t i o n of t h e feed
t o a l l p a r t s of t h e crushing chamber.

The crushing bowl, i n v e r t e d over t h e Cone and screw-threaded t o


permit v e r t i c a l adjustment i n s i d e an adjustment r i n g , i s h e l d down
t o t h e main frame by a s e r i e s of powerful s p r i n g s which allows t h e
bowl t o r i s e when tramp i r o n o r o t h e r uncrushable m a t e r i a l e n t e r s
t h e crushing c a v i t y .

It i s very d e s i r a b l e with t h i s machine t h a t t h e feed be control-.


l e d and t h e m a t e r i a l be evenly d i s t r i b u t e d around t h e circumference
i f optimum e f f i c i e n c y i s t o be obtained. A f e e d - d i s t r i b u t i n g and
r e g u l a t i n g p l a t e is t h e r e f o r e mounted on t h e t o p of t h e main s h a f t
with a v e r t i c a l l y a d j u s t a b l e spout above i t .

CONE CRUSHER APPLICATION

Crushing Stages

To reduce run-of-mine t o m i l l feed r e q u i r e s reduction i n a s e r i e s


of s t a g e s . The p h y s i c a l s i z e and power requirements of a crusher
capable of reducing hard.rock vary depending on t h e a p p l i c a t i o n .

Even when a crusher has t h e c a p a b i l i t y of achieving a high re-


duction r a t i o i t is normally more e f f i c i e n t t o run t h e crusher a t
a mid-setting, a s shown i n t h e manufacturers' t a b l e s , r a t h e r than
choosing t h e c l o s e s t s e t t i n g which o f f e r s t h e g r e a t e s t reduction
r a t i o . The main consideration a t each s t a g e f o r maximum production
i s e f f i c i e n t power draw.

There i s an optimum s e t t i n g f o r each crusher and an optimum number


- of s t a g e s required f o r maximum p l a n t production based on t h e i n d i -
v i d u a l c h a r a c t e r i s t i c s of t h e m a t e r i a l being crushed. Overloading
t h e crusher does not increase production, but i n s t e a d i s counter-
productive and w i l l decrease t h e l i v e s of t h e crusher components.
I d e a l l y , t h e t o p - s i z e feed should receive f o u r t o f i v e impact blows
during i t s progress through t h e crushing chamber. This is a combina-
t i o n of reduction a t t h e upper zone of t h e l i n e r s a s w e l l a s t h e
p a r a l l e l zone. The crusher should be fed s o a s t o be operating a t
o r n e a r continuous f u l l load horsepower c a p a b i l i t y . Operating t h e
CRUSHING 21 5

crusher a t t o o narrow a s e t t i n g decreases c a p a c i t y and c r e a t e s high


wear. Too wide an opening, i n proportion t o t o p s i z e feed, w i l l
prevent crushing i n t h e upper zone and w i l l develop excessive power
draw. Power drawn per ton of crusher feed i s not i n i t s e l f a measure
of p r o d u c t i v i t y . E f f i c i e n t use of power through proper a p p l i c a t i o n
of t h e c a v i t y , w i t h r e s p e c t t o feed and product requirements, w i l l
determine t h e optimum production p e r horsepower drawn. From t h e
following crusher a p p l i c a t i o n d e s c r i p t i o n s , i t can r e a d i l y b e seen
t h a t each crusher has i t s own designed l e v e l of reduction. The
range of feed s i z e s and product s i z e s , f o r each crushing s t a g e ,
somewhat overlaps i n t o t h e succeeding and preceding s t a g e s . This
allows f o r f l e x i b i l i t y i n adjustment a t each s t a g e f o r optimum
production of t h e e n t i r e system. This a l s o p r e s e n t s t h e option of
e l i m i n a t i n g a s t a g e when it i s advantageous.

Primary Crusher

The Primary c r u s h e r ' s main purpose i s t o reduce l a r g e fragments


of b l a s t e d o r n a t u r a l rock down t o a s i z e s u i t a b l e f o r handling by
t r a n s f e r equipment and t h e secondary s t a g e crusher. Feed opening
and product s i z e ranges f o r t h e v a r i o u s models of Gyratory crushers
a r e a s follows:

Maximum Feed Opening -- 1500 MM t o 750 MM (5 f t . t o 2-112 f t . )

Recommended MXnimum Product -- 162 MI4 t o 100 MM (6-112 I n . t o 4 I n )

P r e f e r r e d Reduction Ratio -- 8:l

Standard (Secondary) Cone Crusher (Refer t o Fig. 1 )

The Standard Cone c r u s h e r ' i s normally applied a s a secondary


crusher i n a multi-stage crushing c i r c u i t . The small diameter feed
d i s t r i b u t o r and t h e wide t h r o a t opening a t t h e top of t h e l i n e r s
enable t h e Standard Cone crusher t o accommodate t h e l a r g e r feed
produced by t h e Primary crusher.

Feed opening and product s i z e ranges f o r t h e v a r i o u s models of


t h e Standard ~ 6 n ecrusher a r e a s follows:
. .
Maximum Feed Opening -- 625 MM (25 In.)

Recommended Product Range -- 100 MM t o 19 MM (4 I n . t o 314 In.)

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.,'.

The f e e d t o t h e Standard Cone i s normally s c a l p e d i f o v e r 1 0 t o


1 5 p e r c e n t of t h e ' d e s i r e d e c r u s h e r p r o d u c t i s . p r e s e n t .iii the'new f e e d .
S i n c e t h e r a n g e of f e e d s i z e w i l l o f t e n v a r y from approximately
300 MM t o 5-MM (12 I n . t o 2 I n . ) i n a given i n s t a l l a t i o n , t h e crush-
i n g c a v i t y must be s e l e c t e d t o r e d u c e t h e s e s i z e s e f f i c i e n t l y .
Where t h e m a j o r i t y of t h e t o p s i z e of t h e f e e d i s o n l y 200 MM (8 I n . )
t h e c r u s h i n g c a v i t y would b e modified t o - r e f l e c t t h i s s m a l l e r f e e d
s i z e . To meet t h e s e v a r i a t i o n s i n s i z e of f e e d and d e s i r e d p r o d u c t
s i z e , Standard Cones can b e equipped w i t h v a r i o u s d e s i g n s of f i n e ,
medium, c o a r s e , o r e x t r a c o a r s e c r u s h i n g c a v i t i e s .
. >

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

Short Head ' ( ~ e r t i a r y )Cone crusher .(Refer t o Fig. 2)

The Short Head Cone crusher i s normally applied a s a t h i r d s t a g e


crusher i n p l a n t s designed f o r t h r e e o r . f o u r s t a g e s of crushers.
However, t h e wide range of crushing c a v i t i e s a v a i l a b l e i n t h e Short
Head crusher permits i t s i n s t a l l a t i o n a s a secondary crusher i n
some cases.

Feed opening and product s i z e ranges f o r t h e various models of


Short Head Cone crushers a r e a s follows:

Maximum Feed Opening -- 250 MM (10 I n . )

Finished Product ~ a n g e -- 25 MM t o 3 MM ( 1 I n . t o 118 I n . )

Reduction Ratio -- 4 o r 6:l

The feed t o t h e Short Head Cone crusher is normally screened p r i o r


t o t h e crusher t o remove t h e f i n i s h e d product s i z e s and t o provide
void space f o r the crushed p a r t i c l e s produced i n the c a v i t y . Maxi-
mum production w i l l be obtained when t h e crusher o p e r a t e s a t o r
n e a r f u l l horsepower load continuously. To achieve t h i s condition,
p l a n t design, feed d i s t r i b u t i o n and t h e type of crushing c a v i t y
a r e f a c t o r s which warrant considerations. The schematic arrange-
ment shown i n Figure 3 permits t h e crusher t o o p e r a t e with a con-
t r o l l a b l e feed r a t e . The c i r c u i t shown i n Figure 3 o f f e r s t h e op-
timum i n crusher feed c o n t r o l and automation. The new feed i s with-
drawn from t h e bin d i r e c t l y t o t h e crusher assuring a steady, con-
t r o l l a b l e feed r a t e . I n a properly fed crushing c a v i t y t h e m a t e r i a l
is d i s t r i b u t e d i n a manner which u t i l i z e s the e n t i r e c i r c u m f e r e n t i a l
a r e a of t h e receiving opening. It i s equally important t o have t h e
f i n e r gradations i n t h e feed i n t e r s p e r s e d with the coarse feed.

To meet v a r i a t i o n s i n feed s i z e and ,product requirements, t h e


Short Head Cone c a n ' b e equipped with various designs of f i n e , medi-
um, coarse o r e x t r a coarse crushing c a v i t i e s . E s s e n t i a l l y , t h e
same considerations f o r ' s e l e c t i n g t h e crushing c a v i t y should be
used i n t h i s s t a g e a s was described f o r t h e Standard Cone crusher.

When t h e feed m a t e r i a l i s r e l a t i v e l y nonabrasive, t h e crushing


c a v i t y s e l e c t i o n is u s u a l l y made t o permit a condition where t h e
e n t i r e c a v i t y i s f i l l e d up o r "choked". A c e r t a i n degree of s e l f -
r e g u l a t i o n takes place under t h e s e conditions.

When crushing a m a t e r i a l which is both hard and a b r a s i v e , i t is


p o s s i b l e t h a t t h e f u l l motor power can be drawn without having t h e
. ,
5 0 x 80 X!f! OTY
NORCBERG
PRIIIARY GYRATORY 7 ' S I D . XHY D M SYMONS CONE
1190 LTPH -.4 9 0 L T P H
7 OPEN SIDE SETTING I f C.S. SETTING 3-REO. 1
BIN '1 1
4LTPH
10 .
LTPH

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

3-STAGE CRUSHING FLOWSHEET


Figure 3 FOR ROD .MILL FEED
CRUSHING 221

crushing c a v i t y e n t i r e l y f i l l e d up o r "chokedt'. A s t h e crusher


l i n e r s wear, t h e condition w i l l develop where a "choked" c a v i t y
can be observed.

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 .

Refer t o Tables 6 through 8 f o r c a p a c i t i e s and product analyses


f o r secondary and t e r t i a r y Cone crushers.

GRADATION CONE CRUSHERS


Table 6
SCREEN ANALYSES
SYMONS CONE CRUSHER
"OPEN CIRCUIT"'
MINERAL PROCESSING PLANT DESIGN

CONE CRUSHERS Table 7 GRADATION

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.

PRODUCT SIZE T ~ SIZE


P OF PRODUCT
314" 518 112" 318"
+ 518" 4%
- 518" + 112" 12% 6%
- 112" + 318" 24% 19% 8%
- 318" + 5 / 1 6 14% 15% 13% 4%
- 5 1 1 6 + 114" 12% 16% 19% 12%
- 114" + 3/16" 12% 15% 20% 24%
- 3 / 1 6 + 6M 7% 11% 16% 24%
-6M+lOM 6% 7% 12% 21%
- IOM + 14M 2% 3% 3% 4%
- 14M + 28M 7M 8% 3% 4%
- 28M 6% 7%
- 100% 100% 100% 100%
CONE CRUSHERS.

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.

USING THE CHARTS ON THE FOLLOWING PAGES


TO derermlne crurher capacltv f a r proposed inrtallatlon, detetmlne whether crusher ir t o be
operafed on open c # r c u # t0 1 closed clrcult. as r h o w n ~n schematic o n following pass
For Open C i r c u i t Operation:
A.'Capacitler r h o w n i n c o l u m n listed ar "Capacity 3" lbrtr t h e capacitoer of all size short head
crurherr i n tons per h o u r parsing through crurher Recommended clored ride r e r t l n g f o r each
crusher rize and t y p e o f cavity 8 % l i r t e d f r o m l e f f to rlghl.
6 . T O d e f e r m ~ n ee x a c t tonnage, u r l n g k n o w n data o f proposed feed raze and tonnage. select
correct r u e machnne and proper t y p e o f crurhnng rchematlc on f o l l o w i n g page.

For Closed C i r c u i t Operation


A. C o l u m n lorfed as "Capacdty I" r h o w r capacity a t vartour r e t f l n g r of each rlre Crusher t o p r o
d ~ ca e n e t finished p r o d u c t parrsng rhe etfect8ve square opening o f the screen
6 . u s i n g k n o w n data on proposed feed r i z e and tonnage required, select correct r i r e machane and
proper t y p e of c r u r h l n g cavoty
Crushing Cavity Selection:
For preliminary r e l e c r m n o f crurh!ng cavlrv. proposed feed gradfng l o p r i r e s h o u l d pars a square
opening n o t to exceed 90% o f "0"d ~ r n e n r i o n
a? open rnde
N o t e Capacrrler r h o w n i n c o l u m n lnrted as "Capacity 2" are p r o v t d s f ro assort 8" t h e proper r i z l n y
of convevorr. feeders and rcreenr There capacitler are bared on a n average rcreen e f f i c i e n c y o f
90%.
MINERAL PROCESSING PLANT DESIGN
CONE CRUSHERS
Table 8C

STANDARD SVMONS CONE CRUSHERS-OPEN CIRCUIT 1 Cavities F e d Opninpr Product S i m Capacities.

711. Fmne 3H" 10" 11'' , 370 4m sw 620 750 . i

Mdsum 1" 11 1 1 2 ' 12 314.' SW 800 750 800 1lW


Coarse 1 114" 13 1 1 2 14 718" . 750 850 1200 1400
E i ~ mar!.
n 1112' 16 3 1 4 18 118" 850 1200 l4W

loft Fine 71s" 12 1 1 2 1 4 9W 13W 1650


Md,"rn 1" 15 1 1 2 11' 14m lsw, ism
mane 1 11Y' 8112 20" 1- 2503 3mO
ExaaCaaru 1 112 24 112" 16" l8m 25m 3 ~ 0
MINERAL PROCESSING PLANT DESIGN

Table 8D I -.
SHORT HEAD CAPACITIES

65 105 55 ~5 130 1 7 , IW 330 11s 1sr45 12s IS,so tsr


-"I 112" 2 3,. 4'
90 115
318"
115
111..
135 115 149
518"
1 4 5 2 m 170
,."
> X I 210 180
57W Fmn. 3/18" 11W 1111.. 116" 3116"

w,um 3,lV 15w 3..

bane SI16" 13*" ." 51lb. 318"

E.,.. 5w .s,4" 5112"


--
cmm

5 1n l l F.n 3/16" 11W 2114" 9 318"


90 3118-
110 11. 135 Mo
114' 180 1"-
210 240 X4
65 110 124 175230 196
M d u n 11." 2118" I1ll" 518" 111. SIB'
90 3116"
185 155 136 2W
111' 180 %3 3UXI
14 240
175230 196 210 250 111 745170 216
Come 316" 33W 5 (H" 3nT' 51"
140 130
31" 120 lW 280
220 110 110 3N"
110 120
l75XO 220 XOJY1 3W
T.2,. IW 6" 7 ,14"
hn. ' 175 2M
112" 230 2W 350
518" TXI 518" 105
250150 w
3lO 0150 1%

7 1% Fan IllW 1.. 1114" 3118" 318" V16"


120 140 130
160240
3 I 1 V 110 280 190
11. ?50 518" I W
4105W
315436 190 3C4 a50 361
Mdum 318" ,718" *W4'
YB"
280 410 = 3 k
315440 8 5
360 500
llY' 425 w 470
410550
.
,
5W 510
I
.-
510
b m 112" . 5- T
3 1 5 5In..
00 468 lrr
160 5W
518" 314"
4Y)m 5W 5% Ma 560
Ertr. 518" 6 114" ' 8 114' 516" 5w 31."
corm 360 610 510 45oe.m 510 560 650 600

lOlc Fm. 114" 3.. V 5 W 1116" 314'


500 8W
71." 120 12W 960
518"
610 En' 8% i7W 935 77507450 l W 4
Mdum li2.I 4' 6" 318" 1116.. j,4'
12W 960
9m 518"
670 ILK0 850 650 I l W 935 11501450 llBD
<,.- 518" 7- 9' ,118" w 31.
850 rlw 935 s s o l m !w motsso tao
E.ln II4" 6" lU' 518" 31.
cwrr 950 1300 l W 0 11501550 14W
CRUSHING

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

F i n i s h e d P r o d u c t Range -- 1 2 MM (112 I n . t o ii20)

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 .

For p r o p e r o p e r a t i o n , t h e c r u s h e r always o p e r a t e s w i t h a choke


l e v e l i n t h e cavity. A controlled feed r a t e permitting a constant
power draw i s r e q u i r e d f o r a n e f f i c i e n t c i r c u i t . .

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.

One 84" G y r a d i s c c r u s h e r i s . r a t e d t o produce 180 t o n s p e r hour


of 3 mesh s c r e e n u n d e r s i z e . The f l o w s h e e t , F i g u r e 5, shows t h e
equipment r e q u i r e d t o produce t h e f i n e r m i l l f e e d . ..,.. .

Using t h e a;rangement shown i n t h e f l o w s h e e t , m i l l f e e d r a t e s


a r e i n c r e a s e d by a minimum of 20 p e r c e n t o v e r t h e r a t e s p o s s i b l e
when f e e d i n g t h e nominal 1 2 MM (112 I n . ) s i z e . The work i n d e x and
t h e f i n a l g r i n d , however, d i r e c t l y i n f l u e n c e t h e d e g r e e ' o f f e e d
r a t e improvement.

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

LOWER SPRING SEGMENT '

. .

FLINGER HOUSING
COUNTERSHAFT BOX SEAL

. . .
. . . . ..
,
>
. ,
CRUSHING

FLOW SHEET FOR


GYRADISC CRUSHER APPLICATION
IN THE MINING 1,NDUSTRY
540 TPH

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

Copocttier ~ h a w n , o r enedher ni.ximum nor minimum, o n d ore bosed on rervltr


Closed circuit secured i n .dud prodice. The figures rhown apply, to short tons of material
weighing 100 per cubic foot, and ore bored on o properly groded feed
with the crusher consuming o minimum of 80% of the recommended horsepower.
A feed size o f minus %" is typical, but a Ainus 1%" feed can be readily accepted.
Optimum c ~ p o c i t yi r obtained with o closed ride setting ranging behveen !A" a n d
K". The setting is not necermr~lyrela'ed to the closed circuit screen opening.
F ~ O O ~which
S may affect cop.city include, $ire
of feed, friability, t o ~ g h n e ~
o rn d
moi$ture content. '
Figurer shown under column "TPH rHRU CRUSHER are included for colculding
screen areas. . .
For finer contoct Rernard Process Machinery Division.

, ,

& SD mnd DD rignifie5 ~ ~ ndeck


~ l or
e double deck screen.
CRUSHING

PRODUCTION CURVES GYRADISC CRUSHERS

Table 10

Feed: Copper Ore


Product: Ball Mill Feed
MINERAL PROCESSING PLANT DESIGN

GY RADlSC CRUSHERS PRODUCTION CURVES

Table 11

Feed Iron Ore


Product: Ball Mill Feed

STANDARD SCREEN ANALYSIS

OPINING INCH
CRUSHING 233

FINE CRUSHING PLANT FLOW SHEETS

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 .

T h i s p r a c t i c e h a s been followed s u c c e s s f u l l y i n s e v e r a l Minnesota


t a c o n i t e i n s t a l l a t i o n s . The secondary c r u s h e r p r o d u c t i s screened
and conveyored t o b i n s ahead of t h e t e r t i a r y c r u s h e r s . The t e r t i a r y
c r u s h e r s o p e r a t e i n e i t h e r open o r c l o s e d c i r c u i t w i t h a v a r i e t y of
arrangements a v a i l a b l e i n p o s i t i o n i n g t h e t e r t i a r y s c r e e n s . The
s c r e e n s can b e p l a c e d above o r below t h e t e r t i a r y c r u s h e r s o r i n a
s e p a r a t e screenhouse. With t h e advent of automatic c r u s h e r f e e d
c o n t r o l systems i t becomes important t o r e d u c e t h e r e a c t i o n time be-
tween t h e f e e d c o n t r o l mechanism, such a s a v i b r a t i n g o r b e l t f e e d e r ,
and t h e c r u s h e r t o a minimum.

Where secondary and t e r t i a r y c r u s h e r s a r e s t a c k e d w i t h a s c a l p i n g


s c r e e n between t h e two, s u r g e and f e e d c o n t r o l f o r t h e t e r t i a r y
c r u s h e r becomes more d i f f i c u l t . T h i s r e s u l t s i n lower e f f i c i e n c y
from a power u t i l i z a t i o n s t a n d p o i n t . The i n i t i a l c o s t of c o n s t r u c -
t i o n f o r t h i s t y p e of p l a n t i s u s u a l l y lower t h a n t h e aforementioned
horizontal layout.

The p o s i t i o n i n g of t h e secondary and t e r t i a r y c r u s h e r s depends


on a v a r i e t y of f a c t o r s i n c l u d i n g t e r r a i n , m o i s t u r e l e v e l i n t h e
o r e , s t o r a g e c a p a c i t y b o t h b e f o r e and a f t e r f i n e c r u s h i n g , and
beneficiation steps. - ,

Usually t h e f i n e c r u s h i n g p l a n t i s l o c a t e d some d i s t a n c e from t h e


primary w i t h an i n t e r m e d i a t e o r e s t o r a g e f a c i l i t y between. The
o p e r a t i o n of t h e f i n e c r u s h i n g p l a n t i s independent, t o a l a r g e
d e g r e e , of t h e performance of t h e primary c r u s h e r .

A g r e a t d e a l of thought h a s been g i v e n - t o t h e problem of a t t a i n -


i n g maximum e f f i c i e n c y i n t h i s t y p e of o p e r a t i o n . E f f i c i e n c y i s
measured by t h e work of r e d u c t i o n on t h e o r e p e r u n i t of time and
by p e r c e n t r u n n i n g time. The work of r e d u c t i o n i s r e p r e s e n t e d by
tonnage of throughput and d e g r e e of s i z e r e d u c t i o n .

To a t t a i n t h e maximum work of r e d u c t i o n , each c r u s h e r must b e k e p t


a t f u l l c a p a c i t y . The c a p a c i t y may b e l i m i t e d v o l u m e t r i c a l l y i n t h e
c a s e of s o f t e r o r e s , o r by t h e horsepower t h a t can s a f e l y b e a p p l i e d
t o t h e c r u s h e r i n t h e c a s e of h a r d e r o r e s .
234 MINERAL PROCESS1:NG PLANT DESIGN

The use of h y d r a u l i c mechanisms f o r monitoring and c o n t r o l l i n g


f i n e crusher s e t t i n g s from a c e n t r a l c o n t r o l room gives t h e operator
a means f o r maintaining o v e r a l l crushing p l a n t e f f i c i e n c y . A l l t h a t
is needed f o r complete automatic c o n t r o l i s t h e proper coupling of
t h e power d r a f t and volumetric c o n t r o l s of one s t a g e of crushing t o
t h e p o s i t i o n i n g mechanisms of the preceding s t a g e t o i n s u r e t h e b e s t
balance between successive s t a g e s of crushing.

Figures 6 through 9 show t y p i c a l crushing p l a n t flow s h e e t arrange-


ments.
CRUSHING
OIL
20
ak
CRUSHER .
$
I CLOSED

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

1. Miller, T.W., "Crushers for Stone and Ore".

2. Weiss, Norman and Cheavens, J.H., "Present Trends in M i l l


Design", Milling Methods in the Americas.

3. Data supplied by Rexnord.

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