Professional Documents
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The Art of Crushing
The Art of Crushing
PROCESSING
THE ART OF CRUSHING
Machines
&
Processes
Products
600-2000 tph
300-600 tph
150-300 tph
Raw
material?
How big? (Size of rawmaterial)
How much? (Capacity)
Final products?
Contamination?
Topsize
Impact Work index (Wi)
Abrasion index (Ai)
Type of rock / geology
Density
Wi measured x B.D./1.6 = Wi real
Moisture
Contamination
Quarry Academy 2005
Crushing Gravel
Crushing Ore
9 Limited reduction
9 Maximum reduction
9 Cubical shape
9 Cubical shape
9 Shape of no importance
9 Flexibility
9 Flexibility
9 Crushing and
screening
9 Range of products
9 Contamination?
Limited reduction
9 Range of products
9 Sellable Products !
9 Sellable Products !
Railway ballast
9
9
9
9
Curve limitations
Shape of material
Over and undersize
No contaminations
Product properties
British norms
German norms
NORMS
French norms
Slots
US norms
L
3
100
Jaw crusher
2-3
90
Gyratory crusher
3-4
80
Cone crusher
3-5
70
4-6
60
7-10
50
40
HSI
H-Cone
S-Cone
Jaw
Feed
30
20
10
0
1
10
100
1000
10x7=70
3x4=12
400
= 25
16
Quarry Academy 2005
NOT OK
3- stage Jaw/cone Plant
3x3x4=36
OK
Reduction Ratio 3
Impactors VS Compresive crushers
Imp
Total cost
(Investment + Wear)
act
cr u
she
r
/
w
a
ne
o
C
he
s
c ru
9
9
9
9
Production (tons)
Quarry Academy 2005
Impact crusher
Intermediate storage
Quality producing part of plant
independent of Primary crushing
and loading operation
Even out variations in the material
distribution. Uneven load gives
problems in all machines coming
after.
Better total availability for the Plant
Recommended stockpile volume
for 2 shifts operation
1 feeder
1 feeder
2 feeders
3 feeders
4 feeders
Secondary Circuit
High capacity
Controlled feed
Secondary Crushers
Hydrocone H / S
Secondary Impactor
Hydrocone
S4800 C
Alt.
Hydrocone
H6800 CXD
C.S.S: 150-175 mm
0-18
0-35
Railway
flakes Ballast
Screening
Open / Closed circuit
Open Circuit
By-passing fine
material
Scalping
Closed Circuit
Calibrated product
Higher reduction ratio.
Better cubical shape
More machines
Lower capacity
Closed Circuit
4/5
Closed circuit ~ 1/5 of screen
feed circulating recommended
Smaller or same setting (CSS)
as separation.
5/5
Higher wear
1/5
Cubical shape
Big screen
discrepancy:
4/5
Short jobs
Prod of sand
Screening ahead of
crusher
Screening ahead of
and after crusher
SCREENNING SUMMARY
A
Screen duties
A = Scalping screening
B = Close circuit screening
C = Final products screening
D = Natural fines screening
D
C
Final Crusher
Demands:
Optimised feed
Capacity
Product shape
Feed
H3800 F
80
70
%-Passing
60
50
40
30
20
10
0
Aperture (mm)
0,1
10
100
Good Flexibility
Higher crushing forces
Limited good shape range
Uniform reduction ratio
Feed
RP108
80
70
%-Passing
60
50
40
30
20
10
0
Aperture (mm)
0,1
10
100
Better shape
Uneven Reduction
Limited topsize capacity
High fines production
HYDROCONE MERLIN RP
100
Feed
H3800 F
RP108
90
80
70
60
%-Passing
Hydrocone H3800
F
Ecc: 29 mm
C.S.S: 16 mm
ASR Plus
50
40
30
20
10
0
Aperture (mm)
0,1
Merlin RP 107
Tip speed: 60 m/s
Bi-flow: 0 %
150 kW
10
100
Storage at Crusher
Choke fed Crusher;
Higher Reduction
Better shape
(cubical)
Better utilization of
mantle and liners
Bin volume; 5-10
min operation
Crusher feed
Process Control
Stationary / Mobile
Stationary
Mobile
Contract crushing
Crushing at construction
site
Low product demands
Few products
Flexibility with Fleet
Portable
Wheel-mounted
25
Track-mounted
100
Movements/Year
Wheel-mounted
Track-mounted
10
50
Hours
300
250
200
150
100
10
20
30
40
50
60
Application
Example
2-Stage Plant
Capacity:200 tph
Feed station
Hydrocone
H-4800 EC
Jawmaster
JM 1108 HD
Screen
CS 86-IV
0-4
Bin with
Feeder
4-8
8-16
16-32
Application
Example
3-Stage Plant
Capacity: 200 tph
Bin with
Feeder
Hydrocone
S-3800 EC
Feed station
Hydrocone
H-3800 M
Jawmaster
JM 1108 HD
Screen
CS 86-II
Screen
CS 86-II
0-4
4-8
8-16
16-32
Application
Example
Screen
CS 86-II
Hydrocone
S-3800 EC
Feed station
Jawmaster
JM 1108 HD
Screen
CS 86-II
Bin with
Feeder
16-32
Hydrocone
H-3800 MF
Quarry Academy 2005
Hydrocone
H-3800 M
8-16
4-8
0-4
Application
Example
Feed station
Bin with
Feeder
Jawmaster
JM 1108 HD
16-32
VSI
Quarry Academy 2005
Hydrocone
H-3800 M
8-16
4-8
0-4
Application examples
SUMMARY
Product distribution
Product
2-stage
3-stage
4-stage
4-stage, VSI
0-4 mm
33 t/h
43 t/h
61 t/h
88 t/h
4-8 mm
19 t/h
29 t/h
35 t/h *
38 t/h *
8-16 mm
41 t/h
66 t/h (*)
54 t/h *
44 t/h *
16-32 mm
107 t/h (*)
62 t/h *
50 t/h *
30 t/h *
* Good shape
2-stage
3-stage
4-stage
Cheap
Easy to move
Bad shape
Low flexibility
Medium expensive
Could be moved
Medium shape
Good flexibility
Expensive
Difficult to move
Very good shape
Very good flexibility
Application
Example
Mining Plant
Hydrocone
S-4800 C
Jawmaster
JM 1312 HD
Hydrocone
H-4800 M
EFC
EFC
0-10
2x Hydrocone
H-4800 EF
Quarry Academy 2005