SAJOL, Christine Joy R.

5 – ChE C

Written Report
JAW CRUSHER

Introduction
Throughout the process industries, many solid materials occur in sizes that are too large
to be used and must be reduced by different methods for different purposes. It is essential so that
separation of various elements can be carried out.
Size reduction is the production of smaller mass units from larger mass units of the same
material. It is used because commercial products must often meet strict specification regarding
size and sometimes the shape of the particles they contain. Reduction also makes solids more
reactive, permits separation of unwanted ingredients by mechanical methods, and reduces the
bulk of fibrous materials for easier handling, and it is used for waste disposal.
Crushing is a type of size reduction and is the first step in the process. For some
processes, crushing is sufficient; but for chemical processes, it is usually followed by grinding.
Crushers are slow-speed machines for coarse reduction of large quantities of solids, they do the
heavy work of breaking large pieces of solid material into small particles.
The particles of feed in crushing are first distorted and strained by the actions of the
equipment, particularly the swinging of the jaw. The work here is initially stored in the solid as
strain energy. As additional force is added to the stressed particles, the strain energy exceeds a
certain level, and the material fractures into smaller pieces and forms new surface area which
requires a certain amount of energy. Some of the energy was used to create the new surface
while most of it dissipates only as heat.
For mechanical separation, in order to produce small particles from larger ones, caused
by compressive loads, which are desired either because of their surface, shape, size, and
number; a crusher will be designed. The desired type of crusher to be fabricated is a Blake jaw
crusher with the intent of testing out a different angle of toggles for the crusher and to see whether
the change in angle would result to a greater size reduction ratio or would result to production of
finer particles in comparison to other jaw crushers.

Feed Stock, Operating Conditions, Batch/Continuous, Assumptions & Constraints

In a jaw crusher, the feed is admitted between two jaws, set to form a V open at the top
wherein one jaw is stationary (anvil jaw) and the other one is moving due to an eccentric force, it
reciprocates in a horizontal plane and crusher lumps that are caught between jaws, which are
lined with tough abrasion resistant material and employs a compressive force. It is wide at the top
and narrow at the bottom.
 According to Lowrison (1974) and Marshall (1974), the range of feed to product size is 105
micrometers to 104 micrometers (intermediate coarse) and its typical size reduction ratio is 1 to
40. Feed stock may be lime, alumina, silica, or quarry. Other hard materials that may be reduced
by this type of crusher are quartz, topaz, corundum, and diamond; depending on the compressive
force employed by the crusher. A primary crusher operates on run-of-time material, accepting
anything that comes from the mine face and breaking it into lumps of 15-250mm (6 to 10 inches).
It is assumed that the energy required to produce a change dX in a particle of size X is a
power function of X. But in a real process, the equipment does not yield a uniform product,
whether the feed is uniformly sized or not. The product always consists of a mixture of particles,
ranging from a definite maximum size to very small particles. Although, there is a possibility of
uniformity of individual unit shapes in the product if feed is homogenous, both in the shapes of
the particles and in chemical & physical structure. It’s also important to note that because less
than one percent of energy delivered to the solids is used to create new surface in size reduction,
it is one of the least energy-efficient out of all the unit operations.

Material of Construction
If time and money permits, the material that will be used in fabricating this equipment
would be steel for the main body, toggle seat, fly wheels, and eccentric shaft; disc springs for the
jaw liner holding plate; abrasion resistant materials for the cheek plate; and manganese steel
casting with corrugated surface for the jaw liners. A motor will also be necessary for the blake jaw
crusher to work. Steel is used in most crushers because of its durability, strength, and appearance
for rugged environment and to lessen its maintenance. If not, then much cheaper and easier
materials such as wood, and light-weight steel (roof steel) will be used to create the prototype for
this equipment.

Rationale for Equipment Selection/Relevance to the Process

Crushers do the heavy work of breaking large pieces of solid material into small lumps,
these are chiefly used in mining, cement manufacture, and similar large-scale operations.
The main factors to be considered when selecting a crushing equipment are: size of feed,
size reduction ratio, required particle size distribution of product, throughput, and properties of
material: hardness, abrasiveness, stickiness, density, toxicity, and flammability. Also, capacity in
tons per hour, method of feeding to be adopted, and capacity of dump trucks.
Jaw crushers usually come first, crushing hard materials, and is usually followed by other
types of crushers. It is the most commonly used equipment for coarse size reduction and can
handle not just hard material but sticky materials as well.
The choice between the two types of jaw crushers is generally dictated by the feed
characteristics, tonnage, and product requirements. Seeing the design of the Dodge type which
is easier to fabricate; the Blake type is still a first choice to design because it is more commonly
used. Its reduction ratio averages about 8:1; therefore it would be more useful than the Dodge
type.
Material and Energy Balance/Flow Diagram
The material balance for a jaw crusher is feed equals product (F = P), since the size of the
coarse feed is only reduced to finer particles without removing anything from the equipment during
the process. In order to determine the amount of fine and coarse products as a result of the
crushing, screening of the product is needed. The overall balance for screening is F = P + R;
where P is the desired material while R is the reject. The material balance, on the other hand, is
Xf F = Xp P * Xr R; where X or f, p, and r are the mass fractions of the oversized material.
The energy balance, as mentioned earlier in this paper, is energy input (power supplied
per feed rate) equal to the sum of the energy used to create new surface particles and the energy
dissipated as heat. As for the flow diagram, it is as simple as mass in equal to mass out.

Equipment Design Theoretical Calculations (Properties of Process Materials needed in

Calculations; see APPENDIX for tables and sample calculation)
Theoretically, the problem in size reduction is the estimation of the theoretical amount of
energy required to fracture and create new surface area, which are important factors to consider.
Approximate calculations give actual efficiencies of about 0.1 to 2 percent. The extent and
efficiency of size reduction process are also affected by the magnitude of the mechanical force
applied, duration, type of force (compression), and other factors.
Efficiency is also based on the energy required to create new surface. Since, surface area of a
unit mass of particles increases greatly as the particle size is reduced. The energy required for
fracture is a complicated function of type of material, size, hardness, and other factors. The work
required in crushing is proportional to the new surface area created raised to a power n.
P KW−hr
W = ṁ = tons

Other particle properties considered in crushing are:

1. Particle size and shape
a 6Vp
Φ=b= Dp Sp
Where a and b are shape factors, and Vp & Sp are volume and surface area of any
particle, respectively.

2. Number of particles in a mixture

1
Nw = 3
aρp ̅D̅̅v̅
Where 𝜌𝑝 is the density of the particle and ̅𝐷̅̅𝑣̅ is the volume mean diameter

3. Specific surface of a mixture

n
6 Xi
Aw = (∑ )
Φ ρp ̅
Dpi
i=1
Where Aw is the specific surface of mixture, Φ is the sphericity of the particle, Xi is the
mass fraction in given increment, and 𝐷̅ 𝑝𝑖 is the average particle diameter
 4. Average particle size
a. Volume-surface mean diameter
6 1
̅̅̅
Ds = =
Φ Aw ρp ∑n Xi
i=1 ̅
Dpi
b. Volume mean diameter
1/3
1
̅̅̅v̅ = [
D ]
Xi
∑ni=1 ̅ 3
Dpi
c. Arithmetic mean diameter
∑ni=1 NiD
̅ pi ∑ni=1 NiD
̅ pi
̅̅̅̅
D N = n =
∑i=1 Ni NT

d. Mass-mean diameter
n
̅̅̅̅ ̅ pi
Dw = ∑ XiD
i=1
5. Particle size distribution in comminuted products
̅𝑝
Log x = log a + (k+1) log 𝐷
Power requirement:
1. Rittinger’s Law (n = 2)
P 1 1
= KR [ − ]
ṁ ̅̅̅̅̅
Dsb ̅̅̅̅̅
Dsa
2. Kick’s Law (n = 1)
P ̅̅̅̅̅
Dsa
= K K [ln ( )]
ṁ ̅̅̅̅̅
Dsb

3. Bond’s Crushing Law (n = 1.5)

P 1 1
= KB [ − ]
ṁ √Dpb √Dpa
KB = √100𝑥10−3Wi = 0.3162W i
Wherein work index is defined as the gross energy requirement of feed needed to reduce
a very large feed to such a size that 80% of the product passes a 100 micrometer screen.
The capacity of a Jaw crusher with openings of 4 inches to 2 feet can be determined by
the Taggart formula: T = 0.6 LS; where T is the capacity of the crusher in tons per hour, L is the
normal to gape, gyratory, or perimeter of circle, and S is the greatest width of discharge opening.
Heuristics
From Osborn Hadfields Double Toggle – Heavy Duty: (data based on dry limestone at 1.6 t/m3)

Equipment Specifications/ Spec Sheets for Summary

SPECIFICATIONS
Identification Size reduction equipment: Crusher
Method Compressive force due to swinging jaw,
fracturing particles
Function Reduces large size (coarse) particles into
smaller units
Operation Batch operation
Type Blake jaw crusher (double-toggle type)
Materials Handled From sticky to hard coarse materials (such as
mica, quartz, silica, etc.)
Essential Controls Motor
Appearance Rugged to suit the environment wherein its
usually used, but easy to maintain
Material of Construction Fabricated steel with corrugated manganese
plates; may also be wood
Dimensions 12” x 6” x 7” (LWH)
Capacity up to 705.5 kilograms per hour
Power Requirement up to 57 kiloWatts

Other specifications:
 Toggles are rotated at a higher angle (approximately 8 degrees) for higher reduction size
ratio
 Throat opening is 2.75” by 5”
 Crushing chamber is approximately 4.5” long
 Maximum in-feed size up to 4”
Detailed Diagram (Internal)
Rendered (3D)
Appendix for Calculations
Sample theoretical calculation:
Mica (Φ = 0.28, shape factor = 2, W i = 134.50, and specific gravity = 2.89) is crushed in a blake
jaw crusher and the average size of the particle is reduced from 50 mm to the first crushing DSA
shown in the table. The power for this crushing is 5 kW. Find the properties of the new surface
formed and the power required to produce 2 mm average size of particle. Determine the capacity
of the crusher.
 Mesh Dpmean Xi (after Xi/Dpmean Xi/Dpmean3 Xi(Dpmean) Ni(Dpmean)
crushing)
20/28 0.711 0.0707 0.09944 0.1967 0.05027 4750.7508
28/35 0.503 0.166 0.33002 1.3044 0.083498 7891.3137
35/48 0.356 0.1402 0.39382 3.1074 0.04991 4717.0583
48/65 0.2515 0.1182 0.46998 7.4303 0.02973 2809.4978
65/100 0.1775 0.0907 0.51099 16.2186 0.016099 1521.5242
100/150 0.1255 0.0762 0.60717 38.5499 9.5631x10-3 903.7992
150/200 0.089 0.338 3.79775 479.4537 0.030082 2843.0202

Specific surface of a mixture

n
6 Xi
Aw = (∑ )
Φ ρp ̅ pi
D
i=1
6
Aw = (6.20917)
(0.28) (2.89x10−3 )
Aw = 46039.32
Average particle size
a. Volume-surface mean diameter
6 1
̅̅̅
Ds = =
Φ Aw ρp ∑n Xi
i=1 ̅
Dpi
6 1
̅̅̅
Ds = =
−3
(0.28) (46039.32)(2.89x10 ) 6.20917
̅̅̅
Ds = 0.1611
b. Volume mean diameter
1/3
1
̅̅̅v̅ = [
D ]
Xi
∑ni=1 ̅ 3
Dpi
1/3
1
̅̅̅v̅ = [
D ]
546.261
̅̅̅v̅ = 0.12233
D
Number of particles in a mixture
1
Nw = 3
aρp ̅D̅̅v̅
1
Nw =
(2)(2.89x10−3 )(0.12233)3
Nw = 94509.014

c. Arithmetic mean diameter

∑ni=1 NiD
̅ pi ∑ni=1 NiD
̅ pi
̅̅̅̅
D N = n =
∑i=1 Ni NT
 25436.9642
̅̅̅̅
D N =
94509.014
̅̅̅̅
D N = 0.2691

d. Mass-mean diameter
n
̅̅̅̅ ̅ pi
Dw = ∑ XiD
i=1
̅̅̅̅
Dw = 0.2692

e. Particle size distribution in comminuted products

Log x = log a + (k+1) log 𝐷 ̅𝑝
After plotting: log a = -1.0724
a = 0.08464
k+1 = -0.2773
k = -1.2773
Power requirement:
Rittinger’s Law (n = 2)
P 1 1
= KR [ − ]
ṁ ̅̅̅̅̅
Dsb ̅̅̅̅̅
Dsa
5 1 1
= KR [ − ] KR = 0.8081 kW-mm-hr/ton
1 0.1611 50

1 1
P = ṁK R [ − ]
̅̅̅̅̅
Dsb Dsa ̅̅̅̅̅
1 1
P = 1(0.8081) [ − ] P = 0.3879 kW
2 50

Kick’s Law (n = 1)
P ̅̅̅̅̅
Dsa
= K K [ln ( )]
ṁ ̅̅̅̅̅
Dsb
50
5 = K K [ln (0.1611)] KK = 0.8714 kW-mm-hr/ton

̅̅̅̅̅
Dsa
P = K K ṁ [ln ( )]
̅̅̅̅̅
Dsb
50
P = 1(0.8714) [ln ( 2 )] P = 2.8049 kW

Bond’s Crushing Law (n = 1.5)

P 1 1
= KB [ − ]
ṁ √Dpb √Dpa
KB = √100𝑥10−3Wi = 0.3162W i

P 1 1
= 0.3162Wi [ − ]
ṁ √Dpb √Dpa
 Mesh Dp Xi CAS
number
20 0.833 1
28 0.589 0.0707 0.9293
35 0.417 0.166 0.7633
48 0.295 0.1402 0.6231
65 0.208 0.1182 0.5049
100 0.147 0.0907 0.4142
150 0.104 0.0762 0.3380
200 0.074 0.338 0

From 80% CAS of the graph, Dpb = 0.45 mm

1 1
P = 0.3162(134.5) [ − ]
√0.45 √50
P = 57.38 kW
Pressure exerted by the swinging jaw:
Power in Joules per second
Pressure = Area of swinging jaw plate in sq.m

387.9 J/s
Rittinger: Pressure = 0.0254 𝑚 2 = 23752.9 Pa = 0.0238 MPa
5" (5.0625")( )
1"

2804.9 J/s
Kick: Pressure = 0.0254 𝑚 2 = 171757.2 Pa = 0.1718 MPa
5" (5.0625")( )
1"

57380 J/s
Bond: Pressure = 0.0254 𝑚 2 = 3513646.5 Pa = 3.5136 MPa
5" (5.0625")( )
1"

Capacity:
Sample crusher
T = 0.6 L S
T = 0.6 (4.5”) (0.875”)
T = 2.3625 tons/hr
Prototype
T 0.6(2.6875)(.4375)
=
2.3625 (0.6)(4.5)(0.875)
T = 0.7055 tons/hr or 705.5 kg/hr
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