PRIMARY CRUSHER (LIMESTONE)

TYPE: Gyratory Crusher

Performance Data for Primary Gyratory Crusher

Approx. Open-side setting of discharge opening (in)
Eccentric
Crusher feed Gyrations Pinion Max.
throw 1 1 1 1 1 1 1 1 1 1
size opening per min. (rpm) hp 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12
(in) 2 2 2 2 2 2 2 2 2 2
(in)
5
30-55 30x78 175 585 150 150 205 270 335 390 450 510
8
1
1 605 675 735 800
4
42-65 42x108 150 497 265 1 540 660 790 920 1040 1170
1
1 1040 1260 1490
2
54-74 54x132 135 497 300 1 960 1040 1100 1160 1240 1330
5
1 1950 2070 2210
8
1
60-109 60x150 100 400 1000 1 3250 3500 3750 4000 4250 4500 4750 5000
2
*Allis-Chalmers Corporation. To convert inches to millimeters, multiply by 2.514; to convert horsepower to watts, multiply by 746.
Source: Perry’s Chemical Engineers’ Handbook Seventh Edition
1
Assumption: The Open-side setting of discharge opening (in) from the primary crusher is 2
2
Therefore,

Eccentric
Crusher Approx. feed Gyrations per Pinion Max.
throw
size(in)2 opening (in) min. (rpm) hp
(in)
5
30-55 30x78 175 585 150
8

CAPACITY: 150 tons/hr

NUMBER OF UNITS (N):

tons 1day
Inlet on the Gyratory Crusher = 8178 .3241 ×
day 24hr
tons
Inlet on the Gyratory Crusher = 340.7635042
hr
1
Since the capacity for a 2 in discharge opening is 150 tons/hr
2

N ≈ 3 gyratory units

340.76042 tons / hr
Capacity new =
3 units
tons
Capacity new = 113.5878347
hr • unit

SCREEN 1

TYPE: Stationary Grizzlies (≥2 in)

Number of units: 3 Stationary Grizzlies

Source: Perry’s Chemical Engineers’ Handbook Seventh Edition

 1
For a 2 sieve designation:
2
Sieve Opening Nominal wire diameter
mm in mm in
64.0 2.50 5.50 0.2165

0.4Ct
A=
Cu × Foa × Fs

where A= area of the screen

Ct= Capacity of the Screen
Cu= Unit capacity of the screen
Foa= Open Area Factor
Fs= Aperture slot factor

From Figure 19-21, the unit capacity for the square opening:

tons
Cu = 4.5
hr • ft 2
 tons
Ct = Capacity new = 113.5878347
hr
Aperture slot factor:
Aperture Shape Gluck Colman Nordberg
L/W Fs L/W Fs L/W Fs
Square 1 1 <2 1 1 1
Rectangular >6 1.6 >25 1.4 3-4 1.15
Rectangular 3-6 1.4 4-25 1.2 >4 1.2
Rectangular 2-3 1.1 2-4 1.1
Circular 0.8 0.8

For Square Aperture: Fs=1

Open Area Factor (Foa): Square Aperture

1
M=
L A + dw

1 1
2 in =
2 L A + 0.2165in

L A = 0.1835 in = 4.6609 mm

A open
Foa = cos  × 100
A total

LA2
Foa = cos  × 100
(L A + dw)2

At θ = 0o

4.6609 2
Foa = cos( 0) × 100
( 4.6609 + 5.50)2

Foa = 21.04143⁒

0.4Ct
A=
Cu × Foa × Fs
tons
0.4(113.5878347 )
A= hr
tons
( 4.5 )( 0.2104143 )(1)
hr • ft 2
 2 (0.3048m) 2
A = 47.98483952 ft ×
ft 2
A = 4.457937465 m2

SECONDARY CRUSHER (LIMESTONE)

TYPE: Hammer Mills

Performance Data for Reversible Hammer Mills

Model Rotor dimensions Maximum feed Maximum Speed hp Capacity
no. (in) size (in) (rpm) (ton/hr)
505 30x30 1 1200 100-200 40-60
2
2
605 36x30 4 1200 200-300 80-100
708 42x48 8 900 300-550 140-180
815 48x90 10 900 900-1200 330-400
1014 60x84 12 720 1100-1500 450-500
1217 72x102 14 600 1550-2000 620-685
1221 72x126 14 600 1900-2500 760-850
NOTE: To convert inches to centimeters, multiply by 2.54; to convert horsepower to kilowatts, multiply by
0.746; and to convert tons per hour to megagrams per hour, multiply by 0.907.
Source: Perry’s Chemical Engineers’ Handbook Seventh Edition

1
For 2 in feed size:
2

Model Rotor dimensions Maximum feed Maximum Speed Capacity

hp
no. (in) size (in) (rpm) (ton/hr)
1
505 30x30 2 1200 100-200 40-60
2

NUMBER OF UNITS (N):

tons 1day
Inlet on the Hammer Mill = 8178 .3241 ×
day 24hr
tons
Inlet on the Hammer Mill = 340.7635042
hr
1
Since the capacity for a 2 in discharge opening is 40-60 tons/hr
2
 N ≈ 6 gyratory units

340.76042 tons / hr
Capacity new =
6 units
tons
Capacity new = 56.79340333
hr • unit

SCREEN 2
1
TYPE: Oscillating Screens ( in to 60 mesh)
2
Number of units: 6 Oscillating Screens

Speed: 5-7 oscillations per second (300-400 rpm)

Assume same discharge size with Pan Crusher for clay: pass through No.4-No.16 sieve

For No. 5 sieve:

Sieve Opening Nominal wire diameter Tyler equivalent
mm in mm in designation
4.00 0.157 1.37 0.0539 5 mesh
 0.4Ct
A=
Cu × Foa × Fs

where A= area of the screen

Ct= Capacity of the Screen

Cu= Unit capacity of the screen

Foa= Open Area Factor

Fs= Aperture slot factor

From figure 19-21, the unit capacity for the square opening for 5 mesh sieve:

tons
Cu = 0.84
hr • ft 2
tons
Ct = Capacity new = 56.79340333
hr
Aperture slot factor:
Aperture Shape Gluck Colman Nordberg
L/W Fs L/W Fs L/W Fs
Square 1 1 <2 1 1 1
Rectangular >6 1.6 >25 1.4 3-4 1.15
Rectangular 3-6 1.4 4-25 1.2 >4 1.2
Rectangular 2-3 1.1 2-4 1.1
Circular 0.8 0.8

For Square Aperture: Fs=1

Open Area Factor (Foa): Square Aperture
1
M=
L A + dw

1
5=
L A + 0.0539in

L A = 0.0.1461 in = 3.71094 mm

A open
Foa = cosθ × 100
A total

LA2
Foa = cosθ × 100
(L A + dw)2

At θ = 0o

3.71094 2 mm2
Foa = cos(0) × 100
(3.71094 + 1.37) 2 mm2
Foa=53.34328196⁒
0.4Ct
A=
Cu × Foa × Fs
tons
0.4(56.793 40333 )
A= hr
tons
(0.84 )(0.533432 8196)(1)
hr • ft 2
(0.3048m) 2
A = 50.6989386 2ft 2 ×
ft 2
A = 4.71008552 2 m 2
CRUSHER (CLAY)

TYPE: Discharge Dry Pan Crusher

Grinding pressure per Muller: 33000-90000 N (7500- 20000 lbf)

1 1
Pan Bottom (Outer ring of screen plates opening): 0.16-1.3cm ( to in)
6 2
Feed size: ≤7cm (≤3in)

Product size: Pass through No.4 to No.16 sieve

Pan diameter: 1.8-3m (6-10 ft)

Muller diameter: 0.71-1.6m (28-62 in)

Muller face: 13-46cm (5-18in)

Power: 11-75Kw (15-100hp)

Production rate: 1-53 Mg/hr (1-60 ton/hr)

tons
For the production of 1519.1934
day
tons
Production rate=63.299725
hr
Number of Units ≈1 Discharge Dry Pan Crusher

Grinding pressure per Muller: 90000 N (20000 lbf)

1
Pan Bottom (Outer ring of screen plates opening) 1.3cm ( in)
2
Feed size: ≤7cm (≤3in)

Product size: Pass through No.5

Pan diameter: 3m (10 ft)

Muller diameter: 1.6m (62 in)

Muller face: 46cm (18in)

Power: 75Kw (100hp)

SCREEN 3

1
TYPE: Oscillating Screens ( in to 60 mesh)
2

Number of units: 1 Oscillating Screen

Speed: 5-7 oscillations per second (300-400 rpm)

Discharge size with Pan Crusher: pass through No.5 sieve

For No. 5 sieve:

Sieve Opening Nominal wire diameter Tyler equivalent

mm in mm in designation
4.00 0.157 1.37 0.0539 5 mesh

0.4Ct
A=
Cu × Foa × Fs

where A= area of the screen

Ct= Capacity of the Screen
Cu= Unit capacity of the screen
 Foa= Open Area Factor
Fs= Aperture slot factor

From figure 19-21, the unit capacity for the square opening for 5 mesh sieve:

tons
Cu = 0.84
hr • ft 2
tons
Ct = Capacity new = 63.299725
hr

Aperture slot factor:

Aperture Shape Gluck Colman Nordberg

L/W Fs L/W Fs L/W Fs
Square 1 1 <2 1 1 1
Rectangular >6 1.6 >25 1.4 3-4 1.15
Rectangular 3-6 1.4 4-25 1.2 >4 1.2
Rectangular 2-3 1.1 2-4 1.1
Circular 0.8 0.8

For Square Aperture: Fs=1

Open Area Factor (Foa): Square Aperture
1
M=
L A + dw

1
5=
L A + 0.0539in

L A = 0.0.1461 in = 3.71094 mm

A open
Foa = cosθ × 100
A total

LA2
Foa = cosθ × 100
(L A + dw)2

At θ = 0o

3.71094 2 mm2
Foa = cos(0) × 100
(3.71094 + 1.37) 2 mm2

Foa = 53.34328196⁒

0.4Ct
A=
Cu × Foa × Fs
tons
0.4(63.299725 )
A= hr
tons
(0.84 )( 0.5334328196 )(1)
hr • ft 2
(0.3048m)2
2
A = 56.50707096 ft ×
ft 2
A = 5.249678674 m2
CEMENT MILLING

TYPE: Tube Mill

Types of grinding Circuits: Closed circuit (material at the outlet of the mill passes through a separator)
cm2
Product Fineness: 3000
g
Factors that affect Diameter and Length:
 capacity
 hardness of the material
 feed size
 fineness of the finished product
 open or closed circuit grinding ,and;
 grinding system
Relation between the length and diameter in closed circuit is approximately the following:
L = (3.0 to 3.5) * D
A two compartment mill has a ratio of (L/D) = 3.0
VERTICAL ROLLER MILL FOR KILN FEED

Power Requirement:

Given:

T (Mass Flow Rate): 9094.7748 tons/day

DF (Diameter of Feed Particles): 1.18 mm

DP (Diameter of Product Particles): 0.127 mm

Assuming Bond’s Law

P
T
=1.46 E
i
( ) 1
D
-
1
D
P F
Where:

P is in hp

T is in tons/min

DP and DF are in ft

Ei = 10.57 (Alsop, 2001)

P
T
= 1.46 E
i
( ) 1
D
-
1
D
P F

P 1 1
= 1.46 (10.57 ) -
6.315 4.17 × 10 4 3.87 × 10 3
P = 3208.51357 5 hp

1kW
3208.51357 5 hp (24 hr )
1.341hp
P=
9094.7748 tons/day
kWh
P = 6.3135
ton

VERTICAL ROLLER MILL FOR KILN FEED

Power Requirement:
Given:

T (Mass Flow Rate): 462.12 tons/day

DF (Diameter of Feed Particles): 1.27 mm

DP (Diameter of Product Particles): 0.127 mm

Assuming Bond’s Law

P
T
= 1.46 E
i
( ) D
1
-
1
D
P F
Where:

P is in hp

T is in tons/min

DP and DF are in ft

Ei = 13.00 (Alsop, 2001)

P
T
( )
= 1.46 E
i
1
D
-
D
1

P F

P 1 1
= 1.46 (13.00 ) -
0.32092
4.17 × 10 4 4.17 × 10 3
P = 204.035418 4 hp

1kW
204.035418 4 hp (24 hr )
1.341 hp
P=
462.12 tons/day
kWh
P = 7.9018
ton

LIMESTONE HOPPER

Flowrate = 8178.3241 tons/day

Bulk density = 2500 kg/m3

 1000 kg
8178.3241 tons × = 8178324 .1 kg
ton
m3
817324 .1 kg × = 3271.32964 m3
2500 kg

CAS = 1.39 kPa

Calculating for the minimum outlet diameter (Andrew Jenike Theory)

 CAS
B = (2 + )×
60  × g
Where
B = outlet diameter in m
Θ = angle between the vertical and the bin wall in the discharge zone (30
CAS = critical applied stress in Pa
Ρ = bulk density in kg/m3
1000 Pa 2
30 (1.39 kPa) ( kPa )(1 N / m / Pa) 1 kg m
B = (2 + ) × •
60 (2500 kg / m3 ) (9.81 m / s2 ) N.s2
B = 0.14169215 09 m
Dimensions of Bin and Conical Section
Based from the “Ten Steps to an Effective Bin Design” by Eric Maynard of Jenike and Johanson Inc. the
height of the hopper should be four times its diameter.

V=
π
(D 3 - B 2 ) +  D 2H
24 tan θ 4
where H = 4D

π 
3271.32964 m 3 = (D 3 - 0.14169215 09 3 ) + D 2 (4D )
24 tan 30 4
D = 9.90308380 6 m

H = 4 D = 4 (9.90308380 6 ) = 39.6123352 2 m

CLAY HOPPER
Flowrate = 1443.2337 tons/day

Bulk density =2000 kg/m3

 1000 kg
1443 .2337 tons × = 1443233 .7 kg
ton
m3
1443 .2337 tons × = 721.61685 m 3
2000 kg

CAS = 1.39 kPa

Calculating for the minimum outlet diameter (Andrew Jenike Theory)

 CAS
B = (2 + )×
60  × g
Where
B = outlet diameter in m
Θ = angle between the vertical and the bin wall in the discharge zone (30
CAS = critical applied stress in Pa
Ρ = bulk density in kg/m3
1000 Pa 2
30 (1.39 kPa) ( kPa )(1 N / m / Pa) 1 kg m
B = (2 + ) × •
60 (2000 kg / m3 ) (9.81 m / s 2 ) N.s 2
B = 0.17711518 86 m

Dimensions of Bin and Conical Section

Based from the “Ten Steps to an Effective Bin Design” by Eric Maynard of Jenike and Johanson Inc. the
height of the hopper should be four times its diameter.

V=
π
(D 3 - B 2 ) +  D 2 H
24 tan θ 4
where H = 4D

π 
721.61685 m 3 = (D 3 - 0.17711518 86 3 ) + D 2 (4D)
24 tan 30 4
D = 5.98363091 7 m

H = 4 D = 4 (5.98363091 7) = 23.9345236 7 m

COAL HOPPER

Flowrate = 462.12 tons/day

Bulk density = 865 kg/m3
 1000 kg
462.12 tons × = 462120 kg
1 ton

m3
462129 kg × = 534.2427746 m3
865 kg

Calculating for the minimum outlet diameter (Andrew Jenike Theory)

 CAS
B = (2 + )×
60  × g
Where
B = outlet diameter in m
Θ = angle between the vertical and the bin wall in the discharge zone (30
CAS = critical applied stress in Pa
Ρ = bulk density in kg/m3
1000 Pa
(1.39 kPa) ( )(1 N / m 2 / Pa) 1 kg m
30 kPa
B = (2 + )× •
60 (865 kg / m 3 ) (9.81 m / s 2 ) N.s 2
B = 0.40951488 69 m

Dimensions of Bin and Conical Section

Based from the “Ten Steps to an Effective Bin Design” by Eric Maynard of Jenike and Johanson Inc. the
height of the hopper should be four times its diameter.

V=
π
(D 3 - B 2 ) +  D 2 H
24 tan θ 4
where H = 4D

π 
534.242774 6 m 3 = (D 3 - 0.40951488 69 3 ) + D 2 (4D )
24 tan 30 4
D = 5.41310055 2 m

H = 4 D = 4 (5.41310055 2 ) = 21.6524022 1 m

RAW MIX BLENDING SILO

Flowrate = 9094.7748 tons/day
Bulk density = 2250 kg/m3
 1000 kg
9094 .7748 tons × = 9094774 .8 kg
1 ton

m3
9094774 .8 kg × = 4042.122133 m3
2259 kg
Calculating for the minimum outlet diameter (Andrew Jenike Theory)
 CAS
B = (2 + )×
60  × g
Where
B = outlet diameter in m
Θ = angle between the vertical and the bin wall in the discharge zone (30
CAS = critical applied stress in Pa
Ρ = bulk density in kg/m3
1000 Pa
30 (1.39 kPa) ( )(1 N / m2 / Pa) 1 kg m
B = (2 + )× kPa •
60 (2250 kg / m3 ) (9.81 m / s2 ) N.s2
B = 0.15743572 32 m
Dimensions of Bin and Conical Section
Based from the “Ten Steps to an Effective Bin Design” by Eric Maynard of Jenike and Johanson Inc. the
height of the hopper should be four times its diameter.

V=
π
(D3 - B2 ) +  D2H
24 tan θ 4
where H = 4D
π 
4042.122133 m3 = (D3 - 0.15743572 32 3) + D2 (4D )
24 tan 30 4

D = 10.6267100 7 m

H = 4 D = 4 (10.6267100 7 ) = 42.5068402 8 m