DESIGN AND MANUFACTURING OF HAMMERMILL CRUSHER

1. INTRODUCTION

1.1 LITERATURE REVIEW

The literature collected mostly from the Bevcon company records and the data which was used
in this project is collected from their client. We used the company’s standard procedure for
power calculations and the calculation taken from the company records. And the literature is
collected from the following journals.

1.2 CRUSHER
A crusher is a machine designed to reduce large solid material objects into a smaller volume or
smaller pieces. Crushers may be used to reduce the size and change the form of waste materials
so that they can be more easily disposed or recycled. To reduce the size of a solid mix of raw
materials (as in rock ore) so that pieces of different composition can be differentiated. Crushing
is the process of transferring a force amplified by mechanical advantage through a material made
of molecules that bond together more strongly and resist deformation more than those in the
material being crushed. Crushing devices hold material between two parallel or tangent solid
surfaces, and apply sufficient force to bring the surfaces together to generate enough energy
within the material being crushed so that its molecules separate from (fracturing) or change
alignment in relation to (deformation), each other. The earliest crushers were hand-held stones,
where the weight of the stone provided a boost to muscle power, used against a stone
anvil. Querns and mortars are types of these crushing devices.
1.3 DESCRIPTION
In industry a crusher is typically a machine which uses a metal surface to break or compress
materials. Mining operations use crushers commonly classified by the degree to which they
fragment the starting material with primary and secondary crushers handling coarse materials,
tertiary and quaternary crushers reducing ore particles to finer gradations. Typically crushing
stages are followed by milling stages if the materials need to be further reduced. Crushers are
used to reduce particle size enough so that the material can be processed into finer particles in a
grinder. A typical circuit at a mine might consist of a crusher followed by a SAG mill followed
by a ball mill. In this context, the SAG mill and ball mill are considered grinders rather than
crushers.

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1.4 OPERATION PRINCIPLE

In Hammer mill machine, the motor drives the rotor to rotate at high speed through the belt and
on the rotor there are series of hammers. When the materials get into that working area of the
hammers the rotating hammers with the high rotation speed are crushing them the crushed
products meeting the require shape can be discharged by the outlet and become the final products

1.5 CONSTRUCTION OF MACHINE

The hammer mill crusher consists of a robust fabricated MS body of hinged type for ease of
maintenance. Accordingly the top cover is also divided into three parts and they are two
removable and one fixed part. The crusher gets its motion from a electric motor through v-belt
drive.
Hammer mill crusher mainly consists of the following parts:
Body
Body of a Hammer mill crusher consists of a base frame which is fabricated from thick MS
plates and ribs are provided along the line of stresses to give maximum strength and minimum
vibrations.
Bearings
The whole rotor is supported by two self-aligned roller bearings housed in Plummer blocks,
which are located outside the body.
Rotor shaft
Shaft is made of special steel and is supported at both ends by means of two roller bearings. The
central part of crusher is called rotor. The rotor consists of a heavy shaft machined and
assembled with MS discs and spacers in between discs.
Hammers
The MS disc has holes spaced at 120º for intersection of pins on which hammers are mounted.
These hammers are free to rotate about their own axis and are made up of manganese steel for
high resistance towards wear.
Breaker plate
The breaker plate is held by EN 8 shafts on both top and bottom sides around rotor. The coal is
crushed to the required size between the breaker plate and the rotated hammers.

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Liner plates
The liner plates are made out of manganese steel, which is a very hard material and has high
resistance towards wear. The breaker plate, on which the liner plates are mounted can be
adjusted through take-up screws and nuts to adjust the size of the crushed coal.
Driving motor
The foundation frame of the Driving Motor is provided by projection on one side of the Hammer
mill crusher and supports from base frame are also provided to hold the motor foundation. The
size of motor varies as per the size of Crusher. Normally squirrel cage motor of 980 RPM is
provided.
Driving pulley
This pulley is provided on one side of the center shaft with two v- grooves on it. It is directly
coupled with driving motor with the help of 2 v-belts. The dia of driving pulley has been
calculated as per the requirement of No. of vibration per second.

1.6 TYPES OF CRUSHERS

1. Jaw Crusher
2. Impact Crusher
3. Hammer Crusher
4. Cone Crusher
5. Roll Crusher
6. Wood Crusher

 Jaw crusher
Jaw Crusher is mainly used to crush mining stones and the largest compression resistance of the
material is 320MPa. The jaw crusher is widely used in stone mining, metallurgy industry,
building material, highway, railway, and chemical industry.

Working Principle of Jaw Crusher

The motor transmits power to moving jaw through belt drive to a periodic motion towards the
fixed jaw by the eccentric shaft. The angle between toggle plate and moving jaw plate increases
when moving jaw moves. So the moving jaw moves towards the fixed jaw. The stuff will be

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crushed in this process. The angle between toggle plate and moving jaw decreases when moving
jaw moves down, the moving jaw moves leaves fixed jaw by pulling rod and spring, the final
crushed stuff will be discharged from the outlet.

Merits
1. Simple structure and easy maintenance.

2. Stable performance.

3. High crushing ratio.

Fig. 1.1 Jaw Crusher

 Impact crusher
Impact crusher is widely applied in mining, transportation and chemical industry. They are ideal
choice for crushing and screening. This machine has some extra features such as reasonable
structure, high productivity, easy operation and maintenance with safe performance. The most
outstanding advantage of this machine has its finished powder is in good cubic shape and
without tensility and cranny.

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Merits
1. High reduction ratio and crushing efficiency.
2. No-board connection.
3. Impact plate with a special shape.
4. Crushed product with cubical shape.
5. Easy maintenance and reliable operation.

Fig. 1.2 Line diagram of impact crusher

Working Principle

This impact crushes materials with impact force. When the materials enter the blow bar area,
they are crushed due to the high-speed impact of the blow bar and are thrown to the impact
plates on the rotor for secondary crush. Then the materials will be shot back to the blow bar
again for the third crush. This process repeats until the materials are crushed to the required size
and discharged from the lower part of the machine. The size and shape of the finished powder
can be changed by adjusting the gap between the impact rack and rotor support.

Fig. 1.3 Impact Crusher

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 Cone crusher
Designed on layered crushing theory with features of reliable structure, convenient adjustment
and economical operation. The Cone Crusher is applicable to break various ores and rocks with
medium or above height.

Fig. 1.4 Cone Crusher

 Roll crusher

Heavy-Duty Drive Shafts & Bearings Oversized, heat-treated, alloy steel shafts and self-aligning.
Roller-type bearings assure long life and maximum use of power. Jackshafts for control of roller
speed which are standard on double roll crushers and optional on larger single roll crushers.

Fig. 1.5 Roll Crusher

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 Wood crusher
Wood Crusher is suitable for crushing raw wood with size less than 200mm dia. After milled the
output size can be as small as 3-5 mm dia which is suitable for further palletizing.

Fig. 1.6 Wood Crusher

1.7 WORKING OF HAMMER MILL CRUSHER MACHINE

When coal is delivered to the hammer mill crusher it is prepared for cyclone furnace firing by
being crushed into ¼ inch or smaller size coal. Coal enters from the top and is violently thrown
against the breaker blocks by the hammers. The final crushing is done between the hammer faces
and the screen bars. Tramp iron or material that will not go out between the screen bars is
dropped into the iron pocket and is later removed.

Fig.1.7 Hammer mill crusher

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Fig. 1.8 Working of Hammer mill crusher

The final crushing is done between the hammer faces and the screen bars. Then the crushed coal
goes to the conveyors below and is carried to the storage bunker. Tramp iron or material that will
not go out between the screen bars is dropped into the iron pocket and is later removed.

1.8 BULK MATERIAL HANDLING

Existing methods of bulk material elevation, such as dilute-phase pneumatic conveying, screw
conveying and bucket elevators, can experience a wide range of problems and hazards. A new
type of elevator, called the Olds Elevator, has been developed recently to overcome many of
these problems. This paper describes and reviews this new technology and demonstrates some its
unique features and advantages via industrial case studies. It also describes a new research
facility to investigate particular design and operating issues and the future potential of this new
technology.
Bulk materials handling plants and processes quite often require the elevation (lifting) of bulk
materials to other parts of the plant or process. Numerous technologies and equipment are
currently available for this purpose to the designer and practitioner. For example:
(a) Pneumatic conveyor or air lifter.
(b) Conventional screw conveyor.
(c) Bucket elevator.

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However, these methods of elevation can experience a range of problems and limitations, such
as:
• Pneumatic conveying/lifting: relatively high operating costs (e.g. blower, compressor), product
velocities and wear rates (especially for dilute-phase conveying).
• Screw conveying: relatively high operating speeds (due to slippage between the screw flight
and particles, and also due to the back-flow of material through the screw flight and casing
clearance); increased particle attrition; undesirable casing/screw contact.
• Bucket elevation: relatively high capital and maintenance costs; mis-tracking of belt/chain;
damage to belt/chain, buckets and casing. An example of the latter is shown in Figure 1.

The additional problem or hazard with conventional elevation technology (especially bucket
elevators) is the increased risk of a dust explosion due to: sparking caused by mechanical.
damage or impact (e.g. tramp metal, broken bucket, misalignment of belt/chain/screws); ignition
caused by overheating bearings/pulleys; frictional heating caused by buckets shearing against
product that has built up at the bottom of the bucket elevator casing.

This is exacerbated by the dust generation mechanisms and dust clouds that can be prevalent
inside such conventional elevators. Some typical sources of dust generation include particle-
particle and particle-wall impacts, particle attrition, turbulence and induced/entrained air flows.
Another concern is the propagation of a dust explosion or deflagration through the elevator to
other parts of the plant, in which case some method of explosion control is required (e.g. venting;
explosion detection/suppression; product “isolation” barriers). A new type of elevators called the
old elevator has been developed recently to overcome many of the above problems. The main
aim of this paper is to describe and review the new technology of elevating bulk materials. Some
recent case studies are presented to demonstrate its unique features and advantages.

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CASE STUDIES

(a) Foundry
In 2003, the management Of Bevcon Wayors was faced with the task of elevating sand
to a new moulding machine in his foundry at Olds Engineering in Hyderabad. He soon
discovered that traditional elevators fell short of meeting his objectives of an
economical, compact, simple and trouble-free machine. After some brainstorming and
prototyping, they invented, developed and installed the very first Olds Elevator, and
soon realized the many features and advantages of this novel type of material handling
and quickly patented his device to allow its future application to other products and
industries.

(b) Beans and Grains

In 2004, Bean Growers Australia (BGA), Australia’s largest bean processors sought to
replace three troublesome bucket elevators that were deployed to feed various sorting,
grading and packaging units with five inclined belt conveyors. The Kingaroy facility
ultimately replaced its three bucket elevators with two Olds Bulk Handling, saving
thousands of dollars in capital costs and recovering significant floor space at their plant.
Each elevator was fitted with a variable speed drive to control the flow rate. A large
reduction in the ambient noise level of the plant was also realized. The two Olds
Elevators were both 150 mm N.B. (nominal bore), one 7 m high and the other 7.5 m
high.

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2. TECHNOLOGY OF CRUSHING

There are four basic ways to reduce a material to certain size i.e. by impact, attrition, shear and
compression. Most of the crushers employ a combination of all these crushing methods.

2.1 Impact crushing

In crushing terminology impact refers to the sharp instantaneous collision of one moving object
against another. Both objects may be moving such as a baseball bat connecting with a fast ball or
one object may be motionless such as a rock being struck by hammer blows.
There are two variations of impact such as gravity impact and dynamic impact. Coal dropped
onto a hard surface such as a steel plate is an example of gravity impact. Gravity impact is most
often used when it is necessary to separate two materials which have relatively different
friability. The more friable material is broken while the less friable material remains unbroken.
Separation can then be done by screening.

Fig.1.9 Impact crushing

2.2 Attrition crushing

The Attrition is a term applied to the reduction of materials by scrubbing it between two hard
surfaces. Hammer mills operate with close clearances between the hammers and the screen bars
and they reduce by attrition combined with shear and impact reduction. Though attrition

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consumes more power and exacts heavier wear on hammers and screen bars, it is practical for
crushing the less abrasive materials such as pure limestone and coal.
Attrition crushing is most useful in the following circumstances:
— when material is friable or not too abrasive
— when a closed-circuit system is not desirable to control top size

Fig.1.10 Attrition crushing

2.3 Shear crushing

Shear consists of a trimming or cleaving action rather than the rubbing action associated with
attrition. Shear is usually combined with other methods such as single-roll crushers employ shear
together with impact and compression.
Conditions for shear crushing
— When material is somewhat friable and has a relatively low silica content
— Primary crushing with a reduction ratio of 6 to 1
— When a relatively coarse product is desired the size should be usually larger than 1 h/2
(38mm) top size

Fig. 1.11 Shear crushing

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2.4 Compression crushing

As the name implies crushing by compression is done between two surfaces with the work being
done by one or both surfaces. Jaw crushers using this method of compression are suitable for
reducing extremely hard and abrasive rock. However, some jaw crushers employ attrition as well
as compression and are not as suitable for abrasive rock since the rubbing action accentuates the
wear on crushing surfaces.

As a mechanical reduction method compression should be used as follows:

—If the material is hard and tough
—If the material is abrasive
—If the material is not sticky
—Finished product to be relatively coarse i.e., 1 h/2 (38mm) or larger top size
—Breaking of material cubically

Fig. 1.12 Compression crushing

Hammer mill features:

 Material is reduced by impact from free-swinging bar hammers
 Finished Product size is controlled by grates or crusher
 Materials can be reduced to granular powder at high rate
 Heavy-duty cast-iron or carbon steel construction
 Availability of Right-hand or left-hand machining
 Easy access for maintenance and crusher/grate change

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2.5 Applications of Hammer mill crushers:

 Recycling glass
 Feed industry
 Stone crushing
 Size reduction of waste materials
 Electronics recycling
 Ceramics
 Pulverization of sea shells
 Minerals
 Wood particles for fuel
 Limestone

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3. SCOPE OF PROJECT WOPK

Computer aided design is essential to design the given crusher such that the component can be
viewed before manufacturing any modifications can be made in the design if required and also
we can have different sizes of crusher at a single time without going to the manual process. The
load withstanding capacity of different component can be found out. Finally by checking the
design and with standing capacity of the component is then manufactured manual.

To investigate in more detail the performance characteristics of the Bulk Material

Handling system, a new test rig has been designed and installed at the Vizag Harbour.
Two modes of operation are possible with this new research facility: recirculation mode
with a sight glass to demonstrate the mode of flow; test mode, where a separate feed bin
on load cells is used to supply material to the Olds Elevator feed hopper and a separate
receiving bin on load cells is used to collect the conveyed material and also confirm the
actual throughput. Other important operating conditions, such as electrical power and
rotational speed, also are measured.
This research facility is being employed to investigate particular design and operating
issues (e.g. bulk materials subjected to various rotational speeds; wall friction effects; in-
feed scoop designs; screw flight designs). It is also being used to explore the future
potential of this new technology, in terms of products and industrial applications.

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4. CONCLUSION
The study has led to numerous conclusions. However, major conclusions are as below.
A new type of bulk handling system with the help of the Olds Elevator avoids many of the problems
being experienced by traditional bucket elevators, screw conveyors and pneumatic conveyors. Due
to its full-bore mode of flow transport efficiency is greatly improved and explosion ignition and
propagation hazards are inherently avoided. The externally mounted bearings minimize maintenance
costs and allow the elevator to handle difficult, hot, abrasive or corrosive bulk materials. The
relatively large clearances between the screw and casing and the relatively low slip velocities
between the particles and screw flight help to minimize particle damage and hence, dust generation.
The new research facility at the University of Wollongong is being used to investigate in more detail
the performance characteristics of the Olds Elevator as well as the future potential of this new
technology and also design is carried out in software package known as Pro-e and here the rotor
shaft of hammer mill crusher is designed and assembled in pro-e by slight modifications.

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