Documente Academic
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TO TRAINING PROGRAMME ON MATERIAL HANDLING DURING 17TH 18TH DECEMBER, 2013 AT SAIL / CET , RANCHI ON
INTRODUCTION
Why crushing is required ? To meet the requirements of end users. Beneficiation & etc.
Size requirements of Iron Ore: Lumps for BF Fines for Sinter : (+) 6 mm to (-)30 mm : (+) 0.15 mm to (-)6 mm
: (-) 0.15 mm
:1200mmx1000mmx1000mm
Pulverised Coal - PP
CDI Coal size
: (-)0.074 mm
: 0.09 mm : 100 mm (Approx.)
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Weakest zones
IMPACT CRUSHERS
(Principle of quick impact to crush the material)
CRUSHERS
PRIMARY CRUSHERS SECONDARY / INTERMEDIATE CRUSHERS TERTIARY/ FINE CRUSHERS QUATERNARY / FINE CRUSHERS
CONE CRUSHER
JAW CRUSHERS Mainly used as primary crushers Produce materials that can be transported by belt conveyors to the next crushing stage. Capacity: Upto 1600 tph Principle of operation:
The crushing process takes place between a fixed jaw and a moving jaw
Intermittent process Hydraulic setting adjustment Liner plates JAW CRUSHER IS A RELIABLE, ROBUST Manganese steel, EQUIPMENT AND IS QUITE POPULAR IN Ni-cr alloyed CI PRIMARY CRUSHING APPLICATIONS. 7
BETTER RETURN ON INVESTMENT.
CONE CRUSHERS Mainly used as intermediate or fine crushing to obtain a product with good uniform shape Capacity: Upto 1200 tph
MANTLE WITH LINER BOWL WITH LINER
Principle of operation:
The material is crushed in a crushing cavity between an external fixed element(bowl liner) and internal moving element (mantle) mounted on the oscillating shaft assembly. An eccentric shaft rotated by a gear and pinion produces the oscillating movement of the main shaft. The fragmentation of materials results from the continuous compression that takes place between the mantle liners and bowl liners in the chamber.
CSS OSS
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Principle of operation: The eccentricity causes the cone head to oscillate between OSS and CSS discharge opening. The eccentricity is one of the major factors which determine the capacity of the cone crushers. Adjustment of OSS/CSS: The settings can be adjusted by
Rotating the bowl against the threads so that the vertical position of the outer wear part is changed.
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TERTIARY CONE CRUSHER OF M/s HEC FOR MIOM VARIOUS COMPONENTS UNDER MFG.
Capacity 500 tph Feed Size: (+)30 to (-)75 mm Output: 30 mm
MAIN FRAME
DRIVE SHAFT
TERTIARY CONE CRUSHERS OF M/s HEC FOR MIOM VARIOUS COMPONENTS UNDER MFG.
GEAR ASSEMBLY
MAIN SHAFT
CONE
CONE
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GYRATORY CRUSHERS Efficient primary crushing in mining application. Crushing chamber designed to accept feed materials of relatively larger size. Capacity: 100 tph-9000tph Principle of operation: Same as cone crusher.
Adjustment of closed side settings(CSS): Equipped with a hydraulic setting adjustment, which adjust CSS and thus have better productivity.
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CRUSHER - SUPPLIERS
METSO
FL SMITH
SANDVIK
THYSSENKRUP
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ROLLER CRUSHERS
Purpose: Mainly for crushing easily fractured materials such as soft limestone, chalk and clay. Reduction ratio - 3:1 to 5:1 Principle of operation: The roller crushers consists of two rollers. One of the roller shafts is adjustable while the other has a fixed position and is provided with a flywheel. The gap between the two rollers can be varied depending upon the degree of crushing required. Rollers have scrapers to remove any material sticking to the surface.
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IMPACT CRUSHERS Purpose Generation of fine materials e.g. Sand. Liberate hard minerals from waste materials High reduction ratio and cube shaped product. Capacity: Upto 1800tph Principle of operation The feed material is crushed in the quick rotational movement of hammers/bars fixed to the rotor .
HAMMERS / BARS
The particles produced are then further crushed inside the crusher HIGHER CAPACITY, CUBICAL as they collide against crusher parts PRODUCT & GENERATION OF and against each other, producing a FINES IS NOT A PROBLEM finer, better-shaped product. NOT RECOMMENDED FOR CRUSHING TOO FINES MATERIALS 23
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VERTICAL SHAFT IMPACT CRUSHER Vertical shaft impactor The vertical shaft impactor is like a stone pump which operates like a centrifugal pump. The material is fed through the center of the rotor, where it is accelerated to high speed before being discharged through the openings in the rotor periphery. The material is crushed as it hits on the outer body and also due to the rock-on-rock action. Used for generation of fines e.g. Sand, gravel etc.
VERTICAL SHAFT IMPACTOR
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HAMMER MILLS Purpose To grind and pulverise materials that are not too hard or abrasive.
Principle of operation: Similar to impactors The hammer mill rotor has many pivoted hammers attached to it and the discharge opening consists of a grate through which the material has to pass, thus contributing to the reduction process. The rotor speed and the grate spacing can be optimised to suit different 27 applications.
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SELECTION OF CRUSHERS
Typical maximum Reduction Crusher Typical Feed Size type Process Stage upto (mm) End Product Ratio size (mm) Jaw crushers Gyratory crushers Primary 1400 200-300 3:1 to 5:1
Amount Hardness Abrasiv of Fines Moisture content of material eness Produced Low Soft to very hard Soft to very hard High Dry to slightly wet, not sticky Dry to slightly wet, not sticky
Application
Heavy mining
Primary
1500
200-300
4:1 to 7:1
> 1200
Low
High
Heavy mining
450 300
60-80 0-30
Low Low / Medium Medium / High Medium hard to very hard Low /High Dry or wet, not sticky
Mining, Quarried materials, Sand & gravel Quarried materials, sand & gravel, recycling Sand & gravel, recycling crushing of easily fractured materials
1300
200-300
10:1 to 25:1
Upto 1800
Low
Tertiary
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0-30
6:1 to 8:1
Upto 600
High
Low
Primary
Fines
Fines
3:1 to 5:1
Upto 500
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Characteristics
Type
Jaw crusher
Primary Crushing
Gyratory crusher
Primary Crushing
Cone Crusher
Secondary / Tertiary / Quaternary Medium
( 1200 tph) Continuously 3:1 to 5:1
Capacity
Lesser
( 1600 tph)
Higher
(1000-9000 tph) Continuously 4:1 to 7:1 Heavy
Medium
Larger /Medium feed opening Compression Medium Chances of passage of material without crushing
Larger feed opening Gyration High No chance of passage of material without crushing
Smaller feed opening Gyration Economical No chance of passage 35of material without crushing
Type of crusher
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CRUSHER - SPECIFICATION
Sl. No.
1 2 3 4 5 6 7
Description
TYPE OF CRUSHER Quantity (No.) Rated Capacity (tph) Design Capacity (tph) ROM Dimensions(mm x mm x mm) Material to be handled Crusher Feed F100 (mm)
Specification
JAW / GYRATORY /CONE 1 1000 1300 1200x1000x1000 Direct Ore and Beneficiable ore 1000
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9 10 11 12
600
288 134 2.2 11
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CRUSHER - PERFORMANCE The performance of a crusher depends upon the right choice & correct operation of associated equipments such as feeders, conveyors, screens, drives, silos etc.
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THANK YOU
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