Pennsylvania

Crusher
The Most Choices, The Most Experience
HANDBOOK
OF
CRUSHING

With Posimetric

Feeders
2
We specialize in the manufacture of size reduction and feeding equipment and have pioneered many
basic designs. Pennsylvania

produces more types and sizes of crushers and breakers than any other firm in
the world and is known for offering, "The Most Choices, The Most Experience".
Established in 1905, our equipment is used by numerous basic industries such as power generation,
mining, cement plants, food & chemical processing, the glass industry and many others. In the U.S. in fact, a
high percentage of the coal needed to generate electric power is crushed using our equipment.
Our application expertise is second to none, and we invite you to take advantage of our help in solving
your reduction or feeding problems.
THE TECHNOLOGY OF CRUSHING
The ability to crush material is governed by the laws of physics involving mass, velocity, kinetic energy,
and gravity. However, it is impractical to reduce the process of selecting and sizing a crusher to a series of
formulas. The selection process is largely based on experience and testing: experience with actual field
applications and laboratory tests that show how a given material will be reduced by a given crusher type.
The main purpose of this handbook is to explain the principles that govern the technology of crushing
and also to impart the practical knowledge gained by Pennsylvania Crusher over the past century.
INTRODUCTION
600 Abbott Drive Box 100 Broomall, PA 19008-0100 U.S.A.
Phone: (610) 544-7200 Fax: (610) 543-0190
E-Mail: buster@penncrusher.com
www.penncrusher.com
Pennsylvania
Crusher
The Most Choices, The Most Experience

Table of Contents
THE TECHNOLOGY OF CRUSHING
Introduction .................................................................................................................................................................. 2
Table of Contents ........................................................................................................................................................ 3
Glossary of Terms ........................................................................................................................................................ 4
Mechanical Reduction Methods .................................................................................................................................. 5
Crusher Selection Criteria / Development of Job Specifications ................................................................................ 7
Application Analysis Form............................................................................................................................................ 8
Typical Screen Analysis .............................................................................................................................................. 9
Crushing Tests ............................................................................................................................................................ 10
How to Take Samples .................................................................................................................................................. 10
Measuring Crushing Resistance .................................................................................................................................. 10
Measuring Relative Abrasiveness................................................................................................................................ 10
Index of Abrasiveness.................................................................................................................................................. 11
Definitions of Material Characteristics.......................................................................................................................... 12
Physical Characteristics of Materials .......................................................................................................................... 12
Power Requirements.................................................................................................................................................... 13
Closed Circuit Crushing .............................................................................................................................................. 13
Hammer Technology .................................................................................................................................................... 14
FACILITIES
Facilities and Organization .......................................................................................................................................... 15
Parts and Service ........................................................................................................................................................ 21
PRODUCTS Complete brochures with specifications on individual products are available upon request.
BRADFORD BREAKERS
Roller Mounted Breakers .......................................................................................................................................... 23
Tri-Mounted Breakers ................................................................................................................................................ 23
Bradpactors................................................................................................................................................................ 24
CAGE MILLS .............................................................................................................................................................. 25
GRANULATORS.......................................................................................................................................................... 26
HAMMERMILLS
Reversible Hammermills for Coal .............................................................................................................................. 27
Reversible Hammermills for Fluid Bed Boiler Applications........................................................................................ 28
Reversible Hammermills for Rock, Limestone, Minerals and Chemicals.................................................................. 29
Non-Reversible Hammermills .................................................................................................................................... 29
Non-Clog Hammermills.............................................................................................................................................. 30
IMPACTORS
Coalpactors................................................................................................................................................................ 31
Aluminum Dross Impactors / Metallic Slag Crushers ................................................................................................ 32
Reversible Impactors ................................................................................................................................................ 33
Reversible Impactors, Small ...................................................................................................................................... 34
Twin Rotor Impactors ................................................................................................................................................ 34
JAW CRUSHERS ........................................................................................................................................................ 35
GRINDING MILLS
Brad-Multi-Roll Crushers .......................................................................................................................................... 36
ROLL CRUSHERS
Clinker Crushers ........................................................................................................................................................ 37
Single Roll Crushers.................................................................................................................................................. 38
Double Roll Crushers ................................................................................................................................................ 39
Frozen Coal Crackers................................................................................................................................................ 40
SIZERS ........................................................................................................................................................................ 41
POSIMETRIC FEEDERS ............................................................................................................................................ 42
PENNSYLVANIA BRADFORD HAMMERMILL

FROZEN COAL CRACKER

PENNSYLVANIA REVERSIBLE IMPACTOR

KOAL KING

U.S. Patent Number 4,343,438

BRADPACTOR

FBR

COALPACTOR

BMR BRAD-MULTI-ROLL

U.S. Patent Numbers 3,931,937; 4,009,834

POSIMETRIC

FEEDER PENNTECHNIC

PENNSYLVANIA

Trademarks of Pennsylvania Crusher Corporation

Pennsylvania Crusher Corporation 2000, 2002, 2003
3
4
Angle of Nip The angle formed between the moving
surface of a crusher roll or jaw plate and the
stationary plate surface, at which point the
material will be pinched. Angle varies with
machine size and material lump size.
Bond Work Index (BWI) KW hr. per short ton required to
reduce the material to 80% passing 100 microns.
Breaker Block (Breaker Plate) The steel anvil surface of
a crusher against which material is crushed by
impact or pressure.
Bridging Blocking of crusher opening by large pieces of
material.
Burbank Abrasion Test A standard method of comparing
the relative abrasiveness of rocks, minerals and
ores.
Cage A screening device, fixed or adjustable, made of
precisely spaced bars or slotted plate, where final
sizing is accomplished within the crusher.
Choke Feed Operating the crusher with a completely filled
crushing chamber.
Choke Point Place in the crushing chamber having the
minimum cross section. All compression type
crushers have choke points, but this does not
necessarily mean that choking is likely to occur.
Choking Stoppage of the flow of material through the
crusher, usually the result of wet and sticky
material clogging exit points.
Circulating Load The amount of oversize returned to the
crusher from a screen in a closed-circuit system.
Closed-Circuit Crushing A system in which oversize
material is screened from the output and returned
for another pass through the crusher.
D
50
Denotes that output size is 50% smaller than the
size indicated.
Feed Input to the crusher.
Feeder A device that regulates and distributes material
into the crusher.
Fines Material with particle size smaller than a specified
opening.
Finished Product (Output) The resulting material after it
has been processed.
Friable Material that breaks easily.
Hammers Free-swinging or fixed metal impact surfaces
attached to the rotor assembly of an impactor or
hammermill crusher. Sometimes designated as
beaters.
Hardgrove Index (HGI) The grindability of a coal is
expressed as an index showing the relative
hardness of that coal compared with a standard
coal of 100 grindability.
Height of Drop Vertical, free fall distance from the lip of
the feeding device to the inlet opening of an
impactor or hammermill crusher. Normally
applies to reversible machines.
Hopper The area of the crusher preceding the crushing
chamber. Also, an external bin that holds the feed
material.
MOH Scale Relative hardness of material compared to
1-Talc, 2-Gypsum, 3-Calcite, 4-Fluorite, 5-Apatite,
6-Feldspar, 7-Quartz, 8-Topaz, 9-Corundum, and
10-Diamond.
Nominal Describes product size (output size), usually
denoting that at least 90% of product is smaller
than size indicated.
Oversize Material too large to pass through a specific size
of screen or grizzly opening.
Plugging Restriction of material flow through a crusher.
Primary Crusher The first crusher in a crushing system
into which material is fed. Succeeding crushers
in the system are referred to as secondary or
tertiary crushers.
Product Output from the crusher.
Reduction Ratio The ratio of the top size of input material
to the top size of crusher discharge.
Reversible Crushers Hammermills and impactors with
rotors that can be run both clockwise and
counterclockwise.
ROM Run Of Mine Material from a mine that has not
been crushed or screened.
ROQ Run Of Quarry Material from a quarry that has
not been crushed or screened.
Rotor Rotating assembly of shaft, discs, and hammers
within a crusher which imparts the crushing forces
to the material.
Scalping Removing all sizes smaller than output top size
from the crusher input material.
Screen Bars The bars in the cage of a hammermill or
granulator, spaced to control the output size. Also
called cage bars or grate bars.
Slugger Teeth The large teeth on a single roll crusher
which first strike the material.
Sorbent Stone, usually containing calcium; used to capture
sulfur in a fluid bed boiler.
Tailings Refuse or residue material from a screening
process.
Top Size The largest particle size in an input or output size.
Tramp Iron Bolts, shovel teeth, picks, and other uncrush-
able metal that is often present in crusher input.
GLOSSARY
OF TERMS
5
There are four basic ways to reduce a material
by impact, attrition, shear or compression
and most crushers employ a combination of all
these crushing methods
MECHANICAL
REDUCTION
METHODS
THE TECHNOLOGY
OF CRUSHING
Impact
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: gravity im-
pact 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.
The Pennsylvania Bradford Breaker employs
gravity impact only. This machine revolves so slowly
that for all practical purposes, gravity is the only
accelerating force on the coal.
Material dropping in front of a moving hammer
(both objects in motion), illustrates dynamic impact.
When crushed by gravity impact, the free-falling
material is momentarily stopped by the stationary
object. But when crushed by dynamic impact, the
material is unsupported and the force of impact
accelerates movement of the reduced particles toward
breaker blocks and/or other hammers.
Dynamic impact has definite advantages for the
reduction of many materials and it is specified under the
following conditions:
when a cubical particle is needed
when finished product must be well graded
and must meet intermediate sizing
specifications, as well as top and bottom
specifications
when ores must be broken along natural
cleavage lines in order to free and separate
undesirable inclusions (such as mica in
feldspars)
when materials are too hard and abrasive for
hammermills, but where jaw crushers cannot
be used because of particle shape require-
ments, high moisture content or capacity
Dynamic impact is the crushing method used by
Pennsylvania Impactors.
Attrition
Attrition is a term applied to the reduction of
materials by scrubbing it between two hard surfaces.
Hammermills operate with close clearances between
the hammers and the screen bars and they reduce by
attrition combined with shear and impact reduction.
Though attrition 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
Shear
Shear consists of a trimming or cleaving action
rather than the rubbing action associated with attrition.
Shear is usually combined with other methods. For
example, single-roll crushers employ shear together
with impact and compression. Shear crushing is
normally called for under these conditions:
when material is somewhat friable and has
a relatively low silica content
for primary crushing with a reduction
ratio of 6 to 1
when a relatively coarse product is desired,
usually larger than 1
1
/
2" (38mm) top size
6
Compression
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
where the finished product is to be relatively
coarse, i.e., 1
1
/
2" (38mm) or larger top size
when the material will break cubically
The Pennsylvania Jaw crushes by compression
without rubbing. Hinged overhead and on the
centerline of the crushing zone, the swinging jaw
meets the material firmly and squarely. There is no
rubbing action to reduce capacity, to generate fines or
to cause excessive wear of jaw plates.
Single Roll Crushers reduce large input by a combination
of shear, impact and compression. They are noted for
low headroom requirements and large capacity.
When a Pennsylvania Non-Reversible Hammermill is used
for reduction, material is broken first by impact between
hammers and material and then by a scrubbing action
(shear and attrition) of material against screen bars.
The bottom of the Pennsylvania Reversible Impactor is
open and the sized material passes through almost
instantaneously. Liberal clearance between hammers and
the breaker blocks eliminates attrition, and crushing is by
impact only.
7
CRUSHER
SELECTION
CRITERIA
When selecting a crusher, the following criteria must be considered:
1. Will it produce desired output size and shape at the required capacity?
2. Will it accept the largest input size expected?
3. What is its capacity?
4. Will it choke or plug?
5. Can it pass uncrushable debris without damage to the crusher?
6. How much supervision of the unit is necessary?
7. Will it meet product specifications without additional crushing stages and auxiliary equipment?
8. What is the crushers power demand per ton per hour of finished product?
9. How does it resist abrasive wear?
10. Does it operate economically with minimum maintenance?
11. Does it offer dependable and prolonged service life?
12. Is there ready availability of replacement parts?
13. Does it have acceptable parts replacement cost?
14. Does it have easy access to internal parts?
15. Is the crusher versatile?
16. How does the initial cost of the machine compare with its long term operating costs?
17. Is experienced factory service readily available?
The initial steps in selecting the proper crusher
require the development of complete job specifica-
tions, including the pertinent physical characteristics of
the feed material.
The Application Analysis Form that appears
here is designed to simplify the task of collecting job
specifications. In most cases, the completed form will
enable the engineering staff of Pennsylvania Crusher
to recommend the crusher best suited to meet the
requirements.
On occasion, it may also be necessary to
supply actual samples of the material for test crushing
in the Pennsylvania Crusher test facilities. Refer to
Page 8 for How to Take Samples.
Additional copies of the Application Analysis
Form (Page 6) may be obtained by photocopying or by
request. If you have any questions regarding the
completion of this form, please contact Pennsylvania
Crusher Corporation.
DEVELOPMENTOF
JOB SPECIFICATIONS
8
a. Material: ________________________________________________________________________________
b. Bulk Density: _____________________________________________________________________________
c. Moisture:_______________________________%Total_______________%Surface_____________________
d. Compressive Strength (PSI) _________________________________________________________________
e. MOH Hardness/Hardgrove Index:_____________________________________________________________
f. Material Temperature:___________________Degrees F:____________________Degrees C: _____________
g. Material is:
Free-Flowing ( ) Sticky ( )
Non-Abrasive ( ) Mildly Abrasive ( ) Very Abrasive ( )
h. Other Characteristics: ______________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
a. Mining Method or Process Source:____________________________________________________________
b. Feed Size (Maximum): _______________________ X________________________X___________________
c. Desired Product Size (State size and % passing): ________________________________________________
d. Is product size material removed from feed prior to crushing? ______________________________________
What percentage is removed? _______________________________________________________________
e. Are fines: ( ) desirable ( ) undesirable ( ) no preference
If undesirable, at what size?_________________________________________________________________
f. Can external screens be used to return oversize to crusher (closed-circuit)? ___________________________
g. Capacity desired (tons per hour): _____________________________________________________________
a. Crusher will: ( ) replace existing equipment ( ) be used in new operation
b. Project is: ( ) study for feasibility or budget purposes
( ) funded for purchase. Expected purchase date:________________________________
c. Delivery is required by: _____________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
APPLICATION ANALYSIS FORM
Completion of this sheet will help our
engineers select the crusher best suited to
your requirements.
Box 100
Broomall, Pennsylvania 19008-0100, U.S.A.
Telephone: 610-544-7200
Fax: 610-543-0190
E-Mail: buster@penncrusher.com
COMPANY: __________________________________________
ADDRESS: __________________________________________
CITY: ________________________________________________
STATE:______ ZIP:_____________ COUNTRY: ______________
NAME AND TITLE: ____________________________________
PHONE: ______________________________________________
FAX: ________________________________________________
E-MAIL:______________________________________________
1.
MATERIAL
DESCRIPTION
2.
APPLICATION
REQUIREMENTS
3.
GENERAL
INFORMATION
4.
OTHER
INFORMATION
WHICH MAY BE
OF VALUE
Pennsylvania
Crusher
DATE: ____________________________________________
PROJECT: ________________________________________
PROJECT LOCATION: ______________________________
______________________________________________________
______________________________________________________
PROJECT REFERENCE NUMBER: ____________________
______________________________________________________
9
10
CRUSHING
TESTS
When a new or unusual application is encoun-
tered, samples of the material may be crushed to
determine which crusher is most suitable. This is done
in the Pennsylvania Crusher Test Laboratory. By crush-
ing samples of the material, significant facts can be
learned for predicting the performance of full capacity
machines with acceptable accuracy.
Laboratory tests can prove or disprove the rel-
ative merits of various types of crushers. They also
provide an opportunity to evaluate the effects of various
crusher settings, speeds, feeding methods, height-of-
drop, and size or shape of hammers and breaker blocks.
In the lab, one element at a time can be changed while
all others are held constant. Under such conditions, any
changes in crushing results can be isolated and
evaluated by our application engineers.
Testing Procedure
The normal procedure is to test crush a repre-
sentative sample of the material and to then determine
the product size gradation. From this data, a graph is
plotted showing the cumulative percentage of material
passing each screen size. Page 7 illustrates a typical
screen analysis derived in this manner.
By comparing screen analyses and other
criteria with those associated with familiar materials, an
experienced crusher application engineer can estimate
overall crushing performance as well as power require-
ments. The engineer can also detect characteristics
that require special design considerations or auxiliary
equipment.
Deciding Factors
Tests may show that two or more types of
crushers will perform equally well on a particular
material. But other factors must still be considered such
as headroom, desirability of fines, product shape,
economics of maintenance and operations, and the
adaptability of the crusher to future plant expansions.
HOW TO
TAKE SAMPLES
To ensure meaningful results from the
Pennsylvania Crusher Test Laboratory, it is important
that a truly representative sample of material be pro-
vided. Care must be taken to ensure that the sample is
collected from a true cross section of the material and
that it is packed to retain its original characteristics
(moisture, size, shape, etc.).
A 55-gallon steel barrel of material will usually
be an adequate amount for testing.
Measuring Crushing Resistance
A basic premise in equipment selection is that
the crusher be stronger than the material that it must
crush. How strong are rocks and ore? While there is no
direct measurement of resistance to crushing, it is
possible to measure compressive strength and the
elastic properties of a material.
The graph shows a typical plot of test results for
different materials, and it demonstrates the relationship
between compressive load and resulting displacement.
The material exhibiting twice as much displacement
under compression will normally require twice as much
power to be crushed.
A.S.T.M. Method C-170-50 is used to obtain the
highest accuracy in measuring compressive strength.
However, the Pennsylvania Crusher laboratory has
developed a procedure that is more practical for crusher
selection. This procedure is fully described in an article
by Benjamin B. Burbank, entitled Measuring the
Crushing Resistance of Rocks and Ores. Copies are
available from Pennsylvania Crusher Corporation.
Measuring Relative Abrasiveness
It is difficult to predict the abrasive action of
rocks, minerals, and ores. Often, rocks belonging to the
same geological classification will vary widely in
abrasiveness from one locality to another. Therefore, in
order to select the proper crusher, we must have some
reliable measurement of the abrasiveness of the specific
material.
Abrasiveness can be determined either from
prior experience or by testing in semi-production plants,
but a simpler method has been developed by
Pennsylvania Crusher Corporation. This involves
.004" .008" .012" .016" .020" .024"
0
10
20
30
40
50
60
70
11
9
10
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
Cement rock, NY
Colorado oil shale, CO
Feldspar, NH
Cement rock, Thomaston, ME
Dolomite, NY
Sandstone, AZ
Iron ore, Ozark Mts., AR
Graphic granite (feldspar), NY
Chert, Picher, OK
Granite, Winterport, ME
Quartzite, VT
DISPLACEMENT (Inches)
COMPRESSIVE LOAD
(x 1,000 psi)
11
testing, and it is a reliable way to establish relative
abrasiveness by using four 400-gram samples of the
material to be crushed.
Each sample of material is rotated for 15 min-
utes in a drum with a steel paddle. After the four sepa-
rate batches are run, the average milligrams of weight
loss by the paddle is measured. This will serve as a
relative index of abrasive action. The higher the index,
the greater the abrasiveness.
This test provides the most practical index of
abrasiveness available today. Such test data has been
collected for many years on numerous samples of rocks
and ores. Typical scales of relative abrasiveness derived
from this testing procedure are shown in the table below.
A more complete description of the method and
equipment for obtaining these abrasiveness indices is
contained in our publication entitled, Measuring the
Crushing Resistance of Rocks and Ores.
INDEX OF ABRASIVENESS
MATERIAL AND SOURCE ABRASIVENESS INDEX
Highly Abrasive
Manganese Ore, Georgia............................................................................................................................................................................ 32,946
Aluminum Oxide, New York......................................................................................................................................................................... 14,114
Sandstone, Pennsylvania............................................................................................................................................................................ 13,121
Oxygen Furnace Slag, Ontario.................................................................................................................................................................... 10,828
Chert, Missouri ............................................................................................................................................................................................ 9,829
Stone and Bauxite Clinker, Indiana ............................................................................................................................................................. 9,489
Gravel, Mississippi....................................................................................................................................................................................... 8,888
Stone, Virginia ............................................................................................................................................................................................. 7,969
White Quartz, Maine.................................................................................................................................................................................... 7,000
Calcined Alumina, Louisiana ....................................................................................................................................................................... 6,879
Open Hearth Pot Slag, New York................................................................................................................................................................ 6,830
High-Silica Limestone, Pennsylvania .......................................................................................................................................................... 4,838
Granite, Puerto Rico.................................................................................................................................................................................... 4,517
Feldspar, Virginia......................................................................................................................................................................................... 3,650
Burned Brick and Tile, Pennsylvania........................................................................................................................................................... 3,491
Sintered Ore, Alabama ................................................................................................................................................................................ 3,065
Trap Rock, Pennsylvania............................................................................................................................................................................. 2,928
Feldspar, New Hampshire ........................................................................................................................................................................... 2,871
Tungsten Ore, California ............................................................................................................................................................................. 2,253
Cement Clinker, Pennsylvania..................................................................................................................................................................... 2,206
Abrasive (Wear can be minimized by design and materials of construction)
Iron Ore, Missouri ........................................................................................................................................................................................ 1,992
Transvaal Chrome Ore, South Africa .......................................................................................................................................................... 1,755
Coke Breeze, Alabama................................................................................................................................................................................ 1,690
Calcined Bauxite, Missouri .......................................................................................................................................................................... 1,671
Red Limestone, Vermont ............................................................................................................................................................................. 1,452
Scoria Volcanic Cinder ................................................................................................................................................................................ 1,352
Cement Clinker, Quebec ............................................................................................................................................................................. 1,231
Grog, New Jersey........................................................................................................................................................................................ 1,052
Amorphous Silica, Illinois............................................................................................................................................................................. 978
Travertine, Australia..................................................................................................................................................................................... 838
Phosphate Nodules, Tennessee.................................................................................................................................................................. 813
Cement Clinker, Kentucky ........................................................................................................................................................................... 695
Hematite, Venezuela ................................................................................................................................................................................... 620
Barite, Arkansas .......................................................................................................................................................................................... 550
Limestone, Indiana ...................................................................................................................................................................................... 526
Dolomitic Clinker, Ohio ................................................................................................................................................................................ 494
Cement Rock, Brazil.................................................................................................................................................................................... 444
Ferro-Phosphorous, Oklahoma ................................................................................................................................................................... 443
Dolomite, West Virginia ............................................................................................................................................................................... 417
Low in Abrasion (Parts wear is not critical)
Shale, Virginia ............................................................................................................................................................................................. 345
Antimony Ore, New Jersey.......................................................................................................................................................................... 315
Oil Shale, Colorado ..................................................................................................................................................................................... 270
Chamotte, Michigan..................................................................................................................................................................................... 250
Zinc Sinter, Pennsylvania ............................................................................................................................................................................ 249
Limestone, Ohio .......................................................................................................................................................................................... 241
Extruded Zircon, New Jersey ...................................................................................................................................................................... 186
Weathered Shale, Virginia........................................................................................................................................................................... 131
Zinc Oxide, Pennsylvania............................................................................................................................................................................ 78
Diatomaceous Shale Clinker, England........................................................................................................................................................ 78
Dolomite, Alabama ...................................................................................................................................................................................... 62
Sandstone, California .................................................................................................................................................................................. 38
Red Flux, Australia ...................................................................................................................................................................................... 31
Shale, Virginia ............................................................................................................................................................................................. 30
Clay, Pennsylvania ...................................................................................................................................................................................... 25
Cement rock, Pennsylvania......................................................................................................................................................................... 13
Anhydrite, Kansas ....................................................................................................................................................................................... 9
Limestone, Australia .................................................................................................................................................................................... 7
12
DEFINITIONS OF
MATERIALCHARACTERISTICS
Selection of the most appropriate crusher is greatly influenced
by the precise nature of the material to be crushed. The listings
that follow serve to illustrate how even the same basic materials
can vary widely. Such variances will definitely influence the type
of crusher that should be employed.
CLASS
Low abrasiveness..................................................................................................................................... 1
Mildly abrasive.......................................................................................................................................... 2
Very abrasive............................................................................................................................................ 3
Very free flowing - angle of repose up to 30........................................................................................... 4
Free flowing - angle of repose 30-45 .................................................................................................... 5
Sluggish - angle of repose 45 and up..................................................................................................... 6
Hygroscopic.............................................................................................................................................. A
Highly corrosive........................................................................................................................................ B
Mildly corrosive......................................................................................................................................... C
Degradable when exposed to air ............................................................................................................. D
Very friable................................................................................................................................................ E
Mildly friable.............................................................................................................................................. F
Tough - resists reduction .......................................................................................................................... G
Plastic or sticky......................................................................................................................................... H
SPECIAL
CHARACTERISTICS
PHYSICAL CHARACTERISTICS OF MATERIALS
*Refer to table above for class description
Material
Alumina
Aluminum Oxide
Bagasse
Barite
Bark (wood refuse)
Basalt (broken)
Bauxite (crushed)
Bentonite
Brick
Carbon Electrodes (baked)
Carbon Electrodes (unbaked)
Cement Clinker
Cement Rock
Charcoal
Clay (dry)
Calcined Clay
Coal - Anthracite
Coal - Bituminous
Coal - Sub-bituminous
Coke - Petroleum
Cryolite
Cullet - Glass
Diatomaceous Earth
Dross - Aluminum
Fluorspar
Fullers Earth - raw
Granite - broken
Gravel
Gypsum Rock
Class*
3-5-G
3-G
1-6-C
3-5
2-6-G
3-G
3-5-F
2-5
3-F
2-G
1-F
3-5-F
2-5-F
2-5-D-F
3-5
3-F
1-4-D-E
1-5-C-D-E
1-5-C-D-E
2-5
1-5-F
3-5-E
2
3-F-C
2-5-F
2-5
3-5-G-H
3-5-F
2-5-F
Average Weight in Lbs.
Per Cubic Foot
60
70-120
7-8
140-180
10-20
10-20
75-85
40-50
100-125

75-95
100-110
18-25
60-75
80-100
55-60
45-55
45-55
35-42
110
80-120
11-14

90-100
35-40
90-100
90-100
90-100
Material
Lignite - Texas (ROM)
Lignite - Dakota (ROM)
Lime - Pebble
Limestone - broken
Manganese Ore
Marble - broken
Marl - raw & wet
Middlings - Coal
Phosphate Rock - Ore
Potash Ore
Potash Ore Compactor Flake
Quartz - broken
Refuse - household
Sand - dry bank
Sand - foundry
Sandstone - broken
Shale - broken
Shells - Oyster
Diacalcium Phosphate
Dolomite
Slag - Open Hearth
Slag - Blast Furnace
Slate
Soapstone (talc)
Superphosphate
Traprock - broken
Triple Superphosphate
Trona Ore
Tungsten Carbide
Class*
1-5-D-E
1-6-D-F
1-5-E
2-5-F
3-5-G
2-5-F
2-6-E-H
2-5-G-F
2-5
1-E
1-E
3-5-E
2-G
3-5
3-5
3-F
2-5-F
2-5-E
2-5-E-H
2-5-F
3-G
3-4-F-E
2-E
1-F
2-6-F-H
3-5
2-6-F-H
2-5-F
3-4-G
Average Weight in Lbs.
Per Cubic Foot
45-50
45-50
53-56
90-100
125-140
90-100
130-140

85-95
45-50
90-110
90-110
85-90
90-100
70-80
43
90-100
160-180
80-90
85-95
40-50
50-55
105-110
50-55
90-100

ABRASIVENESS
FLOWABILITY
13
In crushing, the useful or meaningful work is
that expended to reduce the material to a given size. A
number of theories have been expressed to define the
relationship between work input and size reduction.
Kicks Law states that work done is proportional to the
reduction in volume of particles, a theory which applies
to the crushing of large particles. However, finer
product sizes conform more closely to Rittingers
Theory which concludes that work required is
proportional to the new surface area formed, and
inversely proportional to the product diameter.
In any case, reduction ratio is not the only factor
in determining power requirements. Nearly all crushing
projects differ from one another in one or more aspects,
and no hard and fast rule can be applied with regard to
power consumption. However, through extensive
experience in the field of mechanical reduction, some
average values have been compiled regarding the
power requirements of different types of crushers.
Typical Horsepower Requirements
It has been determined that a primary single roll
crusher, reducing run of quarry medium-hard limestone
to a 6" (150mm) product will require approximately
1
/
2
horsepower per ton per hour (HP per TPH). However,
when crushing medium-hard bituminous coal to the
same specifications, the power demand is only
1
/
12 HP
per TPH. Even on the hardest materials, single rolls do
not require more than one full HP per TPH and may
demand as little as
1
/
25 HP per TPH.
Coalpactors for preparing coking coal for coke
ovens are fed with 3" (75mm) and under bituminous
coal. The product usually desired is 80-85% minus
1
/
8"
(3mm). For this service, 1
1
/
2 to 2 HP per TPH is nor-
mally required.
In cement plants, where hammermills or
impactors are used for secondary crushing of cement
rock, the feed is approximately 6-10" (150- 250mm) and
the product is a nominal
1
/
2 " (12mm). This reduction
needs 1
1
/
3 to 1
1
/
2 HP per net TPH.
Impactors generally require approximately 1 HP
per TPH (gross load) to drive them. This may be slightly
increased if an extremely fast rotor speed is required.
Granulators (ring hammermills) are most often
used in the coal handling facilities of power stations
where they reduce run of mine coal to a nominal
3
/
4"
(19mm) product. This typically requires
1
/
2 HP per TPH.
The Pennsylvania Jaw Crusher requires
approximately
1
/
3 or less HP per TPH, depending upon
the reduction ratio desired.
Bradford Breakers and Bradford Hammermills
require approximately
1
/
4 or less HP per TPH.
Motor Selection
The foregoing figures are averages, and each
crushing problem should be carefully studied before
selecting motors. We urge all prospective customers to
consult us prior to selecting motors, since so many
factors will affect power demand. Our experience with
such diverse types of crushers will serve as a guide for
proper motor selection.
CLOSED-CIRCUIT CRUSHING
Closed-circuit crushing is a means of controlling
product top size by screening the product and then
returning oversize material to the feed end of the
crusher for another pass through the machine. While it
may be possible to obtain a specified top size from
crushers without using a closed-circuit system, it is not
always desirable. To control top size from a single
crusher operating in an open circuit, material must
remain in the crushing chamber until it is reduced. This
results in overgrinding a percentage of the product, with
a corresponding increase in fines and a loss of
efficiency.
In a typical multiple-stage crushing plant with
the last stage operated in closed-circuit, the primary
crusher operates at a setting which produces a
satisfactory feed size for the secondary crusher, so that
a balance exists for the work done by each crusher.
POWER
REQUIREMENTS
14
Hammer design plays a significant role in
crusher efficiency, because in most types of crushers,
the hammers do most of the work. Early hammer
designs were only concerned with mass and general
shape of the hammer. Today the technology of
Pennsylvania hammers is highly developed, and we
give careful consideration to a great many factors:
Location of the hammers center of gravity
The center of gravity determines the focus of
impact, which in turn helps to control the amount of
impact and the general shape of the shattered particle.
The center of gravity must be controlled to utilize the full
mass of the hammer against the feed.
Air paths created by hammer rotation
The air paths created by the hammer sweep
usually contain a certain amount of fines and other small
particles which must be directed away from the hammer
shanks and rotor discs; otherwise premature wear would
occur. Pennsylvania hammers are designed so that the
resulting air paths are directed toward open areas of the
crushing chamber, away from vital parts.
Edge configuration of the hammer head
The edges of each Pennsylvania hammer face
are shaped to a special geometry in order to produce
maximum hammer life with the lowest amount of friction.
Heat treating
Hammer hardness is the most essential factor
in determining hammer life, for while the hammer head
must be extremely hard and resistant to wear, the shank
must be more ductile in order to absorb shock. To
produce this on certain designs, Pennsylvania uses a
special method of heat treating that creates a gradually
varying hardness between the shank and the tip,
without any abrupt changes. However, in cross section,
the hardness extends for the full depth instead of merely
the surface. Hammer hardness is normally gauged
according to the Brinnel method.
As a result of continued improvements,
Pennsylvania hammer design plays a major role in
producing high efficiency and in reducing maintenance
problems. As the company introduces refinements to
the hammers, users are provided with the latest designs
as part of their normal resupply orders.
CRUSHER
HAMMER
TECHNOLOGY
BAR HAMMER
T-HEAD HAMMER
RING-TYPE HAMMER (plain)
RING-TYPE HAMMER (toothed)
B A S I C H A MME R T Y P E S
15
FACILITIES
AND
ORGANIZATION
Pennsylvania Crusher possesses the most modern facilities in the world devoted
to the design and manufacture of crushers. Still, our companys most valuable assets
reside in the talents of the skilled professionals who staff our many departments.
Design engineering, application engineering, field service, parts, production,
finance, marketing, research and development all work together to provide equipment
that will perform best in your application, with full factory support throughout the
operational life of your crusher.
For an evaluation of your needs, please contact us at any time. We believe you
will be impressed with the experience, the proficiency and the helpful attitude you find at
every level within Pennsylvania Crusher.
Pennsylvania Crusher
Manufacturing Plant (top)
in Cuyahoga Falls, Ohio,
and Headquarters in
Broomall, Pennsylvania.
16
Our manufacturing facility is located in
Cuyahoga Falls, Ohio, near Akron, and is adjacent
to major rail and highway arteries. This facility
contains every type of manufacturing equipment
needed to produce the numerous types and sizes of
crushers and feeders sold by Pennsylvania Crusher.
An exceptionally high percentage of our manufacturing specialists are
qualified journeymen, with a minimum of 8,000 hours of on-the-job
training, coupled with years of formal schooling.
In terms of hands-on experience, fully half of us have
served under the same roof for over ten years, and many
have over twenty and thirty years to our credit.
17
We also handle the repair and remanufacture of Pennsylvania crushers, including
rotor and cage assemblies and other components. This enables the customer to
upgrade to a new design, in order to achieve current operating efficiencies, along
with a new parts warranty.
We operate a Crushing Test Laboratory, fully equipped with
various models of crushers. Test crushing your material in
advance of purchase enables us to determine which model and
size of crusher will be the most suitable. It also enables us to
determine wear rates, height-of-drop data and other valuable
information.
Analyses of materials, equipment and parts by our
testing laboratory constitute the basic data from
which recommendations will be made for selection
and sizing of crushers.
18
Design Engineering. This group is the source of numerous innovations in crusher design . . . including
some basic crushing methods that have been adopted by the entire industry.
Our extensive use of computer-aided design (CAD) helps
to speed the completion of new equipment designs.
All operations of Pennsylvania Crusher
are linked by an integrated, state-of-the-art
management program that embraces advance
planning, accounting, engineering, order entry,
scheduling, manufacturing, shop floor reporting,
and shipping.
This has enhanced our ability to provide
you with timely information regarding the status
of your order, and to expedite manufacture to
suit your schedule.
19
Communications Center. This group is
responsible for our companys contact with all
points on the globe. The innovative equipment
used here helps to enhance the speed and
accuracy of communications.
Field Service. We can supply trained personnel to
supervise the installation of Pennsylvania Crushers.
Their practical and extensive experience helps to
achieve significant cost savings.
Management Information Systems. Computer-based procedures have
enhanced Pennsylvanias customer service and order acknowledgment
systems. They also help the company to achieve more accurate levels
of inventory to meet changing customer needs.
20
Sales and Applications Engineering. These groups possess unparalleled skill and experience with material reduction projects
worldwide. To complement the high professional expertise of each member, the application department maintains one of the most
extensive data bases of information about materials, equipment, and test results on tens of thousands of mineral samples from every
continent.
Accounting and Finance
Group. The significant
financial strength of our
company is enhanced by
the efficiency and
smooth operation of this
department. This section
is staffed by professionals
who clearly understand
the special requirements
of the markets we serve.
21
Parts & Service Group. This group goes far
beyond the usual concept of simply supplying
replacement parts. They operate under a philosophy of
service completely oriented to the continuing
needs of the customer, regardless of whether the
customer is working with new Pennsylvania equipment
or with equipment that was placed in service over ninety
years ago.
As part of this practice, there are three
important areas in which this department is of practical
service to customers:
1. Basic supply requirements.
2. Refinements to older design equipment for
improved performance.
3. Major modifications to equipment either for
improved performance or for different applications
than that for which it was originally designed.
For maximum effectiveness, the Pennsylvania
parts staff maintains thoroughly detailed records on
all machines shipped, including details of past
modifications, service records and all other pertinent
data. Complete drawings are kept on modifications as
far back as ninety years, for there are numerous
instances where such Pennsylvania equipment is still in
productive service.
The Parts Department operates almost as an
extension of the customers maintenance department,
since the objectives are similar, i.e., to keep the
equipment operating effectively and economically.
Parts and Service sales representatives are available
for consultation with the customer on questions
regarding parts, service, or modification work.
Electronic Data Interchange
Our on-line system for electronic data
interchange (EDI) speeds the flow of acknowledgments,
RFQs, POs and invoices, using a standard, ready-to-
process form.
If you already have such a system, please
contact us about establishing a link directly to your
company or to your consulting service.
The Pennsylvania Crusher Parts and Service Group has forged a reputation for responsiveness, experience and versatility.
22
These machines are used for crushing, sizing,
and cleaning of run-of-mine coal and other friable
materials. They are used to produce a product that is
relatively coarse, with minimum fines, and that is 100%
to size.
Bradford Breakers crush by gravity impact only.
A large cylinder made of perforated screen plates is
fitted with internal shelves. As the cylinder rotates, the
shelves lift the feed and, in turn, the feed slides off the
shelves and drops onto the screen plates below, where
it shatters along natural cleavage lines.
The size of the screen plate perforations
determines the product size. Sized product falls
through these perforations but oversized pieces will
again be lifted and dropped by the shelves until they too
pass through the screen plates.
Tramp iron, lumber, or other uncrushable debris
that enters the breaker along with the feed is
transported to the discharge end of the cylinder. There,
these uncrushables are scooped out continuously by a
refuse plow which channels this debris out of the
cylinder and into a disposal bin.
Often a Pennsylvania Bradford Breaker is used
merely to clean debris from coal that has already been
sized. This gives some indication of the economy of
operation and versatility of this machine.
Breaker cylinders rotate at slow speeds of 12 to
14 RPM depending upon cylinder diameter. Compared
with most other crushers, Bradford Breakers are
extremely long lived. Screen plates, for example,
frequently last ten years or more, crushing millions of
tons of coal, and there are numerous examples of
Pennsylvania Bradford Breakers in continuous service
for upwards of forty years.
Pennsylvania has also designed the screen
plates in the breakers to be interchangeable, so that the
screen plates from the feed end, where wear is
greatest, can be switched with screen plates from other
areas of the cylinder where there is less wear.
The profile of the perforations in the screen
plates has been scientifically designed to obtain a
maximum self-cleaning effect, without product bridging
across the perforation itself.
BRADFORD BREAKERS
PENNSYLVANIA
CRUSHER
PRODUCTS
23
Roller Mounted
Many prefer this model because its three
support points provide a stable yet forgiving platform,
minimizing the attention to wheel alignment needed with
the roller mounted arrangement to compensate for
shifting foundations.
This model also features the design standards
found on our other Bradford Breakers such as lapped
screen plates, adjustable feed plows, and roller chain
drive.
Longitudinal beams are bolted to the end cones
never welded so that replacement can easily be
accomplished at your job site. These, plus numerous
other features, make this an extremely low maintenance
breaker.
TRI-MOUNTED BRADFORD
BREAKERS
(Not illustrated)
ROLLER MOUNTED
BRADFORD BREAKERS
The roller mounted Bradford Breaker is suited
for coal mines where the feed often includes unusually
large pieces of coal. This model will readily accept
these larger pieces of coal without blocking the entry.
24
The Bradpactor is a highly
successful innovation based on the
Bradford Breaker design. In the Brad-
pactor, the breaker cylinder is
equipped with a rotor that is mounted
with a series of paddle hammers. The
rotor runs the entire length of the
cylinder and the speed of the rotor can
be varied.
This gives operators the ability
to tune the Bradpactor to the type of
friable material that is to be crushed.
The paddles impact against the
oversize material dropped into their
path by the rotating cylinder. The
paddles drive the material against the
cylinder walls until the product is sized
and screened out through the screen
plate holes.
By varying the rotor speed,
impact force as well as fines can be
controlled. Compared with a breaker,
a Bradpactor gives greater capacity
while occupying far less space than a
conventional breaker.
PENNSYLVANIA BRADPACTORS
25
This crusher is employed for size reduction of
friable, dry bulk substances such as chemicals, grain,
fertilizer, coal, slag, glass, soap and many others. Its
also used for beneficiation of materials that vary in
hardness.
In this model, material is reduced in size purely
by impact. Feed enters the innermost cage where it is
initially struck by the first row of sleeves. They scatter
the shattered material toward the next row which rotates
in the opposite direction.
Further reduction occurs in that and each
successive row until the material exits the final row, to
be thrown against impact plates that line the crushing
chamber. The sized material then discharges through
the open bottom of the mill.
For production of fine, medium or coarse sizes,
the spacing between sleeves on each row can be
selected. Product size can also be changed by varying
the speed of the cages.
We have improved the cage mill design in
several ways. For example, the two motors used to
drive the cages are on the same side, away from the
feed area, so as not to interfere with access to the
crushing chamber for maintenance. This arrangement
also produces a smaller footprint than ordinary cage
mills, thereby allowing use of a smaller, less costly
foundation. Additionally, total access to the whole
interior is provided by the hinged hopper door. It swings
wide open, completely out of the way, and an integral
cage hoist can be installed at our factory or added later.
We normally recommend that your material be
test crushed in the full-scale cage mill at our Crushing
Test Facility in Broomall.
CAGE MILLS
26
GRANULATORS
Pennsylvania Granulators use rows of ring
hammers which crush with a slow, positive rolling action.
This produces a granular product with minimum fines.
Offered in three models and nearly fifty sizes,
Granulators are used for crushing coals, particularly for
power plants. They are also used for gypsum, salt,
chemicals and moderately hard materials.
Granulators crush by a combination of impact
and rolling compression, producing high reduction ratios
at high capacities. Product size is determined by screen
openings, and is adjusted by changing the clearance
between the cage and the path of the ring hammers.
All Pennsylvania Granulators possess an
external adjustment for the cage assembly which is
operable while the crusher is operating. Granulators
also have a tramp iron pocket for continuous removal of
uncrushables from the crushing zone.
This series includes the Koal King

Granulator, a
machine that crushes fuel for both pulverized coal boilers
and fluid bed boilers.
The Koal King Granulator will handle virtually
any type of coal, including low quality coals that are wet,
frozen, high in fines, or high in ash content, with virtually
no clogging problems.
It has a number of important servicing advan-
tages. It opens like a clamshell to expose the inside of
the machine for inspection or maintenance, without
disturbing the feed system.
The rotor can be removed through the opening
quickly and easily, and rigging to open the rear quadrant
is totally unnecessary when the optional hydraulic door
opener is specified.
The Koal King Granulator accepts feed sizes up
to 12" (300mm). Product sizes of 100% minus
1/2" (12
mm) can be maintained when necessary.
27
HAMMERMILLS
Hammermills are among the oldest, yet still the
most widely used crusher designs. Although recent
years have witnessed the introduction of new types of
crushers, many are a refinement of the basic hammermill
design to serve more specialized purposes.
Pennsylvania Hammermills crush material in
two stages: First, the material is reduced by dynamic
impact; crushing then occurs by attrition and shear in
the second zone, where small clearances exist between
hammers and screen bars. This second zone is the
final sizing zone for the product.
One of the advantages of Pennsylvania
Hammermills is their ability to produce the specified top
size without the need for a closed-circuit crushing
system. Hammermill crushing produces a cubical
product with a minimum of flats and slivers, and is
recommended when the material to be crushed is not
unusually abrasive. In a Hammermill, large particles
cannot escape the cage bars until sized, resulting in
great product uniformity with a minimum of oversize.
Hammermills have high reduction ratios and will
produce high capacities whether used for primary,
secondary or tertiary crushing. Cages can be adjusted
to regulate product size, and a tramp iron pocket is
standard on all models.
REVERSIBLE HAMMERMILLS
Pennsylvania Reversible Hammermills are
symmetrically designed crushers with a rotor that can
be run clockwise or counter-clockwise. Reversal of the
rotor permits the operator to utilize the opposite face of
the hammer daily for maximum hammer sharpness.
This ability to reverse totally eliminates the requirement
of manual hammer reversal.
In addition to more effective use of the
hammers, reversal also brings the opposing set of
breaker blocks and screen bars into use. The user of a
Reversible Hammermill virtually has two crushers in one
machine, reversal being done with a simple motor
switch.
REVERSIBLE
HAMMERMILLS FOR COAL
Pennsylvania builds this Reversible Hammer-
mill specifically for the reduction of pulverizer coals,
cyclone fuel and other finely crushed coal.
To produce the smaller product sizes required,
this model has more rows of hammers than are found in
the Reversible Hammermills used for stone or rock.
The internal configurations of the coal and rock
models differ, though the crushing actions are similar.
28
These units are specifically designed to reduce
both fuels and sorbents in fluid bed boiler applications.
They meet the needs of utility and cogeneration plants
for crushers that perform effectively and efficiently.
They are also suitable for similar reduction
problems in other industries.
Low investment cost and low power con-
sumption have enabled these units to enjoy rapid
acceptance. While they constitute the state-of-the-art of
this technology, their design is based upon our
companys many decades of experience with reversible
hammermills of many types.
Pennsylvanias exclusive high performance,
forged steel hammers are supplied for most applica-
tions. Alloy steel is used for breaker plates, scrubber
and screen sections.
Both sides of these units open fully for complete
access to the crushing chamber. Product sizing and
wear compensation are accomplished by adjusting the
cage, and a tramp iron pocket is included for protection
of the rotor. Options include air sweeping and drying.
As plant needs change in future years, this
design readily allows for modifications that can be
performed whenever needed without compromising the
original investment in this equipment.
Our extensive experience with fluid bed
applications will allow us to determine the configuration
and size that match the needs of your plant. We also
provide peripheral equipment and systems as needed
to ensure a fully integrated operation.
REVERSIBLE HAMMERMILLS
FOR FLUID BED BOILER APPLICATIONS
29
REVERSIBLE HAMMERMILLS
FOR ROCK, LIMESTONE,
MINERALS AND CHEMICALS
In these machines, the breaker blocks and the cage
bars are more massive than those used for crushing coal or
other relatively friable materials.
This type of Reversible Hammermill has fewer rows
of hammers than the coal version, and the hammers
themselves are of a different type and size.
These are used for primary or secondary reduction of
dry, friable, low abrasive rocks, ores and chemicals,
particularly when uniform product gradation is important.
This type of crusher is often used for primary
crushing of quarry-run feed to the final product size in a single
pass. It is also used for secondary crushing when oversize
must be controlled, but where a closed-circuit crushing
system is not practical.
Size reduction starts by impact when the hammer
strikes the material as it enters the crushing zone. Shattered
fragments are swept down into the final crushing zone for
further reduction at the pinch points between the hammers
and screen bars. Oversize material remains in the machine
until it is reduced sufficiently to fit through the screen bar
openings.
Some of these models are available with adjustable
cages, a feature that permits the user to make changes in the
product size and compensate for wear. The tighter the
clearance between the screen bars and hammers, the
smaller the particle size of the crushed product. However,
major product size changes are controlled by changing the
individual screen bar openings.
When the machine has no adjustable cage, hammer
wear is compensated for by resetting the hammer suspension
bars closer to the outside edges of the rotor discs, and by
moving the breaker plate closer to the hammer circle. Large
access doors provide entry for these adjustments. These
crushers accept feed sizes up to 30" (750mm).
NON-REVERSIBLE HAMMERMILLS
30
This type of hammermill will crush material that
might build up within other kinds of hammermills. This
would apply to any product that is very sticky or muddy,
or that is simply too wet to be effectively crushed in other
mills.
In place of the fixed breaker plate, a traveling
breaker plate revolves continuously and carries the
incoming feed into the path of the hammers. This
virtually eliminates any chance for feed to build up
outside of the hammer sweep area. The combined
forces of crushed particle velocity and gravity are
normally sufficient to clear the product through the
machine. However, if the feed is so sticky that it may
accumulate, this machine can be equipped with an
additional traveling rear element which is self-cleaning.
Both the traveling breaker plate and the
traveling rear element have a torque release mechanism
that allows the V-belts to go slack and the motor to shut
off in case of a jammed breaker plate.
Because this type of hammermill is usually
operated under extremely difficult conditions, the motor
drives for the traveling breaker plate and for the rear
element are mounted on the mill itself, above the
working level. This arrangement is very compact and
requires minimum floor space.
Non-Clog Hammermills accept feed sizes up to 36"
(900mm).
NON-CLOG HAMMERMILLS
31
Coalpactors were originated by Pennsylvania
Crusher to crush coking coals and to produce an
optimum percentage of product below
1
/
8 (3mm), but
with a minimum amount of fines (100 mesh or smaller).
Coalpactors are also used for crushing coal and
petroleum coke for fluid bed boilers which have similar
output size requirements.
This crusher permits coke plant operators to
obtain high stability coke from various grades of coal.
When coke is produced from a blend of petrographically
differing coals, the coke strength is improved by control
of the minus
1
/
8 (3mm) pulverization.
A Pennsylvania Coalpactor is similar to an
impactor. It has breaker plates that are fully adjustable
from outside of the frame to enable operators to vary
the degree of pulverization. This allows maintenance of
a uniform product size throughout the life of hammers
and breaker plates.
The Coalpactor rotor may be run either
clockwise or counter-clockwise to provide for equal
wear on both hammer faces. This helps to extend
hammer life and to reduce maintenance problems. To
facilitate servicing, all internal parts of the machine are
readily accessible.
Pennsylvania Coalpactors have largely
replaced other types of crushers for crushing coking
coals because the Coalpactor will maintain rated
capacity even when the coal is wet, and it is not affected
by uncrushables.
When used to crush fuel for fluid bed boilers,
the FB-design Coalpactors use an extended crushing
path to further improve output size control.
COALPACTORS
32
This is a special type of Impactor that takes large
pieces of aluminum dross or slag and reduces the oxide, by
impact, to approximately 8" (200mm) and under. The impact
frees the more friable slag from the harder, uncrushable metal.
Thus, the machine not only reduces the dross, but also
beneficiates the aluminum.
As dross enters the feed hopper, it slides down into the
path of heavy rotating hammers. Upon impact with these
hammers, the dross is driven up against the breaker bars.
Additional reduction also takes place as material ricochets
between the hammers and the breaker bars, until it is finally
swept from the crushing chamber. This machine also
incorporates a protective device for uncrushables.
METALLIC SLAG CRUSHERS
In addition to the Aluminum Dross Impactor, Pennsylvania
Crusher also offers other crushers which are used for crushing dross or
slag.
The Reversible Impactor (CF 9-50) was developed for reduction of
open hearth, B.O.F. and blast furnace slag. This crusher takes 10" - 12" (250-
300mm) slag and reduces it to a minus 2" - 3" (50-75mm) product size in one
pass. In this crusher, the impact breaks the more friable oxides from the
metallic particles. The metallic particles are then separated magnetically and
the oxide or slag body is used for aggregate.
Pennsylvania Jaw Crushers are used to crush residue material
from the zinc smelting process. The crushed material then goes back into
the system for reclamation of usable zinc.
Pennsylvania Jaw Crushers are also used to crush salt
cake, which is a furnace slag containing a high amount of sodium
chloride. To retrieve particles of aluminum, the Pennsylvania
Jaw Crusher reduces the salt cake to minus 5" - 6" (125-
150mm).
ALUMINUM DROSS IMPACTORS
CF 9-50 Reversible Impactor
Jaw Crusher
33
Reversible Impactors are used for secondary
and tertiary crushing, and occasionally for primary
crushing. They are used for reduction of cement rock,
gypsum, fertilizer, chemicals, lime and agricultural
limestone, lightweight aggregate, ceramics and other
materials.
Reversible Impactors are normally recom-
mended when certain requirements exist: high reduction
ratio (35:1 or greater), high capacity, cubically shaped,
well-graded product, and minimum fines.
These crushers can be easily adjusted to
produce a wide variety of product sizes. For coarser
output sizes, Impactors are operated at lower speeds.
When finer output sizes are required, higher speeds are
used. It is also possible to change product size by
making adjustments to the breaker block assemblies.
Material drops through the centrally located
feed chute directly into the rotor, where it is struck by the
rotating hammers. The material then impacts against
the breaker blocks and rebounds into the path of the
hammers. There are no cage bars or screens,
therefore, impact and some shear are the methods of
reduction. The bottom of the crusher is entirely open
and the sized material passes out freely.
When the product must be held to a specific top
size, the machines should be operated in a closed-
circuit system. When operating in closed-circuit, the mill
discharge is carried to external screens or classifiers for
separation, with the oversized particles being returned
to the impactor for further reduction.
The size of the feed may vary up to sizes
produced by primary crushers. In some instances,
these crushers will handle material directly from
quarries or other sources.
Pennsylvania Crusher originated the Reversible
Impactor in order to eliminate manual turning of
hammers. The Reversible Impactor is symmetrical in
design, and by simply pushing the reversing button, the
operator can change the direction of the rotor,
presenting a fresh hammer face to the feed.
REVERSIBLE
IMPACTORS
34
SMALL REVERSIBLE IMPACTORS
These smaller impactors have been designed
for specialized crushing requirements at relatively low
capacities.
Typical applications for these units include:
green brick, mill scale, foundry sand, gypsum,
phosphate rock, flake frit, graphite ore, glass tubing, salt
cake, brass skimmings and tungsten carbide chips.
For servicing, the frame section on both ends of
the machine may be removed to expose the breaker
blocks, liners and rotor. The liners are made of carbon-
manganese steel and are renewable.
The upper breaker
blocks are made of cast
alloy steel and are both
reversible and interchange-
able. The lower breaker
blocks are supplied in fixed
or adjustable configuration.
These impactors
are offered in several sizes.
TWIN ROTOR IMPACTORS
The Pennsylvania Twin Rotor Impactor handles
wet, sticky materials that would clog most other
crushers. It produces a maximum of fines and is widely
used in brick and clay plants as a secondary crusher. It
can also be used as a primary tailings crusher.
The crushing action in Pennsylvania Twin Rotor
Impactors is accomplished solely by impact of the feed
against two counter-rotating sets of manganese steel
hammers. There are no impact blocks, screen bars or
other stationary impact areas, and the product path is
directly through the center of the crusher. This design
demands relatively little power and it facilitates crushing
of wet, sticky materials.
The Twin Rotor Impactor has an inner lining,
separated from the outer shell by a chamber or
plenum. Hot waste gas can be directed into the
plenum, heating the lining. This helps to prevent a major
accumulation of material.
Twin Rotor Impactors are available in three sizes;
the largest can accept feed sizes up to 14" (350mm).
Normally these units are operated in closed-circuit. Each
rotor is driven by a separate motor.
SMALL REVERSIBLE IMPACTOR TWIN ROTOR IMPACTOR
35
For crushing of hard, abrasive materials, Jaw
Crushers are often preferred, since this type of machine
will crush virtually any mineral.
Jaw Crushers differ substantially from other
types of crushers. There is no rotary motion in the
crushing cycle, and all crushing is done by compression
of the feed material between two massive jaws, which in
effect are a type of breaker plate. Jaw plates can be
either smooth or corrugated.
While one jaw is fixed, the other jaw pivots about
a top hinge. This moving jaw is shaped to move firmly
and squarely against the material, at 250 to 400 strokes
per minute. There is no rubbing or grinding, only
compression, which produces a generally cubical product
with minimum fines.
The moving jaw is so balanced that fully 95% of
the drive motor power is used for crushing, while only
5% of the power is needed to move the jaw itself. As a
result of this high mechanical efficiency, smaller motors
may be used, keeping power costs down.
Behind the stationary jaw are shims, used to
compensate for plate wear and to adjust the closed side
setting. For protection from uncrushables, there is also
an automatic drive disengagement feature that acts
instantaneously on the moveable jaw assembly.
Pennsylvania Jaw Crushers accept feed sizes
up to 48" (1200mm) and produce a nominal product size
as small as
3/4" (19mm). Product size is determined by
the distance between the lower end of the jaws. This
gap dimension may be adjusted by shims behind the
stationary jaw assembly. These crushers may be choke-
fed from hoppers or conveyors.
Jaw Crushers for Glass Cullet
The basic Jaw Crusher design is modified for
glass crushing by changing to special corrugated
plates, called cullet plates, on both jaws. These cullet
plates meet and intermesh to provide complete
crushing of the glass. The product is designated as
glass cullet.
JAW CRUSHERS
36
The Brad-Multi-Roll Crusher was introduced to
produce material with output smaller than
1/4" (6mm)
while producing a minimum of extreme fines.
This produces a product having a very steep
gradation curve, making it ideally suited for preparation
of fuel and sorbents for fluid bed boilers and for other
applications that require such a gradation.
This machine is capable of handling moist
materials when operated in open circuit. Drying is usually
recommended when closed-circuit operation is needed to
meet a specific gradation curve.
The Brad-Multi-Roll Crusher is well suited to
abrasive materials. To compensate for any reduction in
charge level resulting from wear, additional charge can
simply be added. This greatly simplifies maintenance,
and provides a machine with exceptionally high
availability.
For some closed-circuit applications, integral
screening can be accomplished. The great compact-
ness of this design means that a smaller building is
required, while minimizing the need for peripheral
equipment. Optional sound housings can be provided
to control noise emissions.
When compared with other machines that
require air classification to achieve specified product
sizes, users of the Brad-Multi-Roll Crusher will enjoy
significant and continuing savings in power costs.
BRAD-MULTI-ROLL CRUSHERS
37
CLINKER CRUSHERS
The Clinker Crusher is used for handling of bot-
tom ash, though it can readily be configured to handle
other materials.
It is now widely employed as a direct replace-
ment for the most common makes and sizes of clinker
grinders. Its efficient design improves maintainability
and increases component life, thereby reducing both
operation and maintenance costs.
For example, the cast, high chrome roll
segments are reversible to maximize their wear life.
These segments can also be changed out with the unit
in place by means of a large door in the rear of the
frame.
For retrofit, no changes to foundations are
needed under normal circumstances.
38
SINGLE ROLL CRUSHERS
Single Roll Crushers are typically used as primary
crushers. A single roll crusher has a roll assembly
consisting of a roll shaft and a fabricated roll shell with
integral fixed teeth.
In the single roll crusher, three different methods
of reduction occur: impact, shear and compression.
Entering the crusher through the feed hopper,
the feed material is struck by the teeth of the revolving
roll. While some breakage occurs here by impact, the
rotation of the roll carries the material into the crushing
chamber formed between the breaker plate and the roll
itself. As the turning roll compresses the material against
the stationary breaker plate, the teeth on the roll shear
the material.
Sized material falls directly out through the
discharge end of the crusher which is completely open.
There are no screen bars, and consequently there is no
recrushing of the sized materials, a factor that helps to
reduce power demand while minimizing product fines.
The clearance between the breaker plate and
the roll determines the product size. This clearance is
adjustable from outside the machine by a shim
arrangement. Adding or removing shims causes the
plate to pivot about its top hinge, moving it into or away
from the roll.
For protection against uncrushable debris, the
breaker plate assembly is secured with an automatic
release device. As pressure from the uncrushable is
exerted against the plate, the device allows the entire
breaker plate assembly to move away from the roll
instantly. The uncrushable drops clear of the machine by
gravity, and the breaker plate assembly immediately
returns to its normal crushing position.
Pennsylvania Crusher Corporation builds
several types of Single Roll Crushers in a great number
of sizes and capacities, with product sizes ranging from
3" (75mm) to 12" (300mm) depending on machine size.
Applications include petroleum coke, coal with
rock, coal, aggregate, limestone, chemicals, phosphate
rock, shale and many other materials.
39
These are typically used in situations in which
fines are to be minimized. They are widely employed on
friable materials such as coal, lime, limestone, petroleum
coke, and chemicals.
As the two rolls rotate toward each other, the
material is pulled down into the crushing zone where it is
grabbed and compressed by the rolls.
Product size is determined by the size of the gap
between the rolls, and this gap can be changed to vary
product size or to compensate for wear.
Since both rolls rotate at the same speed, there
is no relative motion between the two roll surfaces, and
crushing is primarily accomplished by compression.
Compression crushing is extremely efficient, as
energy is only used to crush those particles larger than
the gap between the rolls. Fines are reduced because
already sized material passes freely through the crusher
with no further reduction.
Usual feed sizes are up to 6" (150mm), though
larger feed can be effectively handled in certain
applications. Reduction ratios normally do not exceed 4
to 1.
Protection from uncrushables is provided by
means of a retractable roll assembly. It retracts instantly
when an uncrushable is encountered, then reverts to its
original position once the uncrushable has cleared the
crushing chamber with no stoppage of the crusher.
Pennsylvania offers Double Roll Crushers in a
number of sizes and roll tooth patterns.
DOUBLE ROLL CRUSHERS
Other tooth patterns also available.
ROLL TOOTH PATTERNS
TRAPEZOID SLUGGER
TRAPEZOID
SMOOTH
40
FROZEN COAL
CRACKERS
This type of machine is basically a single roll
crusher. It differs from our other single roll crushers in
the drive mechanism.
Though it utilizes the basic single roll design and
crushing actions, this particular machine has an
extremely wide feed opening which permits the use of
open-throated hoppers to choke feed large lumps of coal
into the machine. It will reduce coal to a nominal 6" to 8"
(150 to 200mm) product size.
Freezing of the coal can occur in railcars and
stockpiles, causing stoppages in handling or conveying.
These frozen coal lumps will often fall from conveyors or
become wedged in hopper throats.
For this reason, Pennsylvania Frozen Coal
Crackers have a low profile, so as to fit into existing
handling systems. The machine is often installed directly
below the railcar delivery hoppers or at the outdoor
stockpile.
The breaker plate may be backed off during
warmer weather to permit coal to flow directly through the
unit unhindered. If desired, the entire roll assembly can
be removed for warm weather operation without
disturbing the feed system in the Model FCC. The FCCR
Model allows easier removal of the roll by a screw
mechanism. The roll assembly is then stored on the
frame, fully aligned and ready to be re-inserted when
freezing conditions recur.
Model FCC
Model FCCR
41
The Mountaineer Sizer crushes a wide variety of
materials. It incorporates all of the features needed to
do a better job than ordinary sizers, for primary or
secondary sizing.
For example, it sizes very accurately, produces
extremely low fines and operates at low speed. Such
low speed also helps to extend component life. It also
uses relatively low horsepower, resulting in reduced
equipment wear and energy costs as well as low noise
levels. Made in U.S.A., its construction is modular and
employs standard components, meaning that
maintenance can be performed more quickly and at less
cost than others. Low headroom, as low as 40 inches,
enables it to fit most plant layouts.
An extremely rugged, high capacity machine,
its crushing chamber is lined with heavy duty liners, and
all side liners are reversible. The sizing rolls are offered
in a variety of tooth patterns to suit the application.
The Mountaineer Sizer is offered in various
lengths, with capacity dependent on many factors, the
most important of which is the output size. The sizers
are direct driven through a gearbox, and a fluid coupling
is provided for tramp iron protection.
MOUNTAINEER

SIZERS
Wheels not shown
42
POSIMETRIC FEEDERS
This unique feeder handles materials having an
extraordinary range of characteristics, including wet, dry,
lumpy, sticky, abrasive or granular. Virtually immune to
jams, it will feed dry, light particles at 1,200 pounds per
hour, or heavy sticky materials at 120,000 cubic feet per
hour, with absolute consistency never before achieved in
ordinary feeders.
It delivers material with unvarying accuracy of up
to 99.5 percent, with no need to recalibrate, unless the
material changes. Regardless of moisture content, it
delivers a constant rate of bulk solid material; each
rotation delivers a fixed volume that cannot vary,
meaning that it feeds at the desired rate, with no surges
and no partial feeding.
This feeder contains only a single moving part
the rotating duct. Because the feed material helps to
turn this duct, only a small motor, usually under 10 hp.,
is required to drive it. Those factors result in very low
stress and exceptionally low maintenance. In addition,
wear is negligible because there is almost no abrasive
action of material against the working parts. Some units
have been in service for up to ten years, without
needing a single replacement part.
43
Printed in U.S.A. Bulletin 4050-D 00-3-03R-1M
600 Abbott Drive Box 100 Broomall, PA 19008-0100 U.S.A.
Phone: (610) 544-7200 Fax: (610) 543-0190
E-Mail: buster@penncrusher.com
www.penncrusher.com
Pennsylvania
Crusher
The Most Choices, The Most Experience

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