TECHNICAL DATA ° metso SYMONS® CONE AND NORDBERG minerals OMNICONE® CRUSHERS TD4-006 "PREPARED BY | APPROVED EY BASIC CRUSHING GUIDELINES pace 1 oF 6 DK RJM PROPRIETARY CODE P DATE OF ISSUE ~ ~ [REV [DATE O1FEB87 Metso Minerals Engineering Department A | seauces 5 E é 3 ‘These technical data sheets contain the basic guidelines on what a cone crusher can be expected to produce, It describes the way in which the rock is crushed and the factors which affect the application of the crusher. 4. How the Rock is Crushed The crushing cavity consists of a stationary upper crushing member called the bowl liner and a gyrating lower member called the mantle. Material fed into the top of the crusher falls through the opening in the platform, onto the feed plate and into the top of the cavity. Itis then reduced by a succession of blows as the material falls through the cavity. The speed and throw of the mantle gyrations are based on the well-known “Symons” crushing prinicole. Normal Range of Application MTS RESERVED. (01) ‘Accone crusher is normally applied as either a SECOND or THIRD stage crusher. The wide range of cavities available may in some cases permit its use as even a PRIMARY crusher. The normal operating range for a cone crusher is to make a crushed product with a top size of from 6 mm to 50 mm (1/4” to 2"). However, the product size is limited by the size THORIZED REPRESENTATIVE. ALL Ri distribution of feed material being fed to the crusher. Using the reduction ratio, RReo (crusher feed size/orusher discharge size, reference 80% passing) as a criteria, it can generally be stated that for a given feed distribution one should not try to achieve a reduction ratio of more than 4 THE INFORIEATION CONTAINED HEREIN I$ CONFIDENTIAL ANO PROPRIETARY TO METSO MINERALS AND I NOT TO BE REPRODUCED, DISCLOSED TO A THIRD PARTY, MODI PeRWSSION OF METSO MINERALS 0SYMONS® CONE AND NORDBERG Use OMNICONE® CRUSHERS TD4-006 BASIC CRUSHING GUIDELINES pace 2 oF 6 PROPRIETARY CODE P metso minerals DK RUM DATE OF ISSUE Rv DATE O1FEBS7 Metso Minerals Engineering Department A | 1eaucs9 Example: Feo = 80 mm (3.15 in.), Peo = 20 mm (.79 in.), Roe = 80/20 = 4.0 Where Feo is the 80% passing size of the crusher feed (F=Feed). ‘And Pap Is the 80% passing size of the crusher discharge (P=Product), But if conditions are right (coarse clean feed with low moisture), it may be possible to effect a reduction ration up to 6, Above these ratios, limits may be reached in either available crushing force, motor power or both Ithas been found that coarser feed materials will allow higher reduction ratios and therefore it : i is common to find a standard liner application with a reduction ratio of 6 or more. 3. Capacity Limitations Limits on the capacity of a cone crusher come from three factors; motor power, crushing force and the volume of the cavity For a given feed gradation, as the crusher product requirement becomes finer the crusher will require a high pecific energy input (Kilowatt hours per ton). Therefore, the allowable throughput tonnage decreases as the crusher product required becomes finer. It takes loss throughput tonnage to reach the allowable power level. ‘Also as mentioned previously, if the reduction ratio is too high (more that 4), the feed rate may have to be reduced or the crusher setting increased to avoid exceeding the available crushing force. This would result in adjustment ring movement which can damage the crusher if allowed on a continuous basis. FeRangSten OF MESO MINERALS OR ITS DULY AUTHORIZED REPRESENTATIVE. ALL RIGHTS RESERVED. (904)TECHNICAL DATA NOT TO BE REPRODUGED, OISCLOSED TO.A THIRD PARTY, MODIFIED OR USED WITHOUT PRIOR OLY AUTHORIZED REPRESENTATWVE. ALL RIGHTS RESERVED. (Cot) “He INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND PROPRIETARY TO METSO MINERALS AND SYMONS® CONE AND NORDBERG mee OMNICONE® CRUSHERS TD4-006 REPAY | HEPROVEDT BASIC CRUSHING GUIDELINES pace 3 oF 6 DK RJM. PROPRIETARY cone P- DATE OF I A FEV Toate 01FEB87 Metso Minerals Engineering Department A | 16AUG99 The crushing force may also be exceeded if the cavity used is too coarse of if the feed material is wet or contains clay. In addition, there exists an upper limit on the volume of material that can physically pass through the crusher cavity. This volumetric limit may be reached if the reduction ratio is low (wide closed side setting compared to the feed size) or if the rock is not very tough. The volumetric limit decreases as the liners wear due to the reduction in throat opening at the top of the bow! liner and mantle and therefore may become an important factor to consider toward the end of the liner life. Any one of the above three limits may be reached independently and thus limit the overall application of the crusher. Itis therefore necessary to consider them all before making an application recommendation. 4, Eeeding a Cone Crusher The feed material sent to the cone crusher can be either quarry materials, gravel or ore. The appropriate type and size of these materials are determined by the maximum feed opening allowable for the various liners available. Slabby materials have a tendency to reduce the throughput capacity of the cone crusher. This is due to the reduction in both density and in the flowabilty of the material into the cavity. Materials fed to the cone crusher should be free of tramp iron and other foreign material. Feed materials should also be washed, if necessary, to remove clay-like materials whichNo PROPRIETARY TO METSO MINERALS AND IS NOT TO BE REPRODUCED, DISCLOSED TO A THIRO PARTY, MODIFIED OR USED WITHOUT PRIOR § z : metso| SYMONS® GONE AND NoRDBERG —_ | "WTNIAL “ATA minerals OMNICONE® CRUSHERS TD4-006 FRESIREDEY | TPR BASIC CRUSHING GUIDELINES pace 4 oF 6 PROPRIETARY CODE P DATE OF ISSUE ~ REV (DATE, O1FEBS7 Metso Minerals Engineering Department A | teAucos will cause packing problems and/or screen problems after the crusher. Excessive fines (material that is smaller than the crusher closed side setting) can also cause these problems and should be removed as early in the circuit as possible. Generally, there should be less than 10% fines in the feed material Moisture in the feed material can also affect the crusher performance. A material with less than 4% total moisture (including both surface and inherent moisture), dependent upon the type of material, can usually be crushed with no adverse operational effects. Packing will result if the material is too wet, especially at small settings. Materials with a coarse feed distribution will be affected less by moisture than material of a fine feed distribution. Exceptionally hard man-made material may generate a high crushing force and the Mineral Research and Test Genter should be consulted on these applications. Materials of this type are tungsten carbi nickel briquettes, or slag materials containing either a large percentage or large size granules of metallic material, The cone crusher should be fed in a manner which permits uniform cistribution of feed to the crusher cavity. Feed to one side of the cavity rather than an even dispersal will result in uneven liner wear and erratic power consumption. When the rusher is operating in Closed circut, the circulating load should be added to the new feed at a point which permits mixing before the material enters the cavity. This will result in a Uniform distribution of the circulating load to the crusher cavity as well as the uniform distribution of the new feed.g metso SYMONS® CONE ANDNORDBERG = WONIPALDATA minerals OMNICONE® CRUSHERS | TD4-006 ae ee BASIC CRUSHING GUIDELINES race 5 oF 6 OK | Runt PROPRIETARY CODE P DATE OF ISSUE Tt : = == REV DAI O1FEBS7 Metso Minerals Engineering Department | A | 1gaucoo 5, Structural and Mechanical Limits ‘The Symons cone and Nordberg Omnicone crushers are designed for operation at motor power draw and crushing force levels which set the structural and mechanical limits on the crusher. The illustration OPERATIONAL LIMITS shows the safe range of operation for the crusher. It should be noted that the power draw and crushing force can change independently based on the operating conditions. The crushing force limit can be reached with low power draw and also the power draw limit can be reached with low crushing force. The crushing force and power draw combinations outside the region bound by the solid lines are overload conditions because of excessive crushing force and/or excessive power draw. Crushing force overloads can readily be seen as adjustment ring movement. The tramp release system, whether springs or hydraulic cylinders, is set to protect the crusher against occasional accidental overloads but regular adjustment ring movement even as small as 1 mm (1/16") is not allowed Power overloads can be monitored by a waltmeter on the drive motor el ical supply. If a wattmeter is not available, the full lad amp draw can be used as a guide. Due to the normal fluctuating power draw related to cone crusher operation, the AVERAGE power draw of a STANDARD cone crusher should not exceed 85% of the rated motor power listed for the crusher to keep intermittent peak overloads within acceptable limits. Whereas, the AVERAGE power draw of a SHORT HEAD cone crusher should not exceed 90%. A STANDARD cone crusher will have a higher fluctuation in its power draw because of the coarse nature or size of the feed, therefore the 85% rating “THE IMFORUATION CONTAINED HEREIY IS CONFIDENTIAL AND PROPRIETARY TO HETSO MINERALS AND IS NOT TO BE REPRODUCED, DISCLOSED TO A THIRD PARTY, MODIFIED OR USED WITHOUT PRIOR ITS RESERVED. (60 q Z| i 3metso minerals SYMONS” CONE AND NORDBERG OMNICONE® CRUSHERS BASIC CRUSHING GUIDELINES TECHNICAL DATA TD4-006 pace 6 oF 6 PROPRIETARY CODE P DK DATE OF BSUE : REY oaTe O1FEBG7 Metso Minerals Engineering Department | A | teaucoo ADJUSTMENT RING MOVEMENT 100% PERCENT OF RATED CRUSHING FORCE .NO PROPRIETARY TO METSO HINERALS AND IS NOT TO BE REPRODUCED, DISCLOSED TO A THIRO PARTY, MODIFIED OR USED WHTHOUT PRIOR DD REPRESENTATIVE. ALL RIGHTS RESERVED, compared to the 90% rating for the SHORT HEAD cone crusher. ‘The motor should NOT be run with oversize heater coils for motor protection as this will well as possible damage to the crusher. OVERLOAD CONDITION SAFE RANGE OF OPERATION PERCENT OF RATED 100% MOTOR POWER OPERATIONAL LIMITS allow continuous operation at too high a power level, and will result in shorter motor life as OVERLOAD CONDITION ‘TRIP_MOTOR OVERLOAD HEATERS,