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1. INTRODUCTION
1.2 CRUSHER
A crusher is a machine designed to reduce large solid material objects into a smaller volume or
smaller pieces. Crushers may be used to reduce the size and change the form of waste materials
so that they can be more easily disposed or recycled. To reduce the size of a solid mix of raw
materials (as in rock ore) so that pieces of different composition can be differentiated. Crushing
is the process of transferring a force amplified by mechanical advantage through a material made
of molecules that bond together more strongly and resist deformation more than those in the
material being crushed. Crushing devices hold material between two parallel or tangent solid
surfaces, and apply sufficient force to bring the surfaces together to generate enough energy
within the material being crushed so that its molecules separate from (fracturing) or change
alignment in relation to (deformation), each other. The earliest crushers were hand-held stones,
where the weight of the stone provided a boost to muscle power, used against a stone
anvil. Querns and mortars are types of these crushing devices.
1.3 DESCRIPTION
In industry a crusher is typically a machine which uses a metal surface to break or compress
materials. Mining operations use crushers commonly classified by the degree to which they
fragment the starting material with primary and secondary crushers handling coarse materials,
tertiary and quaternary crushers reducing ore particles to finer gradations. Typically crushing
stages are followed by milling stages if the materials need to be further reduced. Crushers are
used to reduce particle size enough so that the material can be processed into finer particles in a
grinder. A typical circuit at a mine might consist of a crusher followed by a SAG mill followed
by a ball mill. In this context, the SAG mill and ball mill are considered grinders rather than
crushers.
Liner plates
The liner plates are made out of manganese steel, which is a very hard material and has high
resistance towards wear. The breaker plate, on which the liner plates are mounted can be
adjusted through take-up screws and nuts to adjust the size of the crushed coal.
Driving motor
The foundation frame of the Driving Motor is provided by projection on one side of the Hammer
mill crusher and supports from base frame are also provided to hold the motor foundation. The
size of motor varies as per the size of Crusher. Normally squirrel cage motor of 980 RPM is
provided.
Driving pulley
This pulley is provided on one side of the center shaft with two v- grooves on it. It is directly
coupled with driving motor with the help of 2 v-belts. The dia of driving pulley has been
calculated as per the requirement of No. of vibration per second.
Jaw crusher
Jaw Crusher is mainly used to crush mining stones and the largest compression resistance of the
material is 320MPa. The jaw crusher is widely used in stone mining, metallurgy industry,
building material, highway, railway, and chemical industry.
crushed in this process. The angle between toggle plate and moving jaw decreases when moving
jaw moves down, the moving jaw moves leaves fixed jaw by pulling rod and spring, the final
crushed stuff will be discharged from the outlet.
Merits
1. Simple structure and easy maintenance.
2. Stable performance.
Merits
1. High reduction ratio and crushing efficiency.
2. No-board connection.
3. Impact plate with a special shape.
4. Crushed product with cubical shape.
5. Easy maintenance and reliable operation.
Working Principle
This impact crushes materials with impact force. When the materials enter the blow bar area,
they are crushed due to the high-speed impact of the blow bar and are thrown to the impact
plates on the rotor for secondary crush. Then the materials will be shot back to the blow bar
again for the third crush. This process repeats until the materials are crushed to the required size
and discharged from the lower part of the machine. The size and shape of the finished powder
can be changed by adjusting the gap between the impact rack and rotor support.
Cone crusher
Designed on layered crushing theory with features of reliable structure, convenient adjustment
and economical operation. The Cone Crusher is applicable to break various ores and rocks with
medium or above height.
Heavy-Duty Drive Shafts & Bearings Oversized, heat-treated, alloy steel shafts and self-aligning.
Roller-type bearings assure long life and maximum use of power. Jackshafts for control of roller
speed which are standard on double roll crushers and optional on larger single roll crushers.
Wood crusher
Wood Crusher is suitable for crushing raw wood with size less than 200mm dia. After milled the
output size can be as small as 3-5 mm dia which is suitable for further palletizing.
When coal is delivered to the hammer mill crusher it is prepared for cyclone furnace firing by
being crushed into ¼ inch or smaller size coal. Coal enters from the top and is violently thrown
against the breaker blocks by the hammers. The final crushing is done between the hammer faces
and the screen bars. Tramp iron or material that will not go out between the screen bars is
dropped into the iron pocket and is later removed.
The final crushing is done between the hammer faces and the screen bars. Then the crushed coal
goes to the conveyors below and is carried to the storage bunker. Tramp iron or material that will
not go out between the screen bars is dropped into the iron pocket and is later removed.
However, these methods of elevation can experience a range of problems and limitations, such
as:
• Pneumatic conveying/lifting: relatively high operating costs (e.g. blower, compressor), product
velocities and wear rates (especially for dilute-phase conveying).
• Screw conveying: relatively high operating speeds (due to slippage between the screw flight
and particles, and also due to the back-flow of material through the screw flight and casing
clearance); increased particle attrition; undesirable casing/screw contact.
• Bucket elevation: relatively high capital and maintenance costs; mis-tracking of belt/chain;
damage to belt/chain, buckets and casing. An example of the latter is shown in Figure 1.
The additional problem or hazard with conventional elevation technology (especially bucket
elevators) is the increased risk of a dust explosion due to: sparking caused by mechanical.
damage or impact (e.g. tramp metal, broken bucket, misalignment of belt/chain/screws); ignition
caused by overheating bearings/pulleys; frictional heating caused by buckets shearing against
product that has built up at the bottom of the bucket elevator casing.
This is exacerbated by the dust generation mechanisms and dust clouds that can be prevalent
inside such conventional elevators. Some typical sources of dust generation include particle-
particle and particle-wall impacts, particle attrition, turbulence and induced/entrained air flows.
Another concern is the propagation of a dust explosion or deflagration through the elevator to
other parts of the plant, in which case some method of explosion control is required (e.g. venting;
explosion detection/suppression; product “isolation” barriers). A new type of elevators called the
old elevator has been developed recently to overcome many of the above problems. The main
aim of this paper is to describe and review the new technology of elevating bulk materials. Some
recent case studies are presented to demonstrate its unique features and advantages.
CASE STUDIES
(a) Foundry
In 2003, the management Of Bevcon Wayors was faced with the task of elevating sand
to a new moulding machine in his foundry at Olds Engineering in Hyderabad. He soon
discovered that traditional elevators fell short of meeting his objectives of an
economical, compact, simple and trouble-free machine. After some brainstorming and
prototyping, they invented, developed and installed the very first Olds Elevator, and
soon realized the many features and advantages of this novel type of material handling
and quickly patented his device to allow its future application to other products and
industries.
2. TECHNOLOGY OF CRUSHING
There are four basic ways to reduce a material to certain size i.e. by impact, attrition, shear and
compression. Most of the crushers employ a combination of all these crushing methods.
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
Recycling glass
Feed industry
Stone crushing
Size reduction of waste materials
Electronics recycling
Ceramics
Pulverization of sea shells
Minerals
Wood particles for fuel
Limestone
Computer aided design is essential to design the given crusher such that the component can be
viewed before manufacturing any modifications can be made in the design if required and also
we can have different sizes of crusher at a single time without going to the manual process. The
load withstanding capacity of different component can be found out. Finally by checking the
design and with standing capacity of the component is then manufactured manual.
4. CONCLUSION
The study has led to numerous conclusions. However, major conclusions are as below.
A new type of bulk handling system with the help of the Olds Elevator avoids many of the problems
being experienced by traditional bucket elevators, screw conveyors and pneumatic conveyors. Due
to its full-bore mode of flow transport efficiency is greatly improved and explosion ignition and
propagation hazards are inherently avoided. The externally mounted bearings minimize maintenance
costs and allow the elevator to handle difficult, hot, abrasive or corrosive bulk materials. The
relatively large clearances between the screw and casing and the relatively low slip velocities
between the particles and screw flight help to minimize particle damage and hence, dust generation.
The new research facility at the University of Wollongong is being used to investigate in more detail
the performance characteristics of the Olds Elevator as well as the future potential of this new
technology and also design is carried out in software package known as Pro-e and here the rotor
shaft of hammer mill crusher is designed and assembled in pro-e by slight modifications.