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TABLE OF CONTENTS

LIST OF TABLES

LIST OF TABLES
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EXPERIMENT NO 3
Objective:
The main objectives of impact crushers are:
 To reduce the size of particles.
 To desire mineral purification.
 To separate desired particles from undesired particles.

3.2) Apparatus & Materials:

 Impact mill,
 Feed sample,
 Set of sieve with shakers,
 Spanners
 Meter rod
 Sieve set
 Dolomite

3.3) Theory:

3.3.1) Introduction to Impact Crusher:

In this class of crusher, communication is done by impact rather than compression
by sharp blowers applied at high speed to free falling rocks. These crushers form stress free
products. One of important impact crusher is hammer mill. These are wider used in quarrying
industries.

Fig (3.2) Mechanism of impact crusher.

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Types:
There are two major types of hammer mill.
1. Fixed hammer mill
In this hammer mill, hammers are fixed with rotor. For some rpm, it exerted more force
on feed. It is used for materials whose hardness is more than 7. In this machine material
fall tangentially on to a rotor running at 250-500 rev/min.

Fig (3.2) Impact Mill

2. Swing hammer mill

In this type, hammers are pivoted with rotor. It is used for materials whose hardness is
less than 7. Its capacity increases when speed increases. The rotary impact mill gives a
much better control of product size than does the hammer mill, since there is less
attrition. The product shape is much more easily controlled, and energy is saved by the
removal of particles once they have reached the size required. The blow bars are
reversible to even out wear and can easily be removed and replaced.
3. Construction:
In hammer mill, hammers are made from manganese steel or more recently, modular cast iron
containing chromium carbide which is extremely abrasion resistant. There are basically two main
parts of the hammer mill. They are as follows:
1. Hammers:
They are made from manganese steel. The hammers are pivoted so that
they can move out of path of oversize materials or temp materials, entering the
crusher chamber. Pivoted exerts less force than they would if rigidly attached. So,
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they tend to be used on smaller impact crusher or for crushing soft materials. The
exit from the mill is perforated so, that material which is not broken to the
required size is retained and swept up again by rotor for further impact.
The hammer can weigh over 100kg and can feed up to 20cm.Due to high rate of
wear on these machines they are limited in use. The fractured pieces which can
pass between the clearances is smaller and ten into third smaller chamber. This is
grinding path which is designed to reduce flakiness and gives very good cubic
particles.
2. Breaker plate:

They are made of the same material as the hammer is made.

3.5) Working of Impact Crusher:

In hammer mill, hammers are mostly pivoted so they can move out of the path
oversize material or tramp material entering the crushing chamber. Pivoted hammers
would exert less force than they would if originally attached. This type of machine is
designed to give the particle velocities of the order of that of the hammer. Fracture is
either due to the severity of the impact to the hammers or to the subsequent impact

6. Performance indicators:
i. Reduction ratio:
It is the ratio of feed size to the product size. Decrease in the product size
will cause increase in the reduction ratio.
Reduction Ratio = Feed Size / Product Size.

ii. Capacity:
It is the measure of amount of feed (in tons) that enters the crusher per
hour. Capacity can be increased by increasing the length of breaker plates and due
to increase in length area increase and therefore capacity increase.
Capacity = Tons / Hr.
iii. Energy consumption:
It is the measure of energy that how much energy is consumed per ton of
feed. Energy consumption can increase by increasing the speed of rotor. Due to
increase in speed, kinetic motion increases and hence energy consumption also
increases.
Energy Consumption = kWh / ton
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7. Design parameters:
i. Sieve:
It is a type of utensil consisting of wire or plastic mesh held in a frame for
separating fine from coarse particles. It usually uses for high reduction ratio.

ii. Hammer weight and size:

Increase in size and weight of hammer cause increase in force which
causes increase in capacity and hence require high energy. And the reduction ratio
will also increase.

iii. Breaker plates length and thickness:

Increase in thickness cause increase in force and hence reduction ratio
will also increase. On the other hand, increase in length mean large area and
finally increases in capacity.

8. Operating parameters:
i. Set:
It is the minimum distance between the hammer and breaker plate.
Decrease in set cause decrease in product size and hence reduction ratio
increases.

ii. Speed:
Kinetic motion increases by increasing speed and convert feed into
smallest particles therefore capacity increase and hence energy consumption also
increases.

4. Applications:
i. Impact crushers have a wider use in the quarrying industry than in the
metal-mining industry. They may give trouble-free crushing on ores that tend to
be plastic and pack when the crushing forces are applied slowly, as is the case in
jaw and gyratory crushers. These types of ore tend to be brittle when the
crushing force is applied instantaneously by impact crushers.
ii. Impact crushers are also favored in the quarry industry because of the
improved product shape. Cone crushers tend to produce more elongated
particles because of their high reduction ratios and ability of such particles to
pass through the chamber unbroken. In an impact crusher, all particles are
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subjected to impact and the elongated particles, having a lower strength due to
their thinner cross section, would be broken.
iii. Drawbacks of Impact Crusher:
1. As a result of higher forces on hammer there is more wear and tear.
2. Ores with more then15% silica are not feed to these crushers as they are not fit for
them.
3. Impact crusher is not suitable for abrasive materials.
Procedure:
 Identify each point of machine and draw a sketch and label each point.
 Switch on the machine and study working of each point.
 Examine the feed for its size and record the average minimum size in feed.
 Adjust the set of machine with the help of perforated discharge.
 Feed the material slowly and note how each lump is crushed by hammers.
 Switch on the machine and recover the ground product.
 Transfer the ground material to a sieve set and sieve for 20min.
 Switch of the sieve shaker and recover the retained weights of each sieve.
 Calculate the reduction ratio of the machine for test performed.
 Calculate the weight of each sieve.
 Tabulate the sieve results and plot a graph.

10.Impact Crusher Specification:

Motor power 8 hp

Motor rpm 1400 rpm

Crusher rpm 2100 rpm

Diameter of Motor pulley 18 cm

Set 1 cm

Capacity 200 ton/hr.

No of hammers 8 * 4 = 32

11. Graphs:

a. Draw graph of cumulative passing and retaining mass percentage against

aperture size (geometric mean) and determine cut size, d 10, d25, d50, and d75.
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Observations and calculations:

Size (mm) Individual mass Cumulative mass %

Passing Retaining G.M Measured % Passing Retaining

10mm 4.69mm 6.84 2 0.699 99.301 0.699

4.69mm 3.38mm 3.98 4 1.399 97.901 2.098

3.38mm 2mm 2.6 19 6.64 91.262 8.738

2mm 1mm 1.4 50 17.5 73.762 26.238

1mm 0.5mm 0.71 67 23.43 50.232 49.668

0.5mm 0.25mm 0.35 85 29.72 20.612 79.338

0.25mm 0.12mm 0.02 59 20.63 0 100

Total= 286 =100%

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b. Draw log-normal plot between aperture size (geometric mean) and cumulative
passing mass percentage and determine the standard deviation.

Log (G.M) Cumulative passing %age

0.84 99.301

0.60 97.901

0.41 91.262

0.15 73.762

-0.15 50.232

-0.46 20.612

-1.70 0
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c. Express Gaudin-Schuhmann distribution on graph and determine the constants

involved.

Log (G.M) Log (Cumulative passing %age)

0.84 1.996

0.60 1.990

0.41 1.960

0.15 1.868

-0.15 1.701

-0.46 1.314

-1.70
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d. Express Rosin-Rammler distribution on graph and determine the constants

involved.

Log (G.M) Log (log100/R)

0.84 0.46

0.60 -0.02

0.41 -0.64

0.15 -1.12

-0.15 -1.40

-0.46 -1.60

-1.70 -1.70
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12. Result:
Reduction ratio of impact Crusher was found to be 14.12.
13. Comment:
Mill is not properly there for little amount of feed is wasted. This cause loss of
product.