neem ont ROLL CRUSHER (MO-102)Engineering Growth Convection Foreword Welcome to the fast growing family of KC. Product owners. We appreciate your interest in us and thank you for buying our product. ‘You fiave chosen the finest quality product in the ‘fi market which is produced using latest techniques and has underwent strict quality control Mt tests. It is a product that we are proud to build and you are proud to own it. However your comfort and safety are important to us, so we want you have an understanding of proper procedure to use the equipment, For the purpose, we urge you to read and. follow the step- step operating instructions and safety precautions in this manual. It will ensure that your favourite product delivers relia6le, superior performance year after year. Tiiis manual includes information for all options available on this model. Therefore, you may find some information that docs not apply to your equipment. Alf information, specifications and illustrations in this manual are those in effect at the time of Printing. We reserve the right to change specifications or design at any time without notice, er satisfaction is our primary concern. Feel Free to contact us for any assistance. So what u waiting for, roll up your sleeves and let us get down to work! KC. Engineers Pot. Lid.ig Engineering Growth Connection Important Information About This Manual Reminder for Safety Modification on Equipment: This equipment should not 62 modified: Modification could affect tts performance, safety °F disturbance. In addition damage or performance problems resulting from modification may not be covered under warranties. Precautions and % iis is used to indicate the presence of a hazard that could cause minor or moderate personal injury or damage to your equipment. To avoid or reduce the risk, the procedures must be followed carefull.Me Engineering ED Cmca | Contents | 1. Objective i 2. Aim y 3. Introduction ‘ 4, Theory i 5. Description 2 6. Utilities Required a 7. Experimental Procedure 7 8. Observation & Calculation 3 9. Nomenclature 4 40. Precautions & Maintenance Instructions 5 41. Troubleshooting 5 12, References 5 6 13. Block Diagram Ko. Engineers Pt Limited, Ambala out crustae Engineering Growth Connection Rott CRusHEerR OBJECTIVE: To study the operation of roll crusher. Am: To determine the efficiency of the roll crusher for crushing a material of known work index (VW) IntRobUCTION: achines for coarse reduction of large quantities of solids. The roll crusher is designed to crush ores, minerals, coal, coke, chemicals and other similar material. It is compact and of rugged construction for small pilot plant operations. Such crushers may contain two rolls, smooth roll crushers and toothed roll crushers. Toothed roll crushers are much more versatile than smooth roll crushers within the limitation that they cannot handle very hard solids. THEORY: Roll crusher are used to reduce the particle size of materials to fine particles. They are very common in industry and have a wide application. Crushing rolls consist of two heavy cylinders revolving toward each other, the feed being nipped and pulled downward through the rolls by friction. They rotate in opposite directions and the clearance between them can be adjusted according to the size of feed and the required ize of product. Roll crushers are classified as secondary crusher with feed 12mm to 76mm in size and products 12mm to 1mm. The forces exerted by the rolls can be varied and adjusted by the springs provided. Crushing rolls are used for crushing oil seeds and in the gun powder industry and are also suitable for abrasive materials. They are simple in construction and do not give a large percentage of fines, BOND CRUSHING LAW AND WoRK INDEX: ‘Amore realistic method of estimating the power required for crushing and grinding is He ay D, KO Engineers Put. Limited, Ambala ROLL CRUSHER Page No.1 0F6 (Rev 1}Engneeting Growth mses a the material bei: Where Ks is @ constant which depends on the type of machine nd. on : being D, im , 2s flow crushed, D, is particle size in millimeters, P is power in kilowatts and m is mass flow rate in tons per hour. \ Wis defined as the gross energy requirements in kilo watt hours per ton of feed needed ! to reduce a very large feed. This definition leads to a relation between Ky and WW. (2) K, = 0.3162 xW, if 80 percent of the feed passes a mesh size of D;» mm and 80 percent of the product ‘a mesh of Dp» mm, it follows from eq (1) & (2). VOr. i | P — = 0.3162 xW,] == m p= masieanm| — DESCRIPTION: The set-up consists of two heavy metal rolls. A hopper is provided at the top for feeding the material. Loading bolts are provided for safety. Gap between the rolls are adjustable by loading bolts. The drives are given from an electric motor. Uriuities REQuireD: 6.1 Electricity Supply: Single Phase, 220 V AC, 50 Hz, 5-15 Amp combined socket with earth connection 6.2 Floor Area Required: 1m x 1m. 63 Raw material for feed (size 5-8 mm) 64 — Set of sieves with sieve shaker for analysis. EXPERIMENTAL PROCEDURE: 7.1 Startine PRoceDuRE: 7.4.1. Ensure that switches given on the panel are at OFF position. 7.1.2. Adjust the gap between the rolls. ROLL CRUSHER Ke. Engineers Pvt Limited, Ambala Page No 2016 Rev. 1)we mncnweria Ore Comes 7.1.3 Prepare a suitable feedstock of a solid material 7.1.4 Measure its size distribution 7.1.5 Switch ON the power supply. 7.1.6 Start the machine with no load condition and record the time taken for 10-20 pulses of energy meter. 7.1.7 Start feeding the solid material at a constant rate. 7.1.8 Again record the time taken for 10-20 pulses of energy meter. 7.1.9 Repeat the experiment for different gap between the rolls. 7.2 Ciosine Procepure: 7.2.1 When experiment is over switch OFF the power supply. OBsERVATION & CALCULATION: 8.1 Data: Energy meter constant EMC = 3200 Pulses/kW h WORK INDEXES OF SOME COMMON MINERALS MATERIAL WORK INDEX (Wi) Bauxite (sp.gr =2.20) B78 Cement clinker (sp.gr=3.15) 13.45 Coal (sp.gr =1.40) 13.00 Coke (Sp.ar=1.37) 75.13 Gravel (Sp.gr =2.66) 16.08 Gypsum rock (Sp.gr =2.69) 673 Limestone (Sp.gr =2.66) 12.74 [Quartz (Sp.gr =2.65) 13.57 OBSERVATIONS: Wr =__kg t= sec Dps mm KC. Englneers Pt, Lined, Ambala ROLL CRUSHER Page No. 308 (Rev. 1)Dee ee mm 8.2 OsseRVATION TABLE: tye (SEC) Py tyr (Sec) Po 8,3 CALCULATIONS: ons) K ,=0.3162xW, (KW hiton) I I Peag= XK 534 Kw) 1 al Pct 100 (%) P 2! 9, NomENCLATURE: Units Type mm Measured Column Heading Dye | Average feed size mm Measured PulsesiKWh | Given KWhvion | Calculated Dy | Average product size EMC [Energy meter constant K,_| Bond's constant m_ | Feed rate ton’ h Calculated B, | Namberof pulses counted atno lead condition [ Measured ROLL CRUSHER KG Engineers Pat Linted, Amba Page No 4016 (Rev 1)~we Engneeting Growth Connection Number of pulses counted at loaded condition - Measured Power consume by machine at I condition jad condition ume by machine at no lo: ‘Actual power required for crushing Calculated power required for | Time for P, pulses Time for P2 pulses: Time for crushing Work index of material KW hiton | Weight offeedtaken kg Ie Weasured | Crushing efficiency % | Calculated | © Symbols represent uniliess qual lly 40. PRECAUTION & MAINTENANCE INSTRUCTIONS: 40.1. Never run the apparatus if power supply is less than 180 volts and more than 230 volts 40.2 The machine should not run: when there is no oil in oil cups. 40.3. All the nuts and bolts ‘of motor and unit fixed with the base are to be checked up before operation. 40.4 Clean the rolls and whole unit before and after its use with cloth. 411, TROUBLESHOOTING: 44.4 Ifthe feed material chokes in between the rolls stop the motor and remove the choked material manually. 41.2. Ifthe motor stops during experimentations and as you starl but starter trips while starting, it means starter gets over heated stop the crusher for at least 15 min and start it again 412. REFERENCES: 42.1 McCabe, Warren L. Smith, Julian C. Harriott, Peter (2005) Unit Operations of Chemical Engineering 7" Ed, NY: McGraw-Hill pp 985-986, 988-989 422. Brown, George Granger (1995). Unit Operations. 1 Ed, ND: CBS Publishers & pistibutors. pp 34-36 K€. 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