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Home » AMIT 135: Introduction to Mining Systems and Equipment » AMIT 135: Lesson 5 Crushing
PROGRAM OVERVIEW
AMIT 135: Lesson 5 Crushing
This program is made possible
by a TAACCCT grant, which Contents [show]
provides community colleges
and other eligible institutions of
higher education with funds to
expand and improve their ability
to deliver education and career
Objectives
training programs that can be
completed in two years or less, At the end of this less students should be able to:
are suited for workers who are
eligible for training under the
Explain the need for crushing operation
TAA for Workers program, and
prepare program participants for Define terminologies involved in crushing operation
employment in high-wage, high-
skill occupations. Explain how crushing works
Explain the stages involved in crushing operation (Primary, Secondary and Tertiary)
Recognize different types of crushing equipment used in Mineral industry
CO U R S E S
Compare different equipment components and different methods to control the
crushing process
PRT 110: Introduction to
Occupational Safety, Health and
Environmental Awareness
PRT 110 Syllabus
PRT 110: Lesson 4 Gases, Limited size reduction Maximum size reduction
Vapors, Particles, and Toxic Cubical shape Shape of no importance
Metals
Over and undersize important Over and undersize of minor
PRT 110: Lesson 5 Hazards of
Liquids Flexibility importance
PRT 110: Lesson 6 Hazardous For gravel: less crushing, more Flexibility of minor importance
Chemical Identification:
screening More crushing, less screening
HAZCOM, Toxicology, and DOT
PRT 110: Lesson 7 Fire and For rock: crushing and screening Low production costs, high
Explosion utilization
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AMIT 135: Lesson 7 Ball Mills & Calculation of reduction ratio in crushing [image: (135-5-3)]
Circuits
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Rule 1: Always use a jaw crusher if you can due to lower costs.
Rule 2: For low capacity applications, use jaw crusher and hydraulic
hammer for oversize.
Rule 3: For high capacities, use jaw crusher with big intake openings.
Rule 4: For very high capacities, use gyratory crusher.
Jaw Crusher
Crushing occurs between two moving plates that are arranged to form an acute angle
to apply a compressive force that results in tensile failure
Typically preferred for feed rates of 900 tph or less.
Can be located underground or surface
Typically only a primary crusher.
Operated in open circuit
The gape and the width are set values for a given crusher while the setting can be
altered to adjust the product size.
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< 3.0 x Gape
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Mining Mill Operator Training The largest particle to report to the jaw crusher is typically defined by the drilling
pattern in the mine.
Jaw Reduction
Gape Width Min Max
Crusher Rate Range
Double
125 1600 150 2100 4:1-9:1 2.5 225
Toggle
Single
125 1600 150 2100 4:1-9:1 2.5 400
Toggle
Toggle Speed:
KW/HP
H MM L MM W MM WEIGHT
TYPE MAX
(INCH) (INCH) (INCH) ( TO N )
POWER
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H MM L MM W MM WEIGHT
TYPE MAX
(INCH) (INCH) (INCH) ( TO N )
POWER
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Measurement of the crusher’s closed side setting (CSS) varies depending on the jaw profile that
is being used and has an impact on the crusher’s capacity and product gradation.
Save
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Mining Mill Operator Training Terex Pegson XA400S jaw crusher in quarry
Throw = 1 – 7em
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Mining Mill Operator Training operating characteristics like the length of stroke, the number of strokes per
minute, and the nip angle.
Rose and Hill (1967) considered crusher capacity by determining the amount of time
and distance a particle takes between two jaw plates.
Particles in the A-B zone discharges at the next reverse movement of the jaw.
The maximum size of a particle dropping out of the crusher dmax is determined by the
open size setting (Lmax).
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Mining Mill Operator Training The rate at which the crushed particles move through the crusher is a function of the
cycle frequency, Ï….
Rose and Hill (1967) recognized that the capacity of a jaw crusher increases with
frequency up to a maximum and then decreases with a further increase in frequency.
Above a critical frequency Ï…c, the particles are unable to move downward a distance
h during each cycle.
Rose and Hill derived an expression for quantifying the critical frequency value.
At this frequency, the maximum capacity is realized.
Gyratory Crushers
Invented by Charles Brown in 1877 and developed by Gates in 1881; Gates Crusher.
A conical element is supported in a flared shell or frame creating a chamber wide at the
top and narrow at the bottom.
The center element is caused to gyrate about its fulcrum point causing it to advance
and retreat with relation to the shell.
Rock introduced at the top is broken as it passes through the crusher chamber.
Typical Capacities:
Reduction Ratio = 3:1 to 10:1
300 to 9100 tph
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For sizes < 66cm, the circumference along the opening = 8-10 x Gape
For sizes > 66cm, the circumference = 6.5 x 7.5 x Gape.
Mantle diameter to Gape = 1.3-1.7:10.
Feed size= 0.9 x Gape
Angle of nip varies for large crusher between 21 °to 24 °. For curved surfaces, the nip
varies from 27 ° to 30 °.
The distances between the concave surface and the mantle on top and bottom are
usually used to describe the size of the crusher.
Other characteristic identifications:
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WEIGHT
H MM W MM
TYPE ( TO N )
KW/HP
(INCH) (INCH)
MAX POWER
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[image: (135-5-18)]
Gyratory Operation
Performed in dry conditions.
Water may be used occasionally for lubrication purposes .
Up to 8%-10% moisture feed is acceptable; however, fines should be less than 10%.
Performance affected by:
Recirculating load
Mining Mill Operator Training
SIZE
(GAPE LMAX
LMIN
WORK
X (OPEN (CLOSED C A PA C I T Y
G Y R AT I O N / M I N INDEX
GAPE
LMAX
C A PA C I T Y
MODEL
(MM) (MM) (TPH)
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P ↓A = 0.75 Q P
This expression is valid for primary crushers. For secondary cone crushers, the 0.75
value takes a value of unity.
Disadvantages:
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Mining Mill Operator Training
Cone Crushers
Originally designed and developed by Symons (1920).
Similar to gyratory except the spindle is supported at the bottom of the gyrating cone
instead of being suspended.
The head to depth ratio is larger than gyratory crushers.
Cone angle are flatter and the slope of the mantle and concaves are parallel.
The flatter cone angles increase residence time and thus produce finer particles.
Shell is held by springs which allow passage of unbreakable rock.
Breakage is by impact.
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Mining Mill Operator Training 용원기계공업(주) - Super Cone Crusher "SP400" Medium Type Operating in
Sit…
Sit…
DESIGN
OPEN CIRCUIT CLOSED CIRCUIT
CHARACTERISTICS
Medium 92 10 260-335
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Impact Crushers
One or two heavy rotors carrying fastened projections, revolve inside a cas1ng.
The projections break the rock by primary impact and propels the rock against the
case for the secondary impact.
Impactors are utilized in soft and non- abrasive applications.
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Advantages:
Disadvantages:
discrimination against any individual: Comments feed
AMIT F145
chemicals
course intro
crushers
evacuation
explosives
fires
flotation
ground control
hazards
housekeeping
instructors
leaching
loops
measurement
mill
MSDS
noise
Open Pit
OSHA
PPE
process safety
PRT F110
PRT F140
regulations
rescue
safety
schedule
screens
separation
supports
syllabus
vibration
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