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10/8/21, 10:31 AM AMIT 135: Lesson 5 Crushing – Mining Mill Operator Training

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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 Course Schedule Reading & Lecture


PRT 110: Lesson 1 Introduction
to Process Safety

PRT 110: Lesson 2 Hazard The Art of Crushing


Classification

PRT 110: Lesson 3 Routes of


Crushing Gravel & Rock Crushing Ore
Entry and Environmental
Effects

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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PRT 110: Lesson 8 Electrical  


Mining Mill
Noise, Heat, Operator Training
Radiation, 
Ergonomic, and Biological
Hazards

PRT 110: Lesson 9 Safety


Permit Systems

PRT 110: Lesson 10 Personal  


Protective Equipment (PPE)

PRT 110: Lesson 11


Engineering Controls Crushing of Ore and Minerals
PRT 110: Lesson 12
Normally the size reduction by crushing is of limited importance besides the top size of
Administrative Controls
the product going to grinding.
PRT 110: Lesson 13 Regulatory
Overview: OSHA, PSM, EPA, This means that the number of crushing stages can be reduced depending on the feed
NFDA, DOT size accepted by primary grinding stage.
PRT 110: Lesson 14
HAZWOPER

AMIT 129: Surface Mine Safety


AMIT 129: Syllabus

AMIT 129 Course Schedule

AMIT 129: Lesson 1 Intro

AMIT 129: Lesson 2 Open Pit


and PPE

AMIT 129: Lesson 3 Mine


Entering

AMIT 129: Lesson 4 Clean


Housekeeping

AMIT 129: Lesson 5 Hazard


Recognition

AMIT 129: Lesson 6 Conveyor


System
Image of a “Classical” 3-stage ore crushing prior to rod mill [image: (135-5-1)]
AMIT 129: Lesson 7 Mine
Explosives and Blasting

AMIT 129: Lesson 8 Mine Maps,


Emergency Evacuation,
Barricading

AMIT 129: Lesson 9 Mine Fires


and Fire Fighting

AMIT 129: Lesson 10 Mine


Ground Control

AMIT 129: Lesson 11 Mine


Electrical Hazards

AMIT 129: Lesson 12 Crusher


and Mill Operation Safety

AMIT 129: Lesson 13 Chemical


Hazards

AMIT 129: Lesson 14 General


Hazards

AMIT 130: Surface Mine


Operations
AMIT 130: Syllabus

AMIT 130: Course Schedule

AMIT 130: Class 1

AMIT 130: Class 2


Diagram of Typical 1-2 stage ore crushing prior to AG-SAG mill [image: (135-5-2)]
AMIT 130: Class 3

AMIT 130: Class 4

AMIT 130: Class 5


Calculation of Reduction Ratio in Crushing

AMIT 130: Class 6

AMIT 130: Class 7

AMIT 130: Class 8

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AMIT 130: Class 9


Mining Mill Operator Training 
AMIT 130: Class 10

AMIT 135: Introduction to Mining


Systems and Equipment
AMIT F135: Syllabus

AMIT F135: Course Schedule

AMIT 135: Lesson 1


Introduction

AMIT 135: Lesson 2 Circuit


Mass Balancing

AMIT 135: Lesson 3 Particle


Size Distribution

AMIT 135: Lesson 4


Performance Modeling &
Assessment

AMIT 135: Lesson 5 Crushing

AMIT 135: Lesson 6 Grinding


Circuit

AMIT 135: Lesson 7 Ball Mills & Calculation of reduction ratio in crushing [image: (135-5-3)]
Circuits

AMIT 135: Lesson 8 Rod Mills

PRT 140: Industrial Process


Instrumentation I
PRT 140: Syllabus
 
PRT 140: Course Schedule

PRT 140: Lesson 1 Introduction

PRT 140: Lesson 2 Pressure Crushing Equipment


PRT 140: Lesson 3
Temperature The selection of the right crushing equipment is influenced by many factors some of
which are upstream of the crushing plant (e.g. blasting pattern and mining method)
PRT 140: Lesson 4 Level
and others which are downstream of the crushing plant (e.g. mill and grinding circuit
PRT 140: Lesson 6 Flow
Measurement
selection).

PRT 140: Lesson 7 Analytics


and Miscellaneous Crushers have more efficient transfer of applied power to the breakage of rock than
Measurement grinding mills.
PRT 140: Lesson 8 Introduction
to Control Loops
Typically a crushing flowsheet for a mineral processing plant will have from one-to-
PRT 140: Lesson 10 Control three stages of crushing. There are some cases where the process requires a fine dry
Loops, Sensors, and
product and a quaternary stage of crushing will also be included.
Transmitters

PRT 140: Lesson 12 Control


Loops, Control Elements  
PRT 140: Lesson 13 Control
Loops, Control Valves, and
Regulators Primary Crushing
PRT 140: Lesson 14 Symbology
The purpose of the primary crusher is to reduce the ROM ore to a size amenable for
and Course Review
feeding the secondary crusher or the SAG mill grinding circuit.
AMIT 145: Introduction to Mineral
Benefication The ratio of reduction through a primary crusher can be up to about 8:1.
AMIT 145: Syllabus
Feed:
AMIT 145: Course Schedule
ROM up to 1.5 m
AMIT 145: Lesson 1 Industrial
Screens
Product:
AMIT 145: Lesson 2 Classifying
Cyclones -300mm (for transport) to -200mm (for SAG mill)
AMIT 145: Lesson 3 Dense
Medium Separation
Feed Rate: 
AMIT 145: Lesson 4 Gravity
Separation 160 to 13,000 tph

AMIT 145: Lesson 5 Froth


Flotation

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AMIT 145: Lesson 6 Dewatering


Mining Mill Operator Training
& Clarification The family of primary crushers include: 

AMIT 145: Lesson 7 Leaching Gyratory Crushers


 Jaw Crushers
 Impact Crushers

Typical rules for primary crusher selection:

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.

Diagram of a jaw crusher [image: (135-5-4)]

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Mining Mill Operator Training 

Diagram of a jaw crusher [image: (135-5-5)]

Single Toggle Jaw


Crusher
The maximum motion is at
the top of the jaw.
Light to medium duty
crusher and capable of
crushing ores up to 200 Mpa
(27.500 psi)

Diagram of a single toggle jaw crusher [image: (135-5-6)]

Double Toggle Jaw 


Crusher
The maximum motion is at
the bottom of the jaw
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Capable of crushing ores up


Mining Mill Operator Training 
to 350 Mpa (90,000 psi)

Diagram of a double-toggle jaw crusher [image: (135-5-7)]

The dimensions defined by those


particle sizes are:

Gape: The distance between


the jaws at the feed opening
Closed side set (CSS): The
minimum opening between
the jaws during the crushing
cycle (minimum discharge
aperture)
Open side set (OSS): The
maximum discharge
aperture
Throw: The stroke of the
swing jaw and the difference Diagram of a Jaw Crusher

between OSS and CSS. [image: (135-5-9)]

Jaw Crusher Fundamentals

Vertical Height = 2 x Gape


Width of Jaw   > 1.3 x Gape


< 3.0 x Gape

Throw = 0.0502 (Gape) 0.85


Gape is measured in meters.
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Mining Mill Operator Training 

Jaw crusher action

MBMMLLC.com: Crushing granite with a jaw crusher

Jaw Crusher Sizes and Power Ratings


Size is specified in terms of the gape and width, typically listed as gape x width.
Largest jaw crusher is 1600 x 2514 mm with motor ratings of 250-300 kW.
Metso crushers (C200 series) are 1600 x 2514 mm with motors rated at 400 kW.
The largest particle that can enter the opening of the jaw crusher can be estimated by: 

Largest particle size= 0.9 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.

Typical Jaw Crusher Characteristics

Size (mm) Power (kW)

Jaw Reduction
Gape Width Min Max
Crusher Rate Range

Min Max Min Max

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:

maximum = 300 rpm


minimum = 100 rpm

Jaw Crushers (Metso Minerals)

Jaw Crusher Specifications

KW/HP

H MM L MM W MM WEIGHT
TYPE MAX
(INCH) (INCH) (INCH) ( TO N )
POWER

C63 1600 (63) 1950 (77) 1390 (55) 6.05 45/60

C80 1700 (67) 2020 (80) 1565 (62) 7.52 75/100

C100 2400 (95) 2880 (113) 2250 (89) 20.10 110/150

C105 2050 (81) 2630 (104) 1920 (76) 13.50 110/150

C110 2670 (105) 2830 (112) 2385 (94) 25.06 160/200

C125 2900 (114) 3370 (133) 2690 (106) 36.70 160/200


C140 3060 (121) 3645 (144) 2890 (114) 45.30 200/250

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Mining Mill Operator Training K W /H P

H MM L MM W MM WEIGHT
TYPE MAX
(INCH) (INCH) (INCH) ( TO N )
POWER

C145 3330 (131) 3855 (152) 2870 (113) 53.80 200/250

C160 3500 (140) 4200 (165) 3180 (125) 68.60 250/300

C200 4220 (166) 4870 (192) 3890 (153) 118.40 400/500

C3055 2400 (95) 2920 (115) 2550 (100) 25.50 160/200

Feed top size chart [image: (135-5-11)]

Jaw crusher diagram [image: (135-5-12)]


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Closed-Side Setting Effect on Feed Size


Mining Mill Operator Training 

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

Diagram of closed-side setting effect on feed size [image: (135-5-13)]

Feeding Jaw Crushers


It is desirable to feed jaw crushers continuously.
However, feed is often provided intermittently using front end loaders, shovels or
trucks.
When the feed rate exceeds the product rate, the condition is known as choke feeding.
In choke feeding, particle breakage occurs between the plates and particles and
between the particles themselves.
Choke feeding produces fines; desirable for liberation purposes.

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Mining Mill Operator Training Terex Pegson XA400S jaw crusher in quarry 

Typical Jaw Crusher Operation


Product size is smaller than the open side setting.
Typical operating and performance characteristics:

Top Feed Size = 0.8- 0.9 x Gape

Reduction Ratio = 4:1 to 7:1

Throw = 1 – 7em

Speed = 100 – 359 rpm

Frequency of Stroke = 100 – 300 cycles/minute

Jaw Crusher Capacity


Capacity is primarily a function of:

crusher design characteristics such as width and depth of crushing 


chamber.
open and closed side settings.
options on feeding method, intermittent or continuous.

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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.

Mathematically, capacity can be represented by the expression:

w = width Lr – length of stroke

L = height n = frequency (rpm)

Lmax = open side setting K = machine characteristic constant

Lmin = closed side setting θ – jaw angle

Critical Jaw Crusher Parameters

A Diagram of Jaw Crushers [image: (135-5-14)]

Frequency Effect on Capacity

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.

Jaw Crusher Advantages


Lower installed cost than gyratory crushers.
Can handle high abrasion with low maintenance.

Jaw Crusher Disadvantages


Maximum capacity of 1,000 MTPH.
Can be used for primary crushing only.

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

https://youtu.be/1CpjRMICXNM

Gyratory Crusher History 

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Mining Mill Operator Training 

Gyratory Crusher History [image: (135-5-15)]

Gyratory Crusher Dimensions


Breaking head (mantle) is fixed to a central spindle which is suspended from a spider
hydraulically or mechanically.
Bottom end of the spindle is connect to a bevel and pinion arrangement.
Primarily compressive breakage.
Tolerates different particle shapes including slabby rock.
Dimensions :

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:

Bowl diameter at the discharge x Gape


Bowl diameter at the feed end x Gape
Bowl circumference at the feed end x Gape
Maximum diameter at the head x Gape.


 

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Mining Mill Operator Training 

Diagram of a gyratory crusher [image: 135-5-16)]

Gyratory Crushing Action


Designs of the breaking faces vary with manufacturer.
As a result, the product size distribution varies.
When the feed drops into the crusher, the mantle squeezes the rock against the
concave surface.
When the mantle moves away and the rock drops down further and subject to
additional crushing during the next cycle .
Material exits the crusher through the open side setting.
Thus, the top size of the product is determined by the open side setting.

Vertical view of the crushing action [image: (135-5-17)]

Long Shaft Gyratory (generally, not used


commercially)

CHARACTERISTICS SMALL LARGE

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Mining Mill Operator TrainingC H A R A C T E R I S T I C S SMALL LARGE 

Size, mm 63 - 711 1829 - 2294

Set Range 25.4 - 44.5 228 - 305

Rev/minute 700 175

Power, kW 2.2 298

Short Shaft Gyratory


CHARACTERISTICS SMALL LARGE

Size, mm 762 - 1524 2133 - 2794

Set Range 50.8 - 152 178 - 305

Rev/Minute 425 275

Power, kW 149 750

Gyratory Design Characteristics

WEIGHT
H MM W MM
TYPE ( TO N )
KW/HP
(INCH) (INCH)
MAX POWER

S 42-65 4807 (189) 3937 (155) 119.4 375/502

S 48-74 5915 (233) 4597 (181) 248.0 450/603

S 54-75 5915 (233) 4928 (194) 248.0 450/603

S 60-89 7169 (282) 6299 (248) 570.0 750/1006

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Mining Mill Operator Training 

Gyratory Design Specifications

[image: (135-5-18)]

Gyratory Circuit Design


Large units are rarely installed underground.
Charge is fed by trucks, tip-wagons, side dump cars, and conveyor belts.
Feed enters from a hopper and passes through a grizzly screen to remove oversize
Gyratory crushers are operated in open circuit.
The feed is limited to 1 to 1.5 meters in size.
Thus, based on reduction ratio, the rock size is reduced to 10 to 15 cm.
Typical reduction ratios are:

Primary crusher: 3:1 to 10:1


Secondary crusher: 6:1 to 8:1
Tertiary crusher: 10:1

Therefore, if a 3 mm crusher product is required, maximum feed size to the


secondary crusher would be 240 mm. Thus, the feed to the primary crusher
should not exceed 2400 mm.

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:

Feed fines content (< 10%)


Inherent and total moisture content 

Feed distribution in the crushing area


Feed bulk density
Hardness of ore (W;)
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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

MANTLE SIDE, SIDE, (T/H)


(KWH/T
DIA., MM) MM)
MM)

1219 x 1879 200 34 135 2200 --

1371 x 1879 137-223 44 135 3100 --

1828 x 2311 194 44 111 2750 13

1524 x 2268 200 - 275 37 113 3200 6

1524 x 2268 238-275 37 92 3180 12

1219 x 2057 175-188 37 93 1330 10

1524 x 225 34 134 2290 --

Minimum Gyration Speed


The gyration speed determines that rate at which product is generated at the desired
particle size .
It is also known that gyration speed must be slowed if the particle size of the feed is
increased.
Friction controls the flowability of the material through the gyratory.
Friction values are typically between 0.2 and 0.3 .
For a cone angle of 75 °, friction of 0.2, and product size of 10.2 cm, the minimum
gyration speed is 190 rpm.

GAPE
LMAX
C A PA C I T Y

MODEL
(MM) (MM) (TPH)

42-65 1065 140-175 1635-2320 

50-65 1270 150-175 2245-2760

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Mining Mill Operator Training GAPE


LMAX
C A PA C I T Y

MODEL
(MM) (MM) (TPH)

54-75 1370 150-200 2555-3385

62-75 1575 150-200 2575-3720

60-89 1525 1645-230 4100-5550

60-110 1525 175-250 5575 - 7605

Specific Power Requirements


Run-of-mine material contains a range of particle sizes
Thus, only the power required to break particles that are greater than the open-side
setting should be included in the overall power requirement
In actual practice, it has been found that the total power requirement PA is:

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.

Advantages vs. Disadvantages of Gyratory Crushers


Advantages:

Designed for direct dump from trucks up to 300 tons.


High capacity rating.
Lowest maintenance per ton processed .
Highest availability.
Can handle crushing ore with compressive strength of up to 600 MPa (90,000psi).

Disadvantages:

Highest installed capital cost. 

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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.

How does a Cone Crusher works- Mineral Processing

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Mining Mill Operator Training 

Cone Crusher Diagram [image: (135-5-19)]

Symons Cone Crusher Drawing [image: (135-5-21)]

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Mining Mill Operator Training 용원기계공업(주) - Super Cone Crusher "SP400" Medium Type Operating in
Sit…
Sit…

Secondary crushers are typically Standard Head with stepped liners


Tertiary crushers are Short head which have smoother crushing faces and steeper
breaking head cone angles.

Standard Symons Cone Crushers

DESIGN
OPEN CIRCUIT CLOSED CIRCUIT
CHARACTERISTICS

Maximum Minimum Maximum Minimum

Size (mm) 3050 600 3050 600

Crusher Chamber Size (mm) 76-432 25-76 76-178 25-51

Discharge Setting (mm) 22-38.1 6.4-15.8 6.4-15-19 3.2

Power (kW) 300-500 25-30 300-500 25-30

Typical Metso Cone Crusher Capacities


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Mining Mill Operator Training FEED 


LMIN C A PA C I T Y
CRUSHER TYPE OPENING
(MM) (TPH)
(MM)

HP800 Standard Fine 267 25 495-730


Head

Medium 297 32 545-800

Coarse 353 32 545-800

HP800 Short Head Fine 33 5 ---

Medium 92 10 260-335

Coarse 155 13 325-425

MP1000 Standard Fine 300 25 915-1210


2392 mm

Medium 390 32 ---

Coarse 414 38 1375-1750

Commercial Cone Crushers

Principle Technical Data of Cone Crusher Series

Cone Crushers Product Distributions

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Mining Mill Operator Training 

Cone Crusher Stone Grade Distribution

Gyradisk Cone Crusher


For finer size products (e.g., -6 mm), a special cone crusher known as the Gyradisc is
commonly used.
Operation is similar to the Standard Cone Head; however, breakage is mostly by
attrition rather than impact.
Reduction ratio is around 8:1.
Feed size is limited to less than 50 mm with a nip angle between 25 ° and 30 °.
Head diameters are between 900 and 2100 mm.
The Gyradisc is normally maintained in choke feed mode.
Product size between 6 and 9 mm.

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Mining Mill Operator Training 

Gyrasphere System Diagram [image: (135-5-22)]

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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10/8/21, 10:31 AM AMIT 135: Lesson 5 Crushing – Mining Mill Operator Training

Mining Mill Operator Training 

Impact Crusher Diagram [image: (135-5-23)]

Advantages:

Can handle a large size reduction: 1 m to 75mm


High reduction ration for amount of investment.
Impactor provides a high degree of fines (for ores).
Can handle up to 2500 MTPH.

Disadvantages:

Power consumption is higher as more fines are produced.


Cannot handle tramp metal.
Requires feeder.

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Mining Mill Operator Training 


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