Crushers

Crushers for Raw materials
©FLSmidth Private Limited 2017, all rights reserved 1
Cement Crushing solutions

 Raw Material
- The challenges
- chemical and physical testing
 Cement Crushing Solutions
- crushing solutions – general information
- Apron feeders
- Impact crushers
Hammer Crusher
Strike-Bar Crusher
- Roller Crusher
- Gyro Crusher
- Jaw Crusher
- Cone Crusher
 Questions
1
Raw Material Challenges:
Hard/Soft, Dry/Wet, Dense/Porous, Sticky/non sticky
Chalk
soft/high moisture limestone
~15-25% H2O <10% H2O
< 1% H2O
~5-15% H2O
Marble Limestone/marl
dense/low moisture
Raw Material properties:

Hard/Soft, Dry/Wet, Dense/Porous, Sticky/non sticky
Shale
hard/dense/abrasive
Clay
soft/sticky
~5-15% H2O
Clay
soft/
medium
sticky
~15-30% H2O up to ~40% H2O
2
Quarry Operation
Good quarry practice
Keep the moisture content in the raw materials low by:
• Proper draining of water
• Arranging for trenches to evacuate surface water
• Avoiding operation when raining
• Removing materials that are soaked with water
Operation
3
The objective of Crushing
Run of Mine (ROM)

Crushed product
ROM - Operation
(1)ROM
(2) Oversize - screened
(3) Fines - screened
4
Chemical and Physical testing
Material reception hall
Dania test centre
Point load test
 Load is added to the material until

it brakes in its natural patter
 Result is converted into UCS
5
Point load test
 The result’s are presented in a LAB report
Wear Test – Impact Crushers
 Wear (g/ton)
 Power determination (kWh/ton)
6
Impact wear test – Impact crushers
 Test specifically made for Impact crusher – EV and SB in

order to determine the wear in g/t of processed material
Wear Index results for Limestone

45
40
35
30
No. of Samples
25
20
15
10
0
0,5 1,5 2,5 3,5 4,5 5,5 6,5 7,5 8,5 9,5 10,5 11,5 12,5 13,5 14,5 15,5 16,5 17,5 18,5 19,5 More
Wear index [gr/ton]
7
Principle of Crushing
(Vice)
Hammers and Strike Bar
Impactors
(mainly impact and some shear/
attrition as crushing principle)
(Hammer)
Jaw, Gyratory and (File)

Cone Crushers
(mainly compression
as crushing principle)
(Pair of
Scissors)
Roller and Toothed Roller /

Sizer Crushers
(mainly compression and some
shear as crushing principle)
Different Crusher types / Groups
EV Hammer Impact Crusher

AF Apron Feeder (Crusher and mill feed
(inclined / horizontal or negative)
Single Toggle Jaw

crusher
DUI Double
SB / ”Strike Bar ”® rotor impact
Impact Crusher crusher
Gyrotory Crusher
Cone Crusher
UKC Hammer Crusher
EH Roller Crusher MHC Twin Shaft

Low Speed Sizer
Breaker
8
Selection of crusher type
 Stickiness of material: Is the type of crusher suitable

for handling the material to be crushed?
 Abrasiveness of material: Can an reasonable lifetime

of crusher wear parts be expected?
 Reduction ratio: Is it possible to crush down the

material from feed size to desired product size in a single
pass, or will it be necessary to use a multiple stage
solution?
 Product control: How well is the top size controlled and

are there measures for adjustment to compensate for
wear?
Selection of crusher type

Crusher Type Hammer & StrikeBar Gyratory; Roller, Toothed
Impactors Jaw and Roller and Sizer’s
Characteristics Cone Crushers Crushers
Reduction Ratio 100: 1 40:1 7:1 (Gyratory) 4:1
4:1 (Jaw)
3:1 (Cone)
Wear Resistance Reasonable Excellent Good
Power Consumption Moderate Excellent Good
Max. Lump Size Good with grate Questionable Questionable

Control Questionable without
grate
Ability to Handle Good Poor Excellent
Sticky Material
Dust Creation High Low Low
9
Receiving Hopper & Feeders to Crusher
Apron Feeder
Recommended material surface:

Sloping approx 40o downward
from dumping point.
Grizzly Feeder
Apron Feeder – Support roller

system
 Is the grease pump
actually working – or does
it look like the picture?
 Are the grease pipes in
Check the functionality i.e.
that they can rotate.
 Are the rollers greased, or
“welded” with the result
shown below?
10
Apron Feeder – NEW! Support
roller system - Lubrication FREE!
 NOW FLS apron feeders are

equipped with a lifetime
lubricated support roller
system - supporting the
apron’s
 No more issues with
 Clogged grease pipes
 Freezing grease systems
 Grease pump not working!
Crusher Group :
Hammer Crusher and StrikeBar Impactors
Hammer Impactor Strike bar Impactor
11
EV- Hammer Crusher
Mix Crusher principle
• Capacity up to 2250 t/h

• UCS 150 Mpa
• Moisture up to 10%
• MIX crushing installtion – EV Hammer crusher -Main Apron
Feeder (Limestone) + Side Apron Feeder (clay)
EV Crusher – Design Features

1. Hammer rotor.
2. Inlet roller (1 or 2)
3. Hammers.
4. Outlet grate.
5. Rails for sliding grate.
6. Braker plate.
7. Spare hammers.
8. Top part.
9. Hydraulic opening.
EV150x150 EV150x200 EV200x200 EV200x300 EV250x250 EV250x300
2500
2000
Capacity [t/h]
1500
1000
500
0
30 36 44 56 65 85 100 125
Outlet Grate Opening [mm]
12
EV design features
 1 or 2 inlet rollers
 Material flow control to the rotor
Rotor design
 Rotor Shaft
 Roller bearing
 Hammer disc’s
 Hammer bolts
 Stay bolts
 No flywheel
 Staggered hammer pattern
13
Strike-Bar™ Impact crusher
 No outlet grate
 Final grinding plate controls
output size
 Reduction ratio1:40
 Adjustable grinding plates –
both vertical mill output as
well as ball mill output from
one machine.
 Capacity up to 2600 t/h
 UCS up to 150 Mpa
 Moisture up to 10%
Strike-Bar™ Impact crusher
 Primary crushing effected by

impacting
 Secondary crushing takes
place by shearing and
compression between
impact bars and the breaker
plate and
 Final crushing between
impact bars and the grinding
plate
 No oversize particles leaves
the crusher
14
Impact Crusher: Dedusting
Impact Crusher without outlet Grate

(UKC Crusher)
Breaker Plate
Outlet
15
Siliceous Limestone / Iron Ore
Crusher Group: Gyro, Jaw and Cone
16
Single Toggle JAW
Gyratory & Cone Crusher
Gyratory crusher Cone crusher
17
Potentially Sticky Raw materials
~15-30% H2O Up to -40% H2O
Clay Clay
soft/ soft/
medium sticky Extremely sticky
Crusher Group: Roller, Toothed Roller

& Sizer’s
18
EH Roller crusher
 Reduction ratio 6:1

 Capacity +1500 t/h (depending
on raw material, output size
etc.
 UCS up to 150 MPa
 Moisture + 20%
 Application dependent drive
system – Fixed / VFD
 1. stage / 2. Stage or 3 stage
set-up depending on
application and requirements
EH Roller Crusher Inside
 Fixed roller
 Fly Wheel
 Floating roller
 Tooth segments
 Cleaning system, scrapers
 Hydraulic system
19
EH Roller Crusher Tooth segments
 Teeth height based on output

size
EH 150x200 Rollers
 Inside the Chalk crusher
 Wear liners at the sides
 Chalk crusher in operation
20
MHC crusher – Soft Sticky materials
MHC Crusher Range
Crusher Rotor dia. Rotor Tooth Tooth Tooth

series (mm) width config. config. config.
(m)
MHC 500 1.45 50/110 50/80 25/40
2.1 50/110 50/80 25/40
MHC 630 1.45 50/110 50/80 25/40

2.1 50/110 50/80 25/40
21
Crusher performance as function of
Rawmaterial compressive strenght (UCS)
Pressure gauge with peak load indicator
Crusher Type proposals
Limestone Siliceuos Limestone
22
Clay Marl
Laterite
Iron Ore
23
Stickiness Problems:
Apron Feeder and EV Impact Crusher
Crusher Application Summary
Reduction
Type of crusher Ratio
Typical Feed Material
Hammer & Strike Medium to hard, moderate

80:1
Bar Impactor abrasiveness. Low stickiness.
Jaw Crusher 4:1

Hard, tough, high abrasiveness.
Cone & Gyratory 4-7:1 Non sticky.
Crusher
Soft, moderate to very sticky.

(Mix. of hard & sticky materials for
Roller Crusher 4-6:1
high duty EH-Rollers).
Moderate to high abrasiveness.
24

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Crushers

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Crushers for Raw materials

©FLSmidth Private Limited 2017, all rights reserved 1

Cement Crushing solutions

©FLSmidth Private Limited 2017, all rights reserved 2

©FLSmidth Private Limited 2017, all rights reserved 3

Raw Material properties:

©FLSmidth Private Limited 2017, all rights reserved 4

©FLSmidth Private Limited 2017, all rights reserved 5

©FLSmidth Private Limited 2017, all rights reserved 6

Run of Mine (ROM)

©FLSmidth Private Limited 2017, all rights reserved 7

(2) Oversize - screened

(3) Fines - screened

©FLSmidth Private Limited 2017, all rights reserved 8

Material reception hall

Dania test centre

©FLSmidth Private Limited 2017, all rights reserved 9

Point load test

 Load is added to the material until

©FLSmidth Private Limited 2017, all rights reserved 10

 The result’s are presented in a LAB report

©FLSmidth Private Limited 2017, all rights reserved 11

Wear Test – Impact Crushers

 Power determination (kWh/ton)

©FLSmidth Private Limited 2017, all rights reserved 12

 Test specifically made for Impact crusher – EV and SB in

©FLSmidth Private Limited 2017, all rights reserved 13

Wear Index results for Limestone

Wear index [gr/ton]

©FLSmidth Private Limited 2017, all rights reserved 14

Jaw, Gyratory and (File)

Roller and Toothed Roller /

©FLSmidth Private Limited 2017, all rights reserved 15

Different Crusher types / Groups

EV Hammer Impact Crusher

Single Toggle Jaw

EH Roller Crusher MHC Twin Shaft

©FLSmidth Private Limited 2017, all rights reserved 16

 Stickiness of material: Is the type of crusher suitable

 Abrasiveness of material: Can an reasonable lifetime

 Reduction ratio: Is it possible to crush down the

 Product control: How well is the top size controlled and

©FLSmidth Private Limited 2017, all rights reserved 17

Selection of crusher type

Power Consumption Moderate Excellent Good

Max. Lump Size Good with grate Questionable Questionable

©FLSmidth Private Limited 2017, all rights reserved 18

Recommended material surface:

©FLSmidth Private Limited 2017, all rights reserved 19

Apron Feeder – Support roller

©FLSmidth Private Limited 2017, all rights reserved 20

 NOW FLS apron feeders are

©FLSmidth Private Limited 2017, all rights reserved 21

Hammer Impactor Strike bar Impactor

©FLSmidth Private Limited 2017, all rights reserved 22

• Capacity up to 2250 t/h

©FLSmidth Private Limited 2017, all rights reserved 24

EV Crusher – Design Features

EV150x150 EV150x200 EV200x200 EV200x300 EV250x250 EV250x300

©FLSmidth Private Limited 2017, all rights reserved 25

©FLSmidth Private Limited 2017, all rights reserved 26

©FLSmidth Private Limited 2017, all rights reserved 27

©FLSmidth Private Limited 2017, all rights reserved 31