12-04-2023

Introduction
• Aggregates are one of the principal components of composite materials like asphalt and

Construction Equipment cement concrete.

• They act as the reinforcement to add strength to the overall composite material.

Management • Aggregates are used as drainage materials, foundation base for railways and roads.

• Aggregates are produced from rocks by crushing them into crushing plants.
CMT 522
Session 10 - Crushers • Aggregates are sourced from naturally occurring bedrocks and stones called quarry.

• Aggregates are the most mined material in the world.

Aritra Halder
| Aritra Halder | Assistant Professor
Assistant Professor | School of Construction

Classification Jaw Crusher

• Crushes stones by
compression.
• Best for primary crushing.
• Suitable for lesser fines
Crushers requirement.
Primary
Crushers • Composed of two jaws – Fixed
Crushers and Swing.
Jaw Impact Roller Cone Secondary • Capacity is influenced by –
Crusher Crusher Crusher Crusher Crushers – Size
– Nature and type of rock
• Two types –
– Single toggle
– Double Toggle
Single Toggle Jaw Crusher
| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

1
 12-04-2023

Flywheel
Hinge Pin

Components of Jaw Crusher Jaw Crusher Working Video

Frame

Eccentric Shaft

• Frame
• Hinge Pin and Jaw Jaw plates
• Jaw Plates Pitman
• Jaw Adjustment
• Toggles
• Pitman
Jaw Adjustment
• Eccentric Shaft & bearings
• Flywheel
• Single Toggle Jaw Crusher Toggle
– In Single toggle, whole swing jaw is lifted.
– Energy consumption is more
– Flywheels are heavier
– Low initial cost and used for non abrasive soft
rocks.
• Double Toggle Jaw Crusher
– High production for same energy
– Economical
– Wearing rate is low, used for hard abrasive rocks.
Size of jaw crusher is decided by the mouth opening of jaw. Maximum allowable size of rock to feed is 70-80% of the gap size.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

Impact Crusher Components of Impact Crushers

• Crushes stones by impact. • Casing: Wear Resistant cast steel liner. Top lid
• Used for hard and abrasive rocks. can be opened to replace, repair parts. Fitted
• Stone is fed from top hopper carried
with hopper to receive material.
through a conveyor.
• Rotating hammers throw the falling
• Repulsion Plate: high manganese chrome cast
steel; one end pin supported, other end free to
materials onto the impact plates/repulsion swing.
plates.
• Shape of aggregates are good and well • Rotor: Hammers are attached to the rotor in
graded. radial direction. Fixed to the central shaft.
• Two Types – (1) impact breaker & (2)
hammer mills • Product size depends on –
• Low cost • Charging stone amount, size, rotor’s peripheral
• Fewer parts to maintain speed, Gap between repulsion plate and
• Gradation is possible
hammer.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

2
 12-04-2023

Impact Crusher Working Video Roller Crusher

• Roller crushers are reduction crushers and follows
a primary crusher in the circuit.
• Consists of two manganese steel drums mounted
over two motorized shafts rotating towards each
other.

• Advantages –
• More output for same power.
• Handles wide range of materials.
• Cheaper
• Uniformity is maintained.
• Wide range of size adjustments.
• Uniform wearing of the drums due to rotating
action.
• Economical and easy maintenance.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

Roller Dimensions Types of Roller Crushers

• Determining Minimum Roller Dimensions –
• Both roll shells smooth – for production size < 12 mm. one roll
𝐝𝐂𝐨𝐬𝛃 𝐒 is fixed to the shaft while the other is floating (i.e. can slide
• Roll Diameter – 𝐃 = 𝟏 𝐂𝐨𝐬𝛃 according to the size of the input)
• D = roller diameter • Double tooth roll crushers – for production size > 25 mm.
• d = Feed Size Used for reduction of coarse to soft non abrasive materials.
• S = Roll Gap • One smooth and One corrugated Shell – Production size
• 2 = nip angle ( = friction angle) between 12 mm to 25 mm. Medium hard quality material.

• Corrugated Rolls – Rolls are corrugated i.e. fine lines across

• Roll Width – Q = B*S*V*3600* width.
• Q = Capacity in cu.m/hr • Spiked Rolls – Used for high throughput materials. Used for
• B = Roll width in meters coarse crushing of inputs like chemicals, coals and sinters.
Speed is slower than rest.
• S = Roll gap in meters
• V = Surface speed of roll in meters per second
•  = Efficiency
| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

3
 12-04-2023

Roller Crusher Working Video Cone Crusher

• Cone crushers are used to produce the final
product.

• Consists of feed chute, distributor plate,

crusher cone, eccentric shaft and casing.

• The eccentric shaft creates a swinging motion

of the high grade manganese steel crushing
cone which crushes the input against the wall
by direct pressure.

• They receive small stones of ore and produce

more fine aggregates.

• The cone is adjustable by threads to

accommodate proper size of the inputs. The
adjustment is done through hydraulic jacks.
| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

Cone Crusher Working Video Gyratory Crusher

• Gyratory crushers has similar structural built as cone crushers.
• The crushing cone or the mantle rotates along a central shaft and crushes the inputs
through direct pressure on the surface of the shell.
• The gyratory crusher cone is much steeper than the cone crusher.
• It is principally used as primary crusher.
• Gyratory crushers have rotation towards the bottom of the mantle unlike cone crusher
where the movement is around the center or top.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

4
 12-04-2023

Aggregate Processing Plant Primary Crushing Unit

• Crushing of larger rocks (75-250 mm).
• Consists of – (a) feed hopper, (b) Grizzly vibrating feeder, (c) Primary crusher, (d)
Main belt conveyor.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

Secondary Crushing Unit Screening of Aggregates

• Crushes smaller rocks into further grading (5-50 mm).
• Consists of – (a) vibrating screen, (b) Secondary Crusher, (c) Return Belt
Conveyor, (d) Stockpiling Conveyor, ‘(e) chutes.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

5
 12-04-2023

Segregation of Aggregate during stockpiling Aggregate Production – Process Flow

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

Factors affecting crusher output Production of GSB

• Jaw Opening : Lesser the opening lesser the output
• End Product Quantity : Lesser the maximum size requirement, lesser the output.
• Nature of rocks : Softer rocks produce higher output.
• Feedline Efficiency : Continuous feeding generates higher output.
• Working Efficiency : Lesser the maintenance, higher the output.
• Bulk Density : Higher the bulk density, higher the crusher output.
• Water Absorption : With lesser water content, output is higher.
• Specific Gravity : Higher the specific gravity, lesser the output.
• Crushing Strength : Higher crushing strength of stone means lesser output.
• Size of aggregate in raw material : If feed material is undersized, output tends to grow.
• (a) feed material 25% undersize  7.5 to 15% increase in output
• (b) feed material 50% undersize  35 to 45% increase in output
• (c) feed material 75% undersize  50% increase in output.

| Aritra Halder | Assistant Professor | Aritra Halder | Assistant Professor

6
 12-04-2023

Aggregate Lifecycle-from source to destination

Thank You!
Contact Me
at
ahalder@nicmar.ac.in
+91-8504017164

| Aritra Halder | Assistant Professor

| Aritra Halder | Assistant Professor